Abstract:
An apparatus for separating or segregating an insoluble or immiscible fluid mixture into its denser and less dense components is disclosed. The apparatus&#39; serviceability is enhanced through the use of a removably secured focusing plate. The apparatus may be advantageously used to separate grease/water mixtures of commercial food preparation operations into a gray water component for disposal in sewer lines and a grease component for storage and subsequent appropriate disposal.

Description:
BACKGROUND OF THE INVENTION 
     This invention pertains to a separator unit that may be integrated into a system that involves a mixture of insoluble or immiscible fluids to substantially separate the fluid mixture into its components. The separator unit may be used in a commercial food preparation operation to substantially separate a grease/water mixture into a gray water component for direct disposal into a sewer line and a grease component for removal and subsequent appropriate disposal. 
     Grease/water mixtures dispose directly into sewer lines burden municipal sewage systems since the grease builds up in sewer lines and on equipment in sewage treatment plants. To offset maintenance costs resulting from direct grease discharges into municipal sewers, municipal authorities surcharge commercial food preparation operations that directly discharge grease/water mixtures. The present invention may be used to relieve such sewage surcharges. 
     The art is replete with examples of devices for separating insoluble or immiscible fluid mixtures into their components. Although such devices may be effective in separating insoluble or immiscible fluid mixtures into their components, they lack serviceability. 
     U.S. Pat. No. 1,864,511 discloses a method and apparatus for separating immiscible substances. A main tank  1  is provided with a main separating compartment  2 . The compartment  2  is formed between the front and back walls of the main tank  1  and between partitions  5  and  9  that extend across the main tank  1  and are spaced from the bottom of the main tank  1  to provide passages  6  and  10  respectively below the partitions  5  and  9 . A partition  4  extends across the top of the separating compartment  2  and to a point close to partition  9 . From partition  4 , a vertical partition  14  extends upwardly close to partition  9  to form a discharge passage  15  from which the flow of a lighter constituent is controlled by a weir  16  at the upper edge of partition  14 . Since partition  4  appears fixably attached to main tank  1 , the apparatus lacks serviceability. 
     U.S. Pat. No. 1,200,951 discloses a separator that includes a grease and oil collector E removably secured within the trap A. The bottom of the collector E is provided with an inlet G having a wall G′ that projects within the collector above a normal level P, of the fluids in the trap A. Preferably, the wall G′ is formed integral with the bottom of collector E that slopes upward toward the inlet G and has a depending skirt or grease dam H. An intercepting chamber I is formed by the wall G′, the incline bottom and the dam H. Within the collector E is a pipe L, which fills with water in use, having an open end in proximity to the bottom of the collector. 
     U.S. Pat. No. 3,225,936 discloses an apparatus for continuously separating liquids having different specific gravities. A mixture to be separated is introduced through a pipe  22  into a uniformizer  7  and then into the apparatus. Within the apparatus, the mixture passes through gaps formed by sloped sheets where upon the liquids separate spontaneously, by reason of their different specific gravities, into their components. 
     U.S. Pat. No. 4,088,578 discloses a process and apparatus for separating oil from water contaminated with oil. The apparatus includes a partition plate  13  consisting of a flat region  13   a  and another inclined or deflected region  13   b . The flow of oil is first horizontally along the flat region  13   a  of the partition plate  13  and subsequently changes into a rising stream of separated oil that climbs along inclined or deflected region  13   b  that is at an angle from 70 to 90 degrees with respect to the horizon. The deflection of the flow at such an angle is said to greatly enhance the smooth flowing of oil particles so that the oil can be rapidly separated from the water contaminated oil. Thus, the sloping region  13   b  is not provided for the purpose of sequester of the light component, but for aiding in its joint movement with water in a way that is said to lead to separation. 
     U.S. Pat. No. 4,149,973 discloses a pressurized three stage horizontal separator for separating oil from water that includes a first stage for gravity separation of oil from water as an oil-water mixture flows along upwardly sloping baffles  48 . 
     U.S. Pat. No. 4,400,274 discloses a tank having baffles or dams for separating low and high density constituents of a liquid. A top panel  16  in a tank  60  extends in an inclined manner upwardly in an upstream direction over about a third of the length of the tank  16 . In addition, baffles  43  and  44  divide the liquid flow into an upward and downward path causing acceleration that tends to enhance the separation of low and high density constituents. However, since top panel  16  is fixably attached to tank  60 , the tank lacks serviceability. 
     U.S. Pat. No. 4,554,074 discloses a separator for an immiscible fluid mixture. The separator includes a fluid separator box having pairs of channels that convert an initial inlet turbulent high velocity immiscible fluid mixture flow to a substantially lamellar low velocity fluid flow. In an embodiment relating to a cylindrical tank, an inverted funnel baffle  12  is disposed and secured above the fluid separator box and provides a conductive pipe outlet for the separated less dense fluid. In an alternative embodiment relating to a rectangular tank, the inverted funnel  12  is replaced with a tank baffle  96  disposed the length of the tank. This separator lacks serviceability. 
     U.S. Pat. No. 5,492,619, in an alternative embodiment, discloses the inclusion of a concentrator that is provided in the form of a slanted baffle plate like a witch&#39;s hat above an inlet  12  in a collection tank for an automatic grease collection system. This system also lacks serviceability. 
     A particularly popular and effective separator has been the Big Dipper® separator sold by Thermaco, Inc. of Asheboro, N.C., USA. It uses a rotating oleophilic wheel to pull grease from the top of a body of effluent to be scraped off by a blade. However, it has been found that fine solids in the grease can foul the contact between the blade and the wheel, making separation inefficient. 
     It is very apparent that there is a need to provide a separator unit for insoluble or immiscible fluid mixtures that overcome the above problems with the prior art. More specifically, there is a need to provide a separator unit that includes having excellent serviceability. 
     SUMMARY OF THE INVENTION 
     The present invention satisfies the need for a separator unit that is very serviceable. The separator unit of the present invention includes a vessel containing a separation or segregation volume. The separator unit includes a removable focusing plate situated above the separation or segregation volume. The vessel of the separator unit includes an inlet end and an outlet end connected by a bottom and sidewalls. At each of the inlet and outlet ends there are baffles creating inlet and outlet channels as well as defining the separating or segregation volume. The upper portion of the separation or segregating volume is bounded by the focusing plate placed within the vessel and between the baffles and sidewalls of the vessel. The focusing plate guides a component of the immiscible or in soluble fluid mixture having a lower specific gravity or density toward an access port. The component having the lower specific gravity or density is removed from the region proximate to the access port, through an access line after a sufficient quantity has accumulated. The simplicity of the separator unit adds to its serviceability. That is, removably fastening of the focusing plate within the vessel simplifies the plate&#39;s insertion and removal for the frequent and unencumbered service of the separator unit without the need for special tools or inordinate amounts of down time. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other features, aspects and advantages of the present invention will be better understood by those skilled in the art after a review of the following description, appended claims, and accompanying drawings where: 
     FIG. 1 depicts a perspective view of the separator unit for separating an insoluble or immiscible fluid mixture into its less dense component and denser component; 
     FIG. 2 depicts a cross-sectional schematic of the separator unit of FIG. 1 for separating an insoluble or immiscible fluid mixture into its less dense component and denser component; and 
     FIG. 3 depicts a schematic of a system incorporating the separator unit for separating an insoluble or immiscible fluid mixture into its less dense component and denser component. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     An embodiment of the present invention, depicted schematically in FIG. 1, includes a separator unit  10  comprising a vessel  12  and an insert  46  with a sloped bottom. Vessel  12  includes inlet end wall  14 , outlet end wall  20 , sidewalls  18  &amp;  18 ′ and bottom  16 . Inlet baffle  22  and outlet baffle  24  lie within a volume bounded by bottom  16  and walls  14 ,  18  &amp;  18 ′, and  20 . Inlet baffle  22  and outlet baffle  24  bound a portion of separation or segregation volume  26 . Inlet baffle  22  extends between sidewalls  18  &amp;  18 ′ (from their tops) toward, but not to, bottom  16  to create an inlet channel between the inlet baffle  22  and inlet end wall  14  that communicates with separation or segregation volume  26  below baffle  22 . Inlet  30  is located in inlet wall  14  and provides communication between inlet line  32  and the inlet channel. Outlet baffle  24  extends between sidewalls  18  &amp;  18 ′ (from their tops) toward, but not to, bottom  16  to create an outlet channel between the outlet baffle  24  and outlet end wall  20  that communicates with separation or segregation volume  26  below baffle  24 . Outlet  40  is located in outlet wall  20  and provides for communication between outlet line  36  and the outlet channel. 
     Focusing plate  62  of sloped insert  46  bounds the upper portion of separation or segregation volume  26 . Inlet wall  54 , sidewalls  56  &amp;  56 ′ and outlet wall  60  intersect with focusing plate  62  to form the body of sloped insert  46 . In use, sloped insert  46  resides within an upper potion of the volume bounded by sidewalls  18  &amp;  18 ′, inlet baffle  22  and outlet baffle  24 . The top of vessel  12  coincides substantially with the top of sloped insert  46 . In this manner, separation or segregation volume  26  is bounded by sidewalls  18  &amp;  18 ′, inlet baffle  22 , outlet baffle  24 , bottom  16  and focusing plate  62 . Fasteners  74  (such as screw, clasps or other suitable fasteners) removably secure sloped insert  46  to sidewalls  18  &amp;  18 ′. The fasteners prevent insert  46  from falling too far and also prevent it from floating, as the case may be. Although focusing plate is shown to be a part of sloped insert  46  in FIGS. 1,  2  &amp;  3 , applicants contemplate that focusing plate may be a simple plate that is removably attachable to sidewalls  18  &amp;  18 ′, or inlet baffle  22  and outlet baffle  24 , or both. 
     An access port  64  is formed in focusing plate  62  at an elevated end of sloped insert  46 , near outlet wall  60 . Access port  64  provides a path for a component of an insoluble or immiscible fluid mixture  34  having a lower specific gravity or density, to exit the uppermost section of separation or segregation volume  26 . In addition the port  64  may have a vent for permit pressure equalization between the volume under and above focusing plate  62 . 
     During an initial introduction of an insoluble or immiscible fluid mixture into separator unit  10 , access port  64  provides a path for gases, which have been urged to the elevated end of focusing plate  62  and accumulated adjacent to focusing plate  62 , to exit the uppermost section separation or segregation volume  26 . During the operation of separator unit  10 , access port  64  provides a path for liquids, in particular, the component of the insoluble or immiscible fluid mixture  34  having the lower specific gravity or density, to exit the uppermost section separation or segregation volume  26 . A method such as for example, pumping, may be used to withdraw the accumulated component having the lower specific gravity through access line  66 . 
     A gasket type barrier  52  may be placed between sidewalls  56  &amp;  56 ′ of the sloped insert  46  and sidewalls  18  &amp;  18 ′ of vessel  12  to prevent the movement of fluid between and along the length of sloped insert  46  and between sidewalls  56  &amp;  56 ′ and sidewalls  18  &amp;  18 ′. The gasket type barrier  55  may be any material that forms the requisite seal including for example cellular polymers, such as styrene foams (as for example expanded polystyrene also known as “Styrofoam” an early tradename of DOW) and urethane foams, that are compatible with the insoluble or immiscible fluid mixture, its dense component, and its less dense component. The seal need not be perfect; it need only prevent convective current type flow. 
     Optionally, a fluid seal (not depicted) may be provided along the perimeter of focusing plate  62  to prevent any of the insoluble or immiscible fluid mixture, its denser component, and its less denser component from passing beyond the plane of focusing plate  62 . Likewise, fluid seal  50  may be any material that functions to prevent the breach beyond the plane of focusing plate  62 , is compatible with insoluble or immiscible fluid mixture, its denser component, and its less dense component while maintaining the ease of removal and replacement of focusing plate  62  from and to vessel  12 . 
     FIG. 2 is a vertical-sectional schematic of separator unit  10 . Following installation, separator unit  10  contains air. During an initial transient period, insoluble or immiscible fluid mixture  34  is introduced into separator unit  10  through inlet  32  and inlet channel from inlet line  30  and accumulates within the lower portion of vessel  12 . Separation of the less dense component  44  from the denser component  42  may begin and produce a separated layer of less dense component  44  on denser component  42 . The denser component  42  may extend from inlet wall  14  to outlet wall  20 . Over time during this transient period as additional insoluble or immiscible fluid mixture  34  is introduced into separator unit  10 , separated layer eventually contacts the lower portion of focusing plate  62  (on the right in FIG.  2 ). During this period, separated layer may be contained within separation or segregation volume  26  and extent from inlet baffle  22  to outlet baffle  24 . Eventually at the end of the transient period, the volume of insoluble or immiscible fluid mixture  34  introduced into separator unit  10  is such that the separated layer of the less dense component  44  is urged to the uppermost region of focusing plate  62  and accumulates at access port  64 . Any air that may have accumulated may be released through access port  64  to allow separated layer to communicate with access port  64 . 
     The transient period might occur in a single step by introducing a volume of insoluble or immiscible fluid mixture  34  sufficient to fill inlet channel, separation or segregation volume  26 , and outlet channel, in which case some insoluble or immiscible fluid mixture  34  may pass through separator unit  10  without segregating into its components. To avoid the passing of unsegregated insoluble or immiscible fluid mixture  34  through separator unit  10 , a volume of denser component  42  sufficient to fill inlet channel, separation or segregation volume  26 , and outlet channel to outlet line  36  may be initially be introduce into separator unit  10 . 
     During the steady state operation of separator unit  10 , insoluble or immiscible fluid mixture  34  is also introduced into inlet channel through inlet  32  from inlet line  30  and travels toward bottom  16 . As insoluble or immiscible fluid mixture  34  passes inlet baffle  22 , the less dense component  44  and denser component  42  separate. 
     As insoluble or immiscible fluid mixture  34  continues to flow toward outlet  40  separation continues. Less dense component  44  rises to strike focusing plate  62  and is urged to accumulate proximally to access port  64 . Entrained air may also accumulate in the region of access port  64  and might need to be bled off to allow less dense component  44  to accumulate closer to access port  64 . In time, denser component  42  travels beyond separation or segregation volume  26  under baffle  24  through outlet channel and outlet  40  to outlet line  36  for further disposition. Less dense component  44 , after sufficient accumulation is removed through access port  64  via access line  66 . 
     Although separator unit  10  is depicted in FIG. 1 as occupying a substantially rectangular prismatoid, it will be appreciated by those skilled in the art that any shape that accomplishes the separation of the insoluble or immiscible fluid mixture  34  into its component may be used. For example, vessel  12  might be a cylinder having an irregular cross-section or a regular cross-section, such as for example, circular, elliptical, polygonal, etc. Likewise focusing plate  62  may also be any shape that substantially corresponds to the shape of vessel  12  and accomplishes separation. Focusing plate  62  might advantageously posses a shape that directs less dense component to the volume substantially below access port  64 . For example, if the volume defined by inlet baffle  22  and outlet baffle  24  were circular then focusing plate could be an oval or elliptical. The arcuate character of focusing plate might then be used to accommodate access port  64 , having the narrower end furthest from the bottom of vessel  12 . Through the corresponding arcuate form of outlet baffle  24 , less dense components would then be concentrated closer to access port  64 . 
     The separator unit  10  of the present invention addresses a long felt need in the industry, namely, serviceability. Since focusing plate  62  resides removably within vessel  12 , simply loosening fasteners  74  provides access to the interior of separator system  10 . During such access, sediments that may have become entrained in insoluble or immiscible fluid mixture  34  to settle on bottom  16  might be removed. Alternatively, it is conceivable that access port  64  and/or access line  66  might become clogged. The ease with which separator system  10  or its parts may be disassembled, cleaned or replaced, and reassembled provides the advantage of substantially little or no down time for repairs and replacements. 
     Separator unit  10  may be advantageously used to separate grease/water mixtures into a grease component and gray water component in commercial food preparation operations. FIG. 3 schematically depicts an operation incorporating separator unit  10 . The operation includes a source  76  of an insoluble or immiscible fluid mixture, the separator unit  10 , a retainer  80  for the less dense component  44  and a pump  82 . Insoluble or immiscible fluid mixture  34  is transferred to separator unit  10  through inlet line  30 . Within separation or segregation volume  26  the denser component  42  and less dense component  44  segregate. Denser component  42  proceeds below outlet baffle  24 , through outlet  40 , to outlet line  36  for eventual disposal such as to a sewer. Less dense component  44  accumulates at the upper end of focusing plate  62  proximate to access port  64 . Pump  82  is used to transfer the less dense component from separator unit  10  to retainer  80 . 
     The pump may be selectively actuated by various means. For example, if the less dense component  44  comprises grease, then a grease sensor  84  in the upper part of separation or segregation volume  26  may sense grease and output a signal to actuate pump  82 , which continues to run until grease is no longer sensed, or for some preset period of time. Alternately, the pump actuation may be toggled by a timer. Also, access line  66  to the pump  82  may include a dip tube (not depicted) adjustably extending below focusing plate  62  and into the separation or segregation volume  26  to pump to a selected depth below focusing plate  62 . 
     With respect to commercial food preparation operations, source  76  of FIG. 3 may include any equipment or process that produces or results in a grease/water mixture. Examples of equipment that perform processes that might result in grease/water mixtures include a sink, a dishwasher, a cooker, pasteurizer, a blancher, an oven, a dryer, a grille etc. Source  76  may include one or more of the above. 
     In commercial food preparation operations, the grease component may have a tendency to solidify at the normal operating temperature (e.g., substantially room temperature) of separator unit  10 . Therefore, it may be advantageous to provide a heater (not depicted) in the vicinity of access port  64  and/or along access line  66  to maintain the grease in a liquid state. In further regards to commercial food preparation operations, separator unit  10  may be of any size that effectively segregates the grease component from gray water component. For example, in one application, applicants contemplate that separator unit  10  might be of a size that fit beneath a restaurant sink. In another application, the inventor contemplates that separator unit  10  be of a size such as a typical walk-in refrigerator. In yet another application, the inventor contemplates that separator unit  10  be of the size of an inground storage or septic tank. In any of these applications, separator unit  10  is constructed to maintain its serviceability. 
     Separation unit  10  may be constructed from any materials that are compatible with the insoluble or immiscible fluid mixture  34  to be separated, as well as its less dense and denser components. In certain applications, the construction materials might also be dictated by industry and/or government standards. For example, in commercial food preparation operations, county and/or city health codes might need to be consulted and, in the case that the food products are being exported, foreign government health codes might need to be consulted. Notwithstanding the above, separator unit  10 , and its component might be constructed from metals; ceramics including concrete and moldable cements; polymers; composites base on metals, ceramics, and polymers; either partially, completely, or with combinations thereof. A preferred material is stainless steel. 
     The previously described versions of the present invention have many advantages, including allowing the separation of insoluble or immiscible fluids into their components. More particularly, the present invention is advantageous for use in separating grease/water mixtures particularly in commercial food preparation operations to relieve surcharges that might otherwise be charged by municipal authorities. 
     Although the present invention has been described in considerable detail with respect to a certain preferred versions thereof, other versions are possible. Examples include the separation of benzene/water mixtures in refining operations, the separation of oil/water mixtures within ships, the separation of other insoluble or immiscible fluid mixtures be they organic, inorganic or mixtures thereof. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions herein. 
     All patents and other documents identified in the present application are hereby incorporated by reference.