Abstract:
An apparatus and method for mixing at least one fluid flowing through a fluid system using ultraviolet light to control organisms. Ultraviolet lamps are positioned in the fluid flow and arrays of triangularly shaped mixing elements are arranged at spaced intervals along the length of each lamp, wherein the plurality of arrays of triangularly shaped mixing elements create four vortices surrounding each elongated member forming a square array of vortices.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit under 35 U.S.C. §119(e) of the earlier filing date of U.S. Provisional Application Ser. No. 61/200,292 filed on Nov. 16, 2008, the contents of which are hereby incorporated by reference. 
     
    
     FIELD OF INVENTION 
       [0002]    This invention relates generally to systems that use ultraviolet (UV) light to control organisms, and in particular to the mixing of fluids in systems using UV light for the disinfection of fluids. 
       BACKGROUND OF THE INVENTION 
       [0003]    Wastewater treatment plants often use lamp racks oriented horizontally in the direction of flow in an open channel. The lamps emit ultraviolet light (UV) that inactivates pathogenic microorganisms rendering the water safe for discharge to a receiving water body or for re-use of the water (irrigation, indirect potable re-use, industrial use, gray water for non-potable use, etc.) The racks hold lamps in an array dispersed over the cross section of the channel such that none of the water flowing down the channel passes too far from any one lamp. Known open channel fluid treatment devices are shown, by example, in U.S. Pat. Nos. 4,482,809; and 5,006,244 the disclosures of which are incorporated by reference herein. 
         [0004]    There is a practical limit on how far water can pass from a lamp and still receive adequate disinfection.  FIG. 1  is a chart showing the drop off in UV irradiance with distance from the lamp in water with UV transmittance of 55% T and 65% T. 
         [0005]    Typically UV systems using low pressure mercury arc lamps have a lamp spacing of approximately 7.5 cm in a square array. With 2.5 cm diameter quartz tubes this means that the maximum distance from any lamp is approximately 4 cm. This provides sufficient space for the water to pass between the lamps without undue head loss and is close enough to achieve adequate penetration of the UV to all areas and hence adequate disinfection. These low pressure systems have lamps with a total power consumption of under 100 Watts and a UVC (germicidal UV) output of under 50 Watts. 
         [0006]    More recent advancement in lamp technology has produced low pressure lamps with higher output. Higher lamp output means that more water can be disinfected per lamp, and hence the flow of water must be increased proportional to the lamp UVC output. However due to head loss limits across a bank of lamps (too high a head loss means that the level of water upstream of the bank must increase and some of the water will spill over the top of the lamp bank and not be adequately treated), the lamp spacing must be increased to accommodate the greater water flow. For example lamps with an electrical consumption of 250 Watts and UVC output of approximately 100 Watts, must be accommodated in arrays with 10 cm lamp spacing. The additional area for the flow of water limits the velocity and hence head loss across the lamp bank. This results in a reduction in the UV irradiance at the point furthest from all the lamps as shown in  FIG. 2 . 
         [0007]    This reduced irradiance at the furthest point from the lamps results in some decrease in the performance efficiency associated with this greater lamp spacing, especially at lower UV Transmittances (55% T), but the advantages of being able to use fewer lamps overcomes the increase in electrical consumption that results. 
         [0008]    More recent development of even higher powered lamps (500 Watt, with 200 W UVC output) would potentially result in the number of lamps needed being reduced to half that of systems employing 250 W lamps. However this means that the flow per lamp must be doubled, resulting in a quadrupling in the head loss across a lamp bank (head loss is proportional velocity squared) unless the spacing of the lamps is increased even more. However increasing the spacing beyond 10 cm results in a further reduction in treatment efficiency, negating the potential advantages of fewer higher power lamps. 
         [0009]    One means of overcoming this is to close off the top of the lamp bank such that water cannot spill over the top of the bank and is forced to flow at the higher velocity and consequent pressure loss past the lamps with the smaller 4 inch or lower lamp spacing. This has been successfully employed where much higher powered medium pressure (MP) lamps are used (2500 Watt/lamp, 370′Wall UVC) (U.S. Pat. No. 5,590,390, the disclosure of which is incorporated by reference herein) and in a system that employed triangularly shaped or delta wing mixing elements with even greater spacing and 5,000 Watt lamps (750 Watt UVC) (U.S. Pat. No. 6,015,229, the disclosure of which is incorporated by reference herein). Even though the system disclosed in U.S. Pat. No. 6,015,229 had the closed top, the lamp spacing still had to be increased to reduce overall velocity and head loss. In the system disclosed in U.S. Pat. No. 6,015,229, the 5,000 Watt MP lamps are relatively short (60 cm long). One drawback of the system disclosed in U.S. Pat. No. 6,015,229 is that if longer lamps are used, the vortices generated by the delta wings die off and the effectiveness is diminished. The system disclosed in U.S. Pat. No. 6,015,229 therefore is best used with relatively short MP lamps (60 cm long vs. typical 1.8 m long for LP lamps). 
         [0010]    With one delta wing array placed at the beginning of a LP lamp bank the vortices essentially die out after approximately 40 cm. This has been modeled using Computational Fluid Dynamic Modeling (CFD) and is shown in  FIGS. 3 and 4 .  FIG. 3  is a velocity vortex diagram showing vortices 2 cm downstream of delta wings.  FIG. 4  is a velocity vortex diagram showing vortices 40 cm downstream of delta wings. 
         [0011]    The rotational velocity and therefore ability of the vortices to mix in the water furthest from the lamps is represented by the velocity vectors in  FIGS. 3 and 4 , with longer arrows and therefore higher rotational speeds immediately after the lamp ( FIG. 3 ) and smaller arrows and hence lower rotational speed 40 cm downstream of the deltas. 
       SUMMARY OF THE INVENTION 
       [0012]    Embodiments of the invention include an apparatus and method for mixing at least one fluid flowing through a fluid system, comprising an array of rows and columns of elongated members wherein each elongated member is horizontally aligned with elongated members in adjacent columns and vertically aligned with elongated members in adjacent rows of elongated member, and wherein the axis of each elongated member is aligned with the direction of fluid flow; and a plurality of arrays of mixing elements arranged at spaced intervals along the length of each elongated member, wherein the plurality of arrays of mixing elements create four vortices surrounding each elongated member forming a square array of vortices. Embodiments of the invention include wherein each elongated member is an ultraviolet light source and wherein the mixing elements include mixing elements having a triangular shape with one apex pointing upstream and at an angle to the direction of flow. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    Referring now to the drawings, wherein like numerals designate identical or corresponding parts throughout the referred views. 
           [0014]      FIG. 1  is graph showing relative UV irradiance with distance from a lamp/quartz combination shown at water transmittance of 55 (dashed line) and 65% per cm. 
           [0015]      FIG. 2  is graph show relative irradiance at the center point between 4 lamps in a square lamp array vs. lamp spacing between adjacent lamps in the array. 
           [0016]      FIG. 3  is a velocity vortex diagram showing vortices 2 cm downstream of delta wings. 
           [0017]      FIG. 4  is a velocity vortex diagram showing vortices 40 cm downstream of delta wings. 
           [0018]      FIG. 5   a  is a graph of the effect of zero, one, three and four deltas arrays equally spaced down the length of the lamp on microbe inactivation performance. 
           [0019]      FIG. 5   b  is Pilot bioassay test data of the MS2 Reduction Equivalent Dose (“RED”) with delta wings (dashed line) and without at 67% T vs. the flow rate per lamp according to an embodiment of the invention. 
           [0020]      FIG. 6  is Pilot bioassay test data of the MS2 RED with delta wings (dashed line) and without at 60% T according to an embodiment of the invention. 
           [0021]      FIG. 7  is Pilot bioassay test data of the MS2 RED with delta wings (dashed line) and without at 50% T according to an embodiment of the invention. 
           [0022]      FIG. 8  shows prior art embodiments of the use of delta wings have employed a delta wing array that generates 8 vortices around each lamp. This figure is taken from FIG. 4 of U.S. Pat. No. 6,015,229. 
           [0023]      FIG. 9  shows a vortex pattern proposed in U.S. Pat. No. 6,015,229 with smaller quartz diameter to lamp spacing ratio showing region of highly treated water close to the lamp not swept away by the vortices. 
           [0024]      FIG. 10  is vortex pattern with four vortices around each lamp showing improved sweep of water close to lamp according to an embodiment of the invention. 
           [0025]      FIG. 11  shows triangularly shaped mixing elements that produce the vortex pattern shown in  FIG. 10 . 
           [0026]      FIG. 12  is a drawing of lamp rack with triangularly shaped mixing elements according to an embodiment of the invention. 
           [0027]      FIG. 13  is a cross-sectional with three lamp racks together showing frame, wiper drive arm, quartz tubes and triangularly shaped mixing elements according to an embodiment of the invention. 
           [0028]      FIG. 14  is a cross-section view of lamp rack showing wide frame directing more of the water flow past the quartz tubes according to an embodiment of the invention. 
           [0029]      FIG. 15  is a cross-section of lamp rack showing narrow frame directing the water flow away from the quartz tubes according to the prior art. 
           [0030]      FIG. 16   a  shows a triangularly shaped mixing element with the tip removed according to an embodiment of the invention. 
           [0031]      FIG. 16   b  shows a triangularly shaped mixing element without the tip removed. 
           [0032]      FIG. 17  shows half triangularly shaped mixing elements at bottom of channel according to an embodiment of the invention. 
           [0033]      FIG. 18  is a drawing of a half triangularly shaped mixing element according to an embodiment of the invention. 
           [0034]      FIGS. 19   a  and  19   b  are side and end views showing a lamp rack in an open channel with half triangularly shaped mixing elements at the water level at the top, and at the bottom of the channel according to an embodiment of the invention. 
           [0035]      FIG. 20  is an alternate triangularly shaped mixing elements support arrangement with fixed vertical support rods or bars according to an embodiment of the invention. 
           [0036]      FIG. 21  is an alternate triangularly shaped mixing element support arrangement with removable vertical support rods or bars according to an embodiment of the invention. 
           [0037]      FIG. 22  is a possible arrangement for closed vessel reactor with four lamp array according to an embodiment of the invention. 
           [0038]      FIG. 23  shows a perspective view of a closed vessel reactor according to an embodiment of the invention. 
           [0039]      FIG. 24  is a longitudinal cross-sectional view of the closed vessel reactor of  FIG. 23 . 
           [0040]      FIG. 25  is a cross-sectional end view of the closed vessel reactor of  FIG. 23 . 
           [0041]      FIG. 26  is a cross-sectional end view of the closed vessel reactor showing a quartz cleaning mechanism according to an embodiment of the invention. 
           [0042]      FIG. 27  is an arrangement for closed vessel reactor with sixteen lamp array according to an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0043]    Embodiments of the invention employ more than one delta wing (triangularly shaped mixing element) array at spaced intervals along the length of a UV lamp in a system using UV light for the disinfection of fluids. Arrangements of triangularly shaped mixing element arrays were tested using computational fluid dynamic modeling combined with an irradiance field model to simulate the microbe inactivation. In  FIG. 5   a  the effect of zero, one, three and four triangularly shaped mixing element arrays equally spaced along the length of the lamp on microbe inactivation performance is shown. It can be seen that an arrangement of three triangularly shaped mixing elements spaced along a lamp has an improved performance over an arrangement having only one array of triangularly shaped mixing elements. 
         [0044]    This arrangement of three triangularly shaped mixing element arrays spaced along the length of the UV lamps was tested with a pilot system at a waste water treatment plant using surrogate microorganisms MS2 phage and T1 phage (known surrogate organisms used in bioassay testing) with and without the triangularly shaped mixing elements. The lamp spacing on the pilot system was 6 inches (15 cm). 
         [0045]    In addition to testing, the raw water at approximately 67% UV transmittance, the transmittance was adjusted to 60% T and 50% T using humic acid to simulate natural low transmittance waters.  FIGS. 5   b ,  6  and  7  show the improvement in performance that is achieved with and without the three triangularly shaped mixing element array. 
         [0046]    Previous embodiments of the use of triangularly shaped mixing elements have employed a triangularly shaped mixing element array that generates eight vortices around each lamp. This is shown in FIG. 4 of U.S. Pat. No. 6,015,229 reproduced herein as  FIG. 8  wherein UV lamps  5  are surrounded by a tube  13  and each triangularly shaped mixing element produces a pair of counter-rotating vortices  10 . 
         [0047]    The idea as proposed in U.S. Pat. No. 6,015,229 was to take highly treated water in close proximity to the lamp and move it away from the lamp and to take untreated or marginally treated water far from the lamp and move it in close proximity to the lamp. 
         [0048]    This arrangement is not suited to a system where the ratio of the quartz diameter to the lamp spacing is lower than in the system proposed in U.S. Pat. No. 6,015,229 since the vortices do not sweep a large part of the highly treated water that is close to the lamp as illustrated in  FIG. 9 . Specifically,  FIG. 9  illustrates what would happen if the arrangement disclosed in U.S. Pat. No. 6,015,229 were used with a smaller quartz diameter to lamp spacing ration. As illustrated, the vortex pattern shows regions of highly treated water close to the lamp that is unaffected or not swept away by the vortices. 
         [0049]    The arrangement of embodiments of the invention is better suited to a system where the ratio of the quartz diameter to the lamp spacing is lower than in the system proposed in U.S. Pat. No. 6,015,229. In embodiments of the invention, four larger vortices  20  surround each lamp  22  as is shown in  FIG. 10  forming a square array of vortices. As can be seen, the vortices are disposed approximate the lamp  22  taking that highly treated water and moving it away from the lamp  22 , and conversely take the water far from the lamp (at the center-point  24  between four lamps  22 ) and move it in closer to the lamp  22 . 
         [0050]    An arrangement of the invention having delta wings or triangularly shaped mixing elements  26  that produce a vortex pattern having four vortices  20  disposed approximate the lamp is shown in  FIG. 11 . Each triangularly shaped mixing element  26  is arranged with one apex pointing upstream and at an angle to the direction of flow. As illustrated in  FIG. 11 , pairs of triangularly shaped mixing elements  26  are arranged back-to-back such that the longest side  28  of each triangularly shaped mixing element  26  is arranged parallel and adjacent to the longest side (trailing edge)  28  of the other triangularly shaped mixing element  26  in the pair. 
         [0051]    Each triangularly shaped mixing element  26  produces a pair of counter-rotating vortices  20  and the back-to-back triangularly shaped mixing elements  26 , produce four counter-rotating vortices  20  that essentially rotate all the water in the space between four lamps  22  surrounding each pair. This counter-rotation is important in that the vortices  20  reinforce each other for higher rotational speed and longer sustainability. This arrangement of triangularly shaped mixing elements  26  is also preferred from a mechanical standpoint in that the triangularly shaped mixing elements  26  can be attached to their respective lamp rack and the whole lamp rack assembly can be withdrawn without affecting adjacent lamp racks. This is important for routine maintenance of in-channel UV disinfection systems. The support rods  30  that hold the triangularly shaped mixing elements  26  in place are also shown in  FIG. 11 . As can be seen here these rods  30  are placed so as to be outside of the sweep of the two counter-rotating vortices  20  produced by each triangularly shaped mixing element  26 , but still in a good position to be able to secure the trailing edge of the triangularly shaped mixing element  26 . 
         [0052]    An assembled lamp rack  32 , with three lamps  22  per rack  32 , in the preferred embodiment of this system is shown in  FIG. 12 . An additional support  34  is placed further up towards the tip (leading angle)  35  of each triangularly shaped mixing element  26 . This second support  34  is used to correctly align the angle of the triangularly shaped mixing elements  26  to the direction of flow (angle of attack) and further secure the triangularly shaped mixing elements  26  in place. It is also positioned at the centerline of the triangularly shaped mixing elements  26  so as not to interfere with the rotational sweep of the vortices  20 . 
         [0053]    In an embodiment of the invention, the lamp rack arrangement  32  is provided with four, six or eight vertical lamps  22  per rack  32 . However, any number of lamps  22  can be included in a single rack  32 . Several racks  32  are arranged adjacent to each other to form a lamp array for use in an open channel UV disinfection system.  FIG. 13  illustrates a cross-sectional view of three lamp racks  32  together showing the frame  36 , wiper drive arms  38 , quartz tubes containing lamps  22  and triangularly shaped mixing elements  26 . The lamps  22  in this and other disclosed embodiments are arranged in a square array such that each lamp  22  is horizontally aligned with lamps  22  in adjacent columns of lamps and vertically aligned with lamps  22  in adjacent rows of lamps. 
         [0054]    Most open channel rack mounted UV systems have vertical support members  40  at each end of the lamp rack to hold the quartz tubes and lamps  22 . This vertical support in prior art systems is disposed in close proximity to the lamp as shown in the cross-sectional view of  FIG. 15 . This tends to force the water away from the lamps into the area between the lamps and results in lower performance of the UV system. 
         [0055]    An improvement over this in an embodiment of the invention has a wide frame  36  that impedes water in the vertical plane furthest away from the lamps  22  and directs more water in the vertical plane of the lamps  22  as shown in  FIG. 14 .  FIG. 14  also illustrates the point where open area is around the lamps  22  and impediments to flow (frame legs) are kept away from the lamps  22 . 
         [0056]    A UV sensor (not shown) for measuring the UV irradiance in the water is placed between two quartz tubes in a lamp rack. It is desirable to clean this sensor as well as the quartz tubes with a scraper or wiper element that periodically travels down the length of the lamp. This wiper assembly can be driven by a vertical wiper drive arm  38  tied to a motor driven screw drive  41 . An example of a scraper is disclosed in U.S. Pat. No. 7,159,264, the disclosure of which is incorporated by reference herein. An embodiment of the invention has a modified triangularly shaped mixing element  260  having the tip removed. This modified triangularly shaped mixing element  260  provides sufficient clearance between the sensor wiper and the triangularly shaped mixing element  260 . The tip of the triangularly shaped mixing element  260  could interfere with the motion of the UV sensor wiper. The triangularly shaped mixing element with  260  and without  26  the tip removed is shown in  FIGS. 16   a  and  16   b . The clearance necessary for the wiper drive arm  38  is illustrated in  FIG. 13 . 
         [0057]    CFD and irradiance intensity field computer modeling has been performed to show that the removal of this tip has very little effect on the microbial inactivation through the reactor. 
         [0058]    Embodiments of the invention also use half triangularly shaped mixing elements  42  at the top and bottom of the lamp rack. This generates a single full vortex shown in  FIG. 17  in the same way that a full triangularly shaped mixing element generates a pair of vortices. As the bottom of the channel is at the mid-point between two lamps, the half triangularly shaped mixing element  42  is moved up approximately 0.7 cm to accommodate the support rod  30 .  FIG. 18  shows a half triangularly shaped mixing element  42 .  FIGS. 19   a  and  19   b  show a lamp rack in an open channel with half triangularly shaped mixing elements  42  at the water level at the top, and at the bottom of the channel. 
         [0059]    An alternative arrangement to support the triangularly shaped mixing elements  26  is through the use of vertical support rods or bars  44  as shown in  FIG. 20 . This has some disadvantages and advantages over the horizontal support arrangement described above. Vertical supports  44  produce more of an impediment to water flow which results in higher head loss through the reactor and also disrupts the vortices to some degree. However in a large lamp rack (e.g. eight lamps stacked vertically), each rod holds seven full triangularly shaped mixing elements and two half triangularly shaped mixing elements. This is in contrast to the three triangularly shaped mixing elements per rod in the horizontal support arrangement. This therefore reduces cost of the system. In addition, using vertical support rods  44  make it possible to remove the triangularly shaped mixing elements (for cleaning for example) without having to remove the whole rack. This is important in dirtier waters where the triangularly shaped mixing elements may have a tendency to accumulate stringers of debris (algae) that is common in secondary wastewater treatment plant effluents. 
         [0060]    An alternate support arrangement with removable vertical support rods or bars  440  is shown in  FIG. 21 . In addition, it is possible for a single rod to support both of the pairs of triangularly shaped mixing elements between lamp racks in which case a single rod supports fourteen full triangularly shaped mixing elements and four half triangularly shaped mixing elements in the eight lamp rack example cited above, further reducing cost. 
         [0061]    Embodiments of the invention include arrangements in closed vessel reactors as shown in  FIGS. 22 to 27 . A vortex array, similar to that described in the open channel embodiments above, can be generated in a closed vessel UV disinfection system where the lamps are enclosed in a tubular vessel with the flow in the direction of the length of the vessel and the lamps parallel to the flow. 
         [0062]      FIG. 22  shows a four lamp  22  tubular reactor  46 . The additional mixing provided by the triangularly shaped mixing elements  26  enable this reactor to be used for water with lower UV transmittance since, as in the open channel arrangement, the vortices  20  generated by the triangularly shaped mixing elements  26  bring water that is furthest from the lamps  22  into close proximity to the lamps  22  and move the water closest to the lamps  22  away from the lamps  22 . Such a reactor  46  could have an inlet  48  with water flowing parallel to the lamps and an outlet  50  with the water flowing transverse to the lamps as shown in  FIG. 23 . 
         [0063]    As in the open channel reactor one or more sets of triangularly shaped mixing elements  26  are placed at spaced intervals along the length of the lamps.  FIG. 24  shows three sets. A screw drive  410  ( FIGS. 24-26 ) to drive the quartz cleaning elements  52  runs the length of the reactor  46  at the center. 
         [0064]      FIG. 27  shows a sixteen lamp array with four rows of four lamps  22 . In a similar manner, nine, twenty-five or thirty-six lamp arrays could be produced with three rows of three lamps  22 , five rows of five lamps  22  or six rows of six lamps  22  respectively. In the larger arrays, some baffles (not illustrated) may be included to prevent water from flowing in the zones near the wall not covered by the vortices. 
         [0065]    If not otherwise stated herein, any and all patents, patent publications, articles and other printed publications discussed or mentioned herein are hereby incorporated by reference as if set forth in their entirety herein. 
         [0066]    It should be appreciated that the apparatus and methods of the invention may be configured and conducted as appropriate for any context at hand. The embodiments described above are to be considered in all respects only as illustrative and not restrictive.