Patent Publication Number: US-8529845-B2

Title: Brine maker

Description:
FIELD 
     Presented is a system, apparatus and method (i.e., utility) for admixing solid materials with solvents to produce a liquid solution. In one arrangement, the utility is directed to a brine maker that dissolves salt into water to produce a brine that is suitable for use as a snow and ice remover. 
     BACKGROUND 
     It is a common practice in many regions where subfreezing conditions occur to apply solutions to roadways, runways, and the like that facilitate melting and/or removal of snow and ice. For instance, highway snow and ice control is typically carried out by governmental entities utilizing plows to remove snow and ice and/or sanders that apply particulates to roadways. In the latter regard, such particulate may be a mixture of sand and/or salts (e.g., sodium chloride, calcium magnesium acetate (CMA)), which may melt snow/ice on a roadway. While CMA is sometimes used, rock salt is the most commonly utilized deicer. In such arrangements, a mixture of sand and salt granules may be spread onto a roadway. 
     In addition to solid application, it has also been recognized that the application of liquid deicers provide significant benefits. For instance, it has been recognized that application of liquid deicers may more readily melt ice formed on a surface or the application of liquid deicer prior to the accumulation of snow or ice may reduce the adhesion of the snow and ice to the surface and thereby improve removal of the same and/or limit the buildup thereof. Further, if properly applied, the application of a liquid deicer can prevent road surfaces from freezing in the first place. 
     Such liquid deicing solutions may generally be created by directing a liquid solvent (e.g., water) through an amount of a chemical to be dissolved, such as rock salt or CMA, to produce a highly concentrated or saturated solution. For instance, it has been found that a solution of approximately 23.3% NACL by weight in water is an efficient solution for removing ice and snow. At this salinity level, the solution will melt ice and snow with ambient temperatures as low as about −11° Fahrenheit. 
     In highway maintenance applications, large quantity of such salt brine may be required to adequately cover multiple streets, highways, etc. Accordingly, most highway maintenance crews typically prepare and store salt brine for application. That is, most highway maintenance crews have stores of solid salts or CMA pellets they dissolve into water to generate ‘brine solutions.’ As will be appreciated, it may also be necessary to produce such brine solutions to augment or replace the solution as it is utilized. Accordingly, many such entities have brine producing devices at their facility. 
     Various brine producing devices have been proposed. A number of these devices produce a brine solution by directing water through a columnar container holding salt or CMA pellets where water enters at the bottom of the container (e.g., salt hopper) and overflows through an outlet at the top of the container. In such an arrangement, prior to being removed from the top of the container, the liquid may be recirculated to achieve a desired salinity. Other brine producing devices introduce water at the top of a container/hopper holding salt or chemical pellets and allow the water to drain through the container. Again, this solution may be recirculated to achieve desired salinity. The resulting brine is collected and typically pumped into a holding tank. 
     While the process for generating such brines is straightforward, a number of difficulties exist in the actual implementation of this process. One particular problem lies in the amount of sediment that is included with raw salts. That is, commercial rock salt can be quite dirty and may include significant percentages (e.g., 10% or more) of sediment/dirt. This sediment and dirt collects in the salt hopper. Accordingly, it is necessary to periodically clean the brine making apparatus. However, cleaning of these apparatuses has heretofore been a labor-intensive process. In many brine apparatus designs, an operator may have to climb into the hopper itself and physically remove the sediment. Other arrangements have allowed for removing and dumping the hopper. Due to these difficulties, crews often fail to clean or adequately clean these devices. This can result in various fluid inlets or outlets becoming plugged by either sediment or solidified brine (i.e., salt cake). Accordingly, these devices may not be readily available when needed. 
     SUMMARY 
     Provided herein is an admixing apparatus and system that in various arrangements may be utilized to produce deicing solutions including salt brines. To facilitate cleaning of the interior of the device, a mixing hopper is utilized that includes a side access opening that allows for readily accessing the interior of the hopper and removing any sediment that has accumulated herein. 
     According to a first aspect, an apparatus is provided for admixing solids with a solvent to produce a liquid solution. The apparatus includes a hopper having one or more sidewalls and a bottom surface. A portion or an entirety of the upper end of the hopper is open to facilitate placement of solid materials therein. A side gate extends across at least a portion of a width of one of the sidewalls. This side gate moves between an open position and a closed position relative to an opening in that sidewall. In an open position, an edge of the bottom surface of the hopper is exposed. In the closed position, the side gate covers the opening and seals with the sidewall such that the gate, sidewalls, and bottom surface form a liquid-tight tank. The device further includes a fluid inlet for introducing water into the hopper and a fluid outlet extending through the bottom surface. A pump may circulate water through the fluid inlet and/or outlet. In such an arrangement, water may spray over materials in the hopper, filter to the bottom of the hopper, drain from the hopper and/or re-circulate through the fluid inlet. This may allow for increasing the salinity of water passing over salt in the hopper. Accordingly, the device may include various valves, pumps, and plumbing to permit such circulation. Furthermore, the device may be connectable to a storage tank such that upon the fluid achieving a desired concentration (e.g., salinity) fluid may be removed from the hopper and stored in the tank. 
     In one arrangement, the fluid outlet disposed through the bottom surface of the hopper is isolated from the interior of the hopper by a screen. In one arrangement, an edge surface of this screen engages the side gate when the side gate is in a closed position. Accordingly, when the side gate is in the open position, the area under the screen including the outlet is exposed. 
     To permit the side gate to effectively seal with the sidewall of the hopper, a seal or gasket is typically disposed about the periphery of the side gate and/or the mating surface of the hopper. Such a seal may be formed of any appropriate materials. 
     In one arrangement, the bottom surface of the hopper slopes across a width or other cross dimension of the interior of the hopper. In such an arrangement, the edge of the bottom surface that is exposed when the side gate is opened may be a lower edge of this sloping bottom surface. In this regard, the hopper may drain when the side gate is open. Further, the bottom surface may continuously slope from a first sidewall or inner edge to a second sidewall of the hopper, which includes the side gate. In one arrangement, the slope of this bottom surface is at least about 10° and less than about 45°. 
     The side gate may be interconnected to the hopper in any manner that allows for the gate to move between an open and closed position so long as the side gate closes and seals an opening through the side surface of the hopper. In one arrangement, the side gate may extend entirely across the width of the hopper. In other arrangements, the side gate may extend across less than the entirety of the width of a sidewall. To operate the gate, one or more latching mechanisms may be interconnected thereto. Such latching mechanisms may include hydraulic actuators as well as mechanical latches that permit securing the gate relative to the hopper. 
     The brine maker may further include control circuitry that allows for a portion or all of the functions of the system to be automated. In this regard, various floats may be provided that allow for automatically filling a water level in the hopper to a desired level. Other floats may provide information regarding the salinity level of a fluid within the hopper. In further arrangements, salinity measurement devices may be interconnected to measure the salinity of the brine solution. Such devices may be interconnected to plumbing and/or outlets of the hopper. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure and further advantages thereof, reference is now made to the following detailed description taken in conjunction with the drawings in which: 
         FIG. 1  illustrates a front perspective view of the brine maker device. 
         FIG. 2  illustrates a rear perspective view of the brine maker device. 
         FIG. 3  illustrates a side view of the brine maker device with the tailgate in the open position. 
         FIG. 4  illustrates a side view of the brine maker device with the tailgate in the closed position. 
         FIG. 5  illustrates positioning a frontend loader beneath the tailgate of the brine maker. 
         FIG. 6  illustrates the ducting and control componentry of the brine maker. 
         FIG. 7  illustrates a lower hydraulic latching mechanism. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made to the accompanying drawings, which at least assist in illustrating the various pertinent features of the presented inventions. In this regard, the following description is presented for purposes of illustration and description. Furthermore, the description is not intended to limit the disclosed embodiments of the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. 
       FIGS. 1 and 2  illustrate first and second perspective views of a device  10  utilized to admix solids with liquid solvent to generate a liquid solution. Primarily, the device  10  is described herein as producing salt brine where salt is mixed with water to generate a salt brine solution having a desired salinity. However, it will be appreciated that the device  10  may be utilized to admix other materials and is therefore not limited to the mixing of salts and water. 
     As shown, the brine maker device  10  is generally formed as a tank having an open upper end into which salt or other materials may be deposited. More specifically, the brine maker  10  includes a hopper  20  that is defined by four vertical sidewalls and a bottom surface. In the present embodiment the brine maker  10  includes a front wall  22 , a back wall  24 , two sidewalls  26 A,  26 B, and a bottom surface  28 . This bottom surface in various arrangements slopes between the back wall  24  and the front wall  22  to facilitate cleaning of the brine maker  10 , as will be more fully discussed herein. 
     As shown, the hopper  20  is supported above the ground by a frame that includes four vertical legs  12  connected to the outside surface of the hopper. These legs suspend the hopper  20  above the ground such that a front end loader may be positioned beneath the hopper for cleaning purposes as discussed herein. In the present embodiment, the bottom of each leg  12  includes a foot  18  that is adapted for interconnection to an underlying surface. For instance, each foot  18  may be affixed to a concrete pad. In addition, one or more cross supports  14  may extend between the legs  12  and may form a platform beneath the bottom surface of the hopper. In this regard, components (e.g., hydraulic pumps, water pumps, piping, valves, etc.) may be disposed on the platform  16  beneath the hopper and thereby isolated from, for example, potential damage from salt being deposited into the hopper. It will be appreciated that the frame and/or hopper may be made of any appropriate materials. Such materials include, without limitation, carbon steel, stainless steels, and aluminums. 
     As discussed above, cleaning of brine makers has heretofore been problematic. One problem has been accessing the interior space of the brine maker in a manner that allows for easily removing sediment therefrom. To address this difficulty, the present brine maker  10  utilizes a tailgate or side gate arrangement that provides an opening through a side surface in the hopper  20 , which permits an operator easy access into the interior of the hopper for cleaning purposes. In the present embodiment, the tailgate  40  extends entirely across the width of the front wall  22 . However, this need not be the case, and in other embodiments, the tailgate  40  may extend across less than an entirety of a sidewall of the hopper  20 . As shown in  FIGS. 1-4 , in the present embodiment a tailgate  40  is pivotally interconnected to the front wall  22  of the hopper  20  utilizing one or more hinges  46 . Specifically, in the present embodiment, a top edge of the tailgate  40  is pivotally interconnected to the front wall  22  via first and second hinges  46 . However, it will be appreciated that in other embodiments the lower edge or side edge of such a side gate/tailgate  40  may be pivotally interconnected to the hopper. In any arrangement, the tailgate  40  is adapted to move between an open position (e.g., See  FIGS. 1 and 3 ) and a closed position (e.g., See  FIGS. 2 and 4 ). When the tailgate  40  is in the open position, the operator has full access to the interior of the hopper  20  in order to remove sediment that may have accumulated during use. In the closed position, the tailgate pivots into alignment with the front wall  22  and a periphery of the tailgate  40  mates with a gate frame  32  outlining an opening through the front wall  22 . A gasket  38  disposed around the periphery of the tailgate  40  is compressed between the periphery of the tailgate and the gate frame  32 . That is, when the tailgate  40  is closed and the gasket  38  is compressed, the tailgate  40  seals the opening through the front wall  22 . Accordingly, at this time, the hopper  20  is fluid-tight and thereby defines an open-ended tank into which salt may be disposed and mixed with water. 
     In the present embodiment, a hydraulic cylinder  50  provides an opening and closing mechanism for the tailgate  40 . The hydraulic cylinder  50  is operated by a hydraulic pump  54 , which may be mounted below the hopper on the platform  16 . See  FIG. 6 . It will be appreciated that the cylinder  50  and the pump  54  will be connected by various hydraulic hoses  82 . As shown in  FIGS. 1 ,  3  and  4 , the hydraulic cylinder  50  is mounted to the front wall  22  of the hopper  20  by a first support mount  52 . A second end of the hydraulic cylinder  50  is interconnected to the tailgate  40  by a second support mount  48 . As best illustrated in  FIG. 4 , the support mount  52  mounted to the front wall  22  of the hopper  20  extends outwardly from the front wall (i.e., which defines a reference plane) further than the second support mount  48  interconnected to the tailgate  40 . In this regard, when the hydraulic cylinder  50  is extended, the hydraulic cylinder is operative to apply a compressive force between the first mount  52  and the second mount  48 . Furthermore, this provides a moment around the hinges  46  and, thereby, closes the gate and at least partially compresses the gasket  38 . In contrast, when the hydraulic cylinder  50  is retracted (e.g., See  FIGS. 1 and 3 ), the cylinder  50  provides a retractive force between the first and second mounts  52 ,  48  and, thereby, rotates the tailgate  40  into the open position as illustrated in  FIGS. 1 and 3 . 
     The hydraulic cylinder  50  provides the initial closing force for the tailgate. However, once in the closed position a second cylinder  58  provides a further compressive force to the tailgate and gasket. See  FIGS. 1 ,  2  and  7 . This second cylinder  58  is interconnected to a shaft  70  by a pivot linkage  84 . This shaft extends across the width of the bottom surface  38  of the device  10  proximate to the front wall  22 . Interconnected to each end of the shaft  70  are pin catches  34 . As shown in  FIGS. 1 and 2 , these pin latches are adapted to engage pins  36  interconnected to the bottom outside edges of the tailgate once the tailgate  40  is closed. The pin catches  34  rotate with the shaft  70 , which is rotated via extension and retraction of the second hydraulic cylinder  58  as applied through the pivot linkage  84 . As the pin catches  34  rotate, they tighten about the pins  36  and further compress the tailgate  40  against the frame. 
     To maintain compression of the gasket when the hopper is filled with salt and water, the tailgate  40  further includes one or more latching mechanisms for physically locking the tailgate in the closed position. As shown, the side surfaces of the gate frame  32  each include first and second tailgate latches  44 . Typically, these latches  44  are adjustable draw latches that allow for adjusting the amount of compressive force applied between the hopper  20  and the tailgate  40 . In addition to the side latches  44 , first and second bottom latches  42  are attached to the bottom of the frame  32 . It will be appreciated that multiple different latches may be utilized. Such latches may include, without limitation, cam latches, threaded latches, turn buckles, etc. What is important is that the latches allow for compressing the tailgate  40  relative to the frame  32  and/or maintaining compression of the gasket  38  in view of the hydraulic pressure of the water and salt within the hopper  20 . 
     As shown in  FIGS. 1-4 , the bottom surface  28  of the hopper  20  is sloped between the back wall  24  and the front wall  22 . That is, the bottom surface attaches to the back wall  24  (i.e., in relation to a support surface/ground) at a higher elevation that the bottom surface  28  connects to the front wall  22 . By sloping the bottom surface of the hopper  28  continuously between the back wall and front wall, sediment that may accumulate in the bottom of the hopper is easily removed from the brine maker  10 . That is, upon opening the tailgate  40 , a front/lower edge of the bottom surface  28  is exposed. Accordingly, an operator may conveniently spray water into the hopper  20  and drain and/or scrape sediment out of the front of the hopper without having to enter into the hopper itself. In one embodiment, the bottom surface  28  slopes at an angle of about 20° between the front and back wall. This slope angle may vary. However, it is believed that having a slope of at least 10° and less than 45° is preferable. On the lower limit, the angle allows for adequately draining materials out of the hopper. On the upper level, the shallower angle allows for extending the length of the hopper, which increases its capacity and facilitates loading the same, as is discussed herein. 
     As shown in  FIGS. 1 and 2 , the interior of the hopper  20  includes first and second sediment screens  66 . These first and second sediment screens  66  isolate first and second fluid outlets  60  from the main body of the hopper. In this regard, the sediment screens  66  have a plurality of apertures disposed therethrough that limit the amount of granular salt and/or sediment that may pass through. That is, during operation, salt is dumped into the interior of the hopper and water is mixed with the salt to produce the brine solution. More specifically, water is introduced into the hopper until the water level obtains a desired height. The water is received from a fluid inlet  72  and passes through a spray bar  74 , which sprays the water onto the salt in order to dissolve the same. The spray bar  74 , as illustrated, extends across the back wall of the hopper. However, it will be further appreciated that multiple spray bars may extend across the back wall and/or along the top edges of the sidewalls. In any arrangement, such spray bars typically include a plurality of apertures/holes that allow for directing fluid/water into different areas of the interior of the hopper. Accordingly, this water may be directed over different portions of the salt within the hopper to more readily dissolve the same. 
     The water typically achieves a desired salinity in a single pass through the hopper. However, if necessary, the water may be removed from the bottom of the hopper and recirculated into the top of the hopper to continue dissolving the salt and saturating the water (i.e., raising the salinity level). In this regard, water from the bottom of the tank is removed from the first and second fluid outlets  60  and recirculated back into the hopper via a recirculating hose or via the fluid inlet and the spray bar  74 . In this regard, a pump  78  is provided that is fluidly interconnected to the fluid outlet and the fluid inlet. In this regard, various piping and valves may extend between the outlets  60  and the pump  78  and between the pump  78  and the hopper and/or the fluid inlet  72 . Likewise, this pump  78  and/or piping may be interconnected to a water source that allows for initially filling the tank. In any arrangement, the pump  78  is operative to circulate the fluid through the tank. Once a desired salinity is achieved, a user may, for example, open a valve and pump or drain the brine solution from the hopper into, for example, a brine storage tank or into a truck that will be applying the brine to a roadway surface. Once the brine is drained from the hopper, fresh water may be reintroduced to continue dissolving the salt within the hopper. 
     The screens  66  prevent the salt from entering into the fluid outlets. Furthermore, these screens prevent at least a portion of the sediment within the salt from passing into the fluid outlets. In the present arrangement, to further limit the amount of sediment that is in the brine, the first and second fluid outlets  60  each include a screened vent cap  62 . In this regard, the screens of the vent cap  62  may be finer than the screens  66  that isolate the outlets from the hopper. In this regard, additional sediment may be removed from the brine. 
     While the screens  66  prevent most sediment from entering into the outlet area beneath/enclosed by these screens, some sediment does pass into the outlet area. Accordingly, this sediment must also be removed from the brine maker  10  during cleaning. To facilitate the removal of sediment from this area, the present embodiment utilizes screens  66  that have an open end to allow for access into the interior area defined by these screens. That is, an edge surface  68  of each of these screens  66  abuts against an inside surface of the tailgate  40  when the tailgate is closed. As shown in  FIG. 2 , when the tailgate  40  is closed the screen  66  isolates the fluid outlet from the main interior area of the hopper. However, when the tailgate is open (See  FIG. 1 ), an operator may readily clean out the interior area underneath the screen  66 . Furthermore, in one embodiment the screens are angled to reduce the amount of sediment that builds up on the screens themselves. Accordingly, during cleaning, the user may open the tailgate  40 , spray out the inside of the hopper, and spray off the screens. 
     To further facilitate the cleaning of the hopper  20 , the width of the hopper may be less than the width of a bucket of a frontend loader. In this regard, prior to opening the tailgate, the bucket of such a frontend loader may be disposed beneath the tailgate. As best shown in  FIGS. 2-5 , the front legs  12  of the frame of the brine maker  10  are set back from the front wall  22  of the hopper  20 . This allows disposing the bucket  100  of a frontend loader  110  directly beneath the tailgate  40 . See  FIG. 5 . At such time, the tailgate may be opened and any sediment, remaining salt, and/or water within the hopper  20  may be spilled directly into the bucket of the loader. Further, at such time, a user may wash and/or scrape out the interior of the hopper directly into the bucket  100  of the loader  110 . 
     While the width of the hopper  20  is preferably less than the width of the bucket of a frontend loader, the length of the sidewalls  26 A,  26 B is typically greater than the width of such a bucket. In this regard, when dumping salt over the side surface of the hopper, the hopper is long enough such that no spillage occurs over the front and back walls. In this regard, the width to length ratio of the hopper is typically less than one and more commonly less than about 0.8. 
     As illustrated in  FIG. 2 , the brine maker device  10  may include one or more floats  90  that allow for automated operation of the brine maker. As will be appreciated, such floats typically have a specific gravity that allows the floats to move when the salinity of the solution within the hopper reaches a desired level. For instance, the lower float  90 A may have a specific gravity that corresponds with a desired salinity (e.g., approximately 23.3% by weight NACL). Accordingly, water may sit in the hopper and/or the pump  78  may re-circulate fluid until the salinity reaches a level such that the lower float  90 A rises. At this time, the recirculating pump may cease operation, and an indication may be provided that the brine has reached the desired level. The upper float  90 B may provide an indication of overfilling and/or clogging of the outlet pumps. Accordingly, if this float is activated, the pump may stop, and a maintenance warning may be issued. In addition to the floats  90 A,  90 B, water level sensors  92 A,  92 B (See  FIG. 1 ) may be provided that allow for automatically introducing water to a desired level into the interior of the hopper. In this regard, these water level sensors  92 A,  92 B may allow for controlling the opening and closing of a water inlet valve associated with a water source. 
       FIG. 6  illustrates components of the brine maker  10  that are disposed on the platform  16  beneath the hopper. As shown, the first and second outlets  60 A,  60 B are interconnected to a fluid pump  78  via connecting pipes  76 . One or more filters  98  may be disposed within one or more of the pipes. As shown, a number of valves  94 A-C are disposed within this plumbing. Accordingly, by operating these valves a user may selectively direct the output of the pump. For instance, a first valve  94 A may be closed, and a second valve  94 B may be opened to provide an inlet into the system. That is, this valve may be connected to a brine truck to offload brine. A further valve  94 C may be utilized to output water or brine from the hopper to, for example, a storage tank or tanker truck. A recirculating hose (not shown) may be connected to this valve  94 C and disposed over the top edge of the hopper for recirculation. In other arrangements, the pump may be connected to the spray bar  74 . In the present embodiment, an electric motor runs the pump  78 . However, it will be appreciated in other arrangements hydraulic pumps may be utilized. Such arrangements may be utilized for remote applications where the device is operated utilizing a power takeoff of a tractor or other industrial machine. In other arrangements, the power source may be provided by off grid sources such as, without limitation, wind turbines and/or solar panels. 
     In one arrangement, a salinity test point  96  is provided. In various arrangements, the salinity test point  96  may allow a user to draw brine from the plumbing in order to manually test the salinity of the brine. In other arrangements, automated salinity detection devices may be incorporated into the salinity test point. In this regard, the salinity test point  96  may include a measurement device that measures the specific gravity of the brine. Accordingly, in such an arrangement the system may be operative to add water (e.g., via the test point, which may be connected to a water source) to reduce the salinity or continue circulating the water in the tank until a desired salinity is achieved. Also mounted to the platform beneath the hopper is a hydraulic control system  80  that controls the operation of the first hydraulic cylinder  50  and second hydraulic cylinder. In this arrangement, the hydraulic control system includes a user control handle  86  and hydraulic pump  54  that is interconnected to the cylinders  50 ,  58  via various hydraulic lines  82 . A user opens and closes the tailgate by actuating the user control handle  86 . Also included in the hydraulic control system is a hydraulic synchronizing valve  84 . This valve  84  synchronizes the operation of the two hydraulic cylinders. Specifically during closing, the synchronizing valve  84  directs hydraulic fluid such that the first cylinder  50  moves the tailgate from the open position to the closed position before the second cylinder  58  rotates the shaft  70  to lock the bottom of the tailgate. Likewise, during opening, the synchronizing valve directs fluid to operate the second cylinder  58  to rotate the shaft  70  and release the tailgate prior to the first cylinder moving the tailgate from the closed position to the open position. It will be appreciated that other components may be mounted to the platform and/or the hopper. For instance, a vibrator may be connected to the hopper to provide agitation to materials therein to improve the mixing process. 
     The foregoing description of the presented inventions has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described hereinabove are further intended to explain best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.