Abstract:
The invention includes a tablet made from a coagulant that will improve the settling of suspended solids in an aqueous media such as wastewater, recycled water, potable water, storm water, swimming pool water, spa water, boiler water, cooling tower water and industrial process water. The agent is a tablet containing at least one salt from the aluminum sulfate family in a mixture of organic and inorganic binders. The mixed material is especially adapted to lend itself to high speed molding operations. Such agent, when in molded form, provides controlled dissolution in an aqueous media, exhibits strength and non-chipping characteristics which is a benefit in shipping and handling and is free from dusting, flaking or other deteriorative factors. In its tablet form, this agent can be used in combination with a holding apparatus having slotted opening zones.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates to a particular formulation for a chemical tablet. More particularly, the present invention relates to a chemical tablet that removes phosphorus and provides consistent chemical dissolution in water. 
       BACKGROUND 
       [0002]    Phosphorus (P) is commonly found in municipal and agricultural wastewater, originating from the digestion of phosphorus-containing food sources. Soluble reactive phosphorus, typically in the form of orthophosphate (PO 4   +3 ), can be a nutrient for aquatic plants, such as algae, which can be either a health risk to aquatic life or an aesthetic nuisance to those living near or using the waterways. In the case of blue-green algae, toxic by-products can be produced, which create health issues if a lake or reservoir would be used as a source of drinking water. 
         [0003]    Control of phosphorus can be achieved by forming a precipitant when the soluble phosphorus, in the form of orthophosphate, combines with a soluble metal, such as aluminum or iron. Several coagulants are also applicable to remove phosphorus from wastewater or sewage. 
         [0004]    Aluminum sulfate is commonly used for phosphorus control due to its low metal to phosphorus ratio required for formation of a precipitant. It is widely used in some wastewater treatment plants and municipal sewage treatment plants for removing phosphorus. In these plants, aluminum sulfate needs to be added into wastewater, or secondary treated or tertiary treated effluent in certain methods. The chemical needs to be added to a treatment unit constantly. In on-site sewage treatment plants, it is difficult to use special equipment to add any coagulant for phosphorus removal treatment. Therefore, a special composition, form and method need to be developed to carry out the phosphorus removal task in on-site sewage treatment plants. 
       SUMMARY 
       [0005]    In accordance with one or more embodiments of the present invention, is an aluminum sulfate tablet that can be dissolved into water or wastewater constantly. 
         [0006]    In accordance with one or more embodiments of the present invention, is an efficient phosphorus removal system based on the aluminum sulfate tablet. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a side view of an aluminum sulfate tablet showing a cylindrical central body portion and a large beveled top and a large beveled bottom, in accordance with one or more embodiments of the present invention. 
           [0008]      FIG. 2  is a cross-sectional side view of a treatment system with a tablet dispenser unit in which aluminum sulfate tablets shown in  FIG. 1  can be used to remove phosphorus from wastewater, in accordance with an embodiment of the present invention. 
           [0009]      FIG. 3  is a cross-sectional side view of a treatment system with a tablet dispenser unit in which aluminum sulfate tablets shown in  FIG. 1  can be used to remove phosphorus from wastewater, in accordance with another embodiment of the present invention. 
           [0010]      FIG. 4  is a close-up, cross-sectional, isometric view of a bottom portion of the tablet dispenser unit of  FIGS. 2 and 3 , in accordance with one or more embodiments of the present invention. 
           [0011]      FIG. 5  is a top view of a filtering system in which a tablet dispenser unit is installed, in accordance with an embodiment of the present invention. 
           [0012]      FIG. 6  is a cross-sectional, side view of the filtering system in which a tablet dispenser unit is installed in  FIG. 5  along line A-A, in accordance with an embodiment of the present invention. 
           [0013]      FIG. 7  is a flow chart showing the process for manufacturing a tablet, in accordance with an embodiment of the present invention. 
       
    
    
     DESCRIPTION 
       [0014]    In accordance with one or more embodiments of the present invention, a composition for and a method to make an aluminum sulfate tablet includes (i.e., comprises) making the aluminum sulfate tablet with a diameter ranging from 1″ to 3.5″ and a weight ranging from 30 to 200 grams. The tablet is made using granular aluminum sulfate particles with a size ranging from 10 to 200 mesh and a binder or binding agent or an organic bonding material made from plant or plants or a viscosity liquid made from fruits. The bonding material can have a chemical formula of, for example, but not limited to: C 6 H 12 O 6  or C 12 H 22 O 11 . The bonding material also can be a mixture of these two or more different bonding materials. The bonding material can be, for example, but not limited to, a food grade starch hydrolysate. The food grade starch hydrolysate can be, for example, but not limited to, one of the following starch hydrolysates: Apple, corn, molasses, cane and other binders made from fruits or plants. 
         [0015]    While the use of coagulants such as aluminum sulfate to assist in the removal of suspended solids in an aqueous media is well established these coagulants previously have only been available in a granular or pre-diluted liquid form. As a result, using these products required the use of pumps, granular dosing equipment, electricity, and plant modifications. Furthermore, existing dosing systems do not account for variations in the flow rate to be treated, which leads to overdosing of chemical, excess sludge generation and reduced product efficiency. 
         [0016]    In this embodiment of the invention, the aluminum sulfate contained within the agent will assist in the precipitating out of phosphorus from domestic wastewater, thereby minimizing the growth of algae in the environment. 
         [0017]    The formula and ranges for the components of different embodiments of the tablets are listed in Table 1. In general, the process takes place at ambient temperatures between 60° F. to 90° F. 
         [0000]                                                                                          TABLE 1                   Material Ranges of Aluminum Sulfate Tablet                Material                Al 2 (SO 4 ) 3                                 Aluminum   Aluminum   Magnesium           Sulfate   Stearate   Stearate   Inert   Binder   H 2 O                        Percentage (%)   50-92   0.3-3.5   0.3-10    1.0-25       2-10   6.46       Percentage (%)   83.9-91.1   0.3-1.1   0.8-1.8    3-5   0.3-12   4.5-7.0                    
The inert component can include, for example, but is not limited to, Calcium Hydroxide, and the binder component/material can include, for example, but is not limited to, starch hydrolysate.
 
         [0018]    The tablets can be made using an automated high-speed or manual molding process from the mixed material. For example, but not limited to, an eight-ton arbor press that can be used with at least one die having an internal shape configured to produce a predefined shaped tablet from the mixed material, for example, but not limited to, the tablet shape shown in  FIG. 1 . 
         [0019]      FIG. 1  is a side view of an aluminum sulfate tablet  100  showing a cylindrical central body portion  110 , a beveled top  120  and a beveled bottom  130 , in accordance with one or more embodiments of the present invention. In  FIG. 1 , the beveled top  120  and the beveled bottom  130  of the tablet  100  aid in the insertion of each tablet into a feeder device, provide additional surface area for contact by the wastewater as it flows through the feeder, and permit a greater flow rate through the feeder device through the channels created between adjacent tablets by the beveled tops and bottoms. 
         [0020]    Still other embodiments of the tablet shown in  FIG. 1  can include protrusions on the tops and bottoms of the tablet  100  for example, but not limited to, dimples/bumps, cones, ridges, and the like to provide additional spacing between the tablets to promote water flow and tablet dissolution and to prevent adjacent tablets from becoming stuck together. 
         [0021]    Treatment System for Removing Phosphorus. A phosphorus removal system can consist of different combinations of components, but, in general, the removal process includes the following steps:
       (1) Flowing water, wastewater or treated sewage through a tablet feeder or a similar apparatus that is filled with the aluminum sulfate tablets made in accordance with this invention to dissolve the tablets into the liquid at a certain dissolve rate.   (2) Optionally, using a mechanical mixer or an air mixing apparatus to mix the liquid that contains the dissolved aluminum sulfate. The purpose of mixing is to accelerate the reaction between the aluminum sulfate and the phosphates. Any mixing method can be applied in this process. As seen, for example, in  FIGS. 2 and 3 , a pump-diffusion apparatus is applied.   (3) Flowing the treated water to a settling or filtration unit. After the addition of the aluminum sulfate (coagulant), floc grows gradually in this unit and is removed in the settling tank, or clarifier or a filter. The key point of the unit design is that the settling tank volume supplies enough room for chemical sludge storage.
 
This system contains mixing, flocculation, settling or filtration, or a combined chemical sludge removal unit, and a sludge storage zone.
       
 
         [0025]      FIG. 2  is a cross-sectional side view of a treatment system in which aluminum sulfate tablets shown in  FIG. 1  can be used to remove phosphorus from wastewater, in accordance with an embodiment of the present invention. In  FIG. 2 , a treatment system  200  is shown to include a tank  205  through which an inlet pipe  210  passes from an outside of the tank to an inside of the tank. A tablet feeder  220  is connected to an end of and is in fluid communication with the inlet pipe within the tank and the tablet feeder  220  is filled with multiple tablets  230  in, for example, a vertical stack. The tablet feeder  220  includes an upside-down, “T”-shaped base portion  221  and a cylindrical tablet holding portion  225  in which the tablets  230  are stacked. As wastewater flows into the tank  205  through the inlet pipe  210  and the tablet feeder  220  it passes over and dissolves the tablets  230  and spills into a mixing chamber  207  in which an air diffuser  270  is located to provide a mixing action to accelerate the reaction the aluminum sulfate and the phosphates in the water. The air for the air diffuser  270  is provided by an air pump  260  that is, generally, located outside of the tank  205 . The treated water then flows into a settling or filtration chamber  209  in which a filtration media  240  is located and through which the wastewater is upwardly filtered to remove the coagulant formed by the reaction of the aluminum sulfate and the phosphates before the filtered water exits through an outlet pipe  250 . The coagulant and other sludge solids eventually settle down onto a floor of the settling chamber  209 . 
         [0026]      FIG. 3  is a cross-sectional side view of a treatment system in which aluminum sulfate tablets shown in  FIG. 1  can be used to remove phosphorus from wastewater, in accordance with another embodiment of the present invention. In  FIG. 3 , another treatment system  300  is shown to include a tank  305  through which an inlet pipe  310  passes from an outside of the tank  305  to an inside of the tank. A tablet feeder  320  is located outside of the tank  305  and is connected to an end of and is in fluid communication with the inlet pipe  310  within the tank  305  and a cylindrical tablet tube  325  of the tablet feeder  320  is filled with multiple tablets  330  in, for example, a vertical stack. The tablet feeder  320  includes an upside-down, “T”-shaped base portion  321  and the cylindrical tablet tube  325  in which the tablets  330  are stacked. A cap  329  is located on a top end of the cylindrical tablet tube  325  to close the top end of the cylindrical tablet tube  325 . An outer cylindrical tube  335  encircles and covers the cylindrical tablet tube  325  and the cap  329  and a top end of the outer cylindrical tube  335  is similarly covered by an outer tube cap  339 . As wastewater flows into the tank  305  through the inlet pipe  310  and the tablet feeder  320  it passes over and dissolves the tablets  330  at a bottom end of the cylindrical tablet tube  325  and spills into a mixing chamber  307  in which an air diffuser  370  is located to provide a mixing action to accelerate the reaction the aluminum sulfate and the phosphates in the water. The air for the air diffuser  370  is provided by an air pump  360  that is, generally, located outside of the tank  305 . The treated water then flows into a settling or filtration chamber  309  and exits through an outlet pipe  350  as the coagulant and other sludge solids eventually settle down onto a floor of the settling chamber  309 . 
         [0027]      FIG. 4  is a close-up, cross-sectional, isometric view of a bottom portion of the tablet dispenser unit of  FIGS. 2 and 3 , in accordance with an embodiment of the present invention. In  FIG. 4 , the tablet dispenser  220  includes an upside-down, “T”-shaped base portion  410  and an upright cylindrical tablet holding portion  425  in which the tablets  230  are stacked. The upright cylindrical tablet holding portion  425  includes an open top end (not shown) that is covered with a cap (not shown) and one or more ridges  427  across a bottom of the upright cylindrical tablet holding portion  425  to raise the tablets  230  off the bottom of the upright cylindrical tablet holding portion  425 . Raising the tablets  230  off the bottom of the cylindrical tablet holding portion  425  increases the surface area of the bottom tablet  230  that is exposed to the wastewater, which results in better dissolution of the tablets  230 . The cylindrical tablet holding portion  425  is installed through a top opening  441  defined by a top cylindrical wall  440  and rests on a bottom wall  442  of the tablet dispenser  220 . A sealing member  444 , such as, for example, but not limited to, a flexible gasket, fits between an outer surface of the upright cylindrical tablet holding portion  425  and an inside of the top cylindrical wall  440  to form a watertight seal. An opening  426  is defined in and near a bottom of the upright cylindrical tablet holding portion  425  to permit the wastewater to flow into, around and past the tablets  230 . In general, a similar opening  426  is also defined on an opposite side of the upright cylindrical tablet holding portion  425 . The tablet dispenser  220  also includes an inlet cylindrical wall  422  that defines an inlet opening  424  through which the wastewater flows into the tablet dispenser  220  and opposite to the inlet cylindrical wall  422  is an outlet cylindrical wall  432  that defines an outlet opening  434  through which the wastewater flows into the tablet dispenser  220 . The tablet dispenser  220  still further includes a central body portion  443  that defines a central body opening  445  to which are connected and in fluid communication with the inlet opening  424 , the outlet opening  434  and the top opening. 
         [0028]      FIG. 5  is a top view of a filtering system in which a tablet dispenser unit is installed, in accordance with another embodiment of the present invention. In  FIG. 5 , a top of a filtering system  510 , for example, but not limited to, the Bio-Kinetic Filter system sold by Norweco of Norwalk Ohio, is shown to have protruding from it a cylindrical tablet feeding tube  525  that with its top covered by a removable tablet feeding tube cap  529 . The cylindrical tablet feeding tube  525  is located slightly off-center in the top of the filtering system  510 . A second cylindrical tube  560  is located along a diameter of the top of the filtering system  510  and is centered approximately an equal distance away from a center of the top of the filtering system  510  as the cylindrical tablet feeding tube  525 . A tube  560  is connected between and provides for fluid communication between the cylindrical tablet feeding tube  525  and the second cylindrical tube  560 . 
         [0029]      FIG. 6  is a cross-sectional, side view of the filtering system in which a tablet dispenser unit is installed in  FIG. 5  along line A-A, in accordance with another embodiment of the present invention. In  FIG. 6 , the cylindrical tablet feeding tube  525  is seen holding multiple tablets  530  for treating the wastewater flowing into the filtering system  510  through inlet openings (not shown). The wastewater then passes down through and back up the filter member  612 , spills over a flow control weir (not shown) and then passes out of the filtering system  510  through an outlet opening  640 . 
         [0030]    Test results show that the aluminum sulfate tablets can be used to remove phosphorus successfully in an on-site sewage treatment plant. The removal efficiency is directly based upon the tablets dissolve rate, mixing condition and chemical sludge removal efficiency. Tablets made from the formula shown in Table 2 can remove phosphorus to a low level, for example, the phosphate concentration in the treated effluent can be as low as 0.04 ppm. 
         [0000]    
       
         
               
             
               
               
             
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Tablet Formula for Testing 
               
             
          
           
               
                   
                 Material 
               
             
          
           
               
                   
                 Al 2 (SO 4 ) 3   
                   
                   
                   
                 Organic gel 
                   
               
               
                   
                 Aluminum 
                 Aluminum 
                 Magnesium 
                 Lime 
                 forming 
               
               
                   
                 Sulfate 
                 Stearate 
                 Stearate 
                 (Inert) 
                 Binder 
                 H 2 O 
               
               
                   
                   
               
             
          
           
               
                 Weight (g) 
                 124.7 
                 1.0 
                 2.0 
                 6.0 
                 1.0 
                 9.3 
               
               
                 Percentage (%) 
                 86.60 
                 0.69 
                 1.39 
                 4.17 
                 0.69 
                 6.46 
               
               
                   
               
             
          
         
       
     
         [0031]      FIG. 7  is a flow chart showing the process for manufacturing a tablet, in accordance with an embodiment of the present invention. As seen in  FIG. 7 , after the process starts ( 700 ) then:
       1) The wet components are mixed ( 710 ), by combining the binder/binding material, e.g., starch hydrolysate, and the water together until they are completely mixed to form a solution.   2) The dry components are mixed ( 720 ) together by combining the aluminum sulfate, aluminum stearate, magnesium stearate and calcium hydroxide together for 1 to 10 minutes to form a dry material. For embodiment 1, the mixing time is 2 minutes to form the dry material.   3) The solution is poured into the dry material and then mixed ( 730 ) together for 1 to 10 minutes to form a mixed material. For embodiment 1, the mixing time is 3 minutes to form the mixed material.   4) The mixed material is placed in a sealed container and allowed to stand ( 740 ) for 10 to 180 minutes. For embodiment 1, the mixed material is let stand for 40 minutes.   5) A mold in a tablet press is filled with enough of the mixed material to make a tablet and the press is closed and the mixed material is subjected to 5 to 30 tons of pressure for about 1 second to make ( 750 ) each tablet. For embodiment 1, the mixed material is subjected to 20 tons of pressure for about 1 second.   6) The newly pressed tablets are now ready for use.   7) If more tablets are to be made ( 760 ), then the process returns to mixing ( 710 ) the wet components. If not, then the process ends ( 770 ).       
 
         [0039]    Two points to evaluate tablet quality are strength of a tablet and dissolve rate of the tablets. Dissolve rate of the tablets is very important to the quality of treated effluent. If the dissolve rate is too high, extra Aluminum Sulfate will be present in the treated effluent. The extra added coagulant affects the formation of the floc and solids removal efficiency. If the dissolve rate is too low, the ratio of Aluminum to Phosphates will be too low to remove phosphorus efficiently. Therefore, the composition of the tablets is important. The formula of the tablets can be adjusted based on the characteristics of the wastewater or sewage to be treated. 
         [0040]    While the invention(s) has/have been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, Applicant intends to embrace all such alternatives, modifications, equivalents, and variations that are within the spirit and scope of the invention(s) described herein.