Patent Publication Number: US-2023159353-A1

Title: Water Treatment Systems and Methods for Poultry Chillers

Description:
RELATED APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 16/070,644, filed Jul. 17, 2018, which is a 35 U.S.C. § 371 national phase application of PCT International Application No. PCT/US2017/014137, filed Jan. 19, 2017, which claims priority to U.S. Provisional Application No. 62/281,789, filed Jan. 22, 2016, the disclosure of each of which is incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     It is desirable to treat water in poultry chillers to reduce the concentration of fats, oils and grease in order to improve the efficacy of anti-microbial treatment to the water and to increase the length of time such water is suitable for use in chilling poultry products. 
     SUMMARY 
     Some embodiments of the present invention are directed to a water treatment system for a poultry chiller including a chiller tank. The system includes a float holding tank at a downstream section of the chiller tank, a fan at the downstream section of the chiller tank that is configured to blow float formed on a surface of water in the chiller tank into the float holding tank, and a float removal mechanism at the float holding tank that is configured to remove the float from the float holding tank. 
     According to some embodiments, the fan is positioned on a first side of the chiller tank and the float holding tank is positioned on a second, opposite side of the chiller tank. The fan may be adjacent and/or coupled to an upper portion of a sidewall of the chiller tank. 
     According to some embodiments, the float removal mechanism includes a paddle and a drive mechanism configured to advance the paddle across the float holding tank. The float holding tank may include a ramp terminating in a lip at a side portion of the float holding tank, and the drive mechanism may be configured to advance the paddle up the ramp such that float collected by the paddle is discharged over the lip. 
     According to some embodiments, the float removal mechanism includes a rotary screen and a drive mechanism configured to rotate the rotary screen in the float holding tank. The float removal mechanism may include a wiper adjacent the rotary screen, and the drive mechanism may be configured to rotate the rotary screen such that float collected on an outer surface of the rotary screen is removed by the wiper. 
     According to some embodiments, the float removal mechanism includes a floating weir in the float holding tank and a drain chute in communication with the outside of the float holding tank, with the floating weir including an upper opening with a weir edge configured to allow float on a surface of the water to pass over the weir edge into the upper opening and a lower opening configured to allow float passing through the floating weir to exit through the drain chute. The floating weir may be further configured to float in the water of the float holding tank with the weir edge proximate the water level in the float holding tank. The lower opening of the floating weir may be configured to provide a sliding seal against the drain chute. The floating weir may include a plurality of spaced apart flotation segments with a gap defined between adjacent ones of the segments. The gaps may provide a flow path for float to flow therethough and into the upper opening of the floating weir. 
     According to some embodiments, the system includes: a saturation pump in fluid communication with the float holding tank and configured to remove effluent water from the float holding tank; a device configured to introduce air into the effluent water flowing from the floating holding tank to the saturation pump; and/or at least one injection nozzle at an upstream section of the chiller tank, the injection nozzle configured to inject the water received from the saturation pump into the tank to form micro-bubbles that rise to the surface of the water in the chiller tank and collect small pieces of debris so that a layer of float is formed on the surface of the water in the chiller tank. 
     According to some embodiments, the system is in combination with the chiller tank. 
     Some other embodiments of the present invention are directed to a method for treating water held in a poultry chiller including a chiller tank. The method includes: blowing float formed on a surface of the water in the chiller tank to one side of the chiller tank at a downstream portion thereof; receiving the float blown to one side of the chiller tank in a float holding tank; and removing the float from the float holding tank. 
     According to some embodiments, the blowing step is carried out using a fan that is adjacent a top portion of the chiller tank at a first side thereof, and the float holding tank is positioned at a second, opposite side of the chiller tank. 
     According to some embodiments, removing the float from the float holding tank includes advancing a paddle across the float holding tank to collect the float with the paddle and urge the float over a lip of the float holding tank. 
     According to some embodiments, removing the float from the float holding tank includes rotating a rotary screen in the float holding tank to collect the float on an outer surface of the rotary screen and removing the float from the outer surface of the rotary screen using a wiper that is adjacent the rotary screen. 
     According to some embodiments, removing the float from the float holding tank includes receiving the float at a floating weir in the float holding tank such that float flows over an edge of the floating weir and drains under the force of gravity out of the float holding tank. 
     According to some embodiments, the method includes: injecting water saturated with air using an injection nozzle at an upstream section of a chiller tank to form micro-bubbles that rise to the surface of water held in the chiller tank; collecting small pieces of debris with the micro-bubbles so that a layer of float is formed on the surface of the water in the chiller tank; and/or circulating water in the float holding tank back to the injection nozzle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a top view of a poultry chiller and a water treatment system according to some embodiments. 
         FIG.  2    illustrates a skimmer box of the water treatment system of  FIG.  1    according to some embodiments. 
         FIG.  3    is a sectional end view of an upstream section of the chiller and the water treatment system of  FIG.  1    according to some embodiments. 
         FIG.  4    is a sectional end view of a downstream section of the chiller and the water treatment system of  FIG.  1    according to some embodiments. 
         FIG.  5    is a sectional end view of a downstream section of the chiller and the water treatment system of  FIG.  1    including a rotary screen in a suction box according to some embodiments. 
         FIG.  6    is a sectional view through the rotary screen of  FIG.  5   . 
         FIG.  7    is a perspective view of the rotary screen of  FIG.  5   . 
         FIG.  8    is a sectional end view of a downstream section of the chiller and the water treatment system of  FIG.  1    including a floating weir in a suction box according to some embodiments. 
         FIG.  9    is a fragmentary sectional view of the floating weir and the suction box of  FIG.  8   . 
         FIG.  10    is a fragmentary perspective view of the floating weir of  FIG.  8   . 
         FIG.  11    is a perspective view of another embodiment of a floating weir that can be used with the chiller and the water treatment system of  FIG.  1   . 
         FIG.  12    is a side view of the floating weir of  FIG.  11   . 
         FIG.  13    is a fragmentary perspective view illustrating a floating weir having a linear configuration that can be used with the chiller and the water treatment system of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     It will be understood that when an element is referred to as being “coupled” or “connected” to another element, it can be directly coupled or connected to the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly coupled” or “directly connected” to another element, there are no intervening elements present. Like numbers refer to like elements throughout. As used herein the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     In addition, spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     Well-known functions or constructions may not be described in detail for brevity and/or clarity. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “includes,” “comprising,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     It is noted that any one or more aspects or features described with respect to one embodiment may be incorporated in a different embodiment although not specifically described relative thereto. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination. Applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to be able to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner. These and other objects and/or aspects of the present invention are explained in detail in the specification set forth below. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
       FIG.  1    is a top view of a poultry chiller  10  according to some embodiments. The chiller  10  includes a chiller tank  12 . According to some embodiments, the chiller  10  is an auger chiller and includes an auger  14  disposed in the tank  12 . The operation of an auger chiller is well known to those of ordinary skill in the art and, therefore, a detailed description of such operation is omitted herein. 
     A water treatment system  20  is associated with the chiller  10 . Referring to  FIGS.  1 ,  3  and  4   , the water treatment system  20  includes a fan  22 , a float collecting area or float holding tank such as a skimmer box  24 , a saturation pump  32  and an injection nozzle  36 . The float holding tank may include an appendage to the chiller tank in fluid communication with the chiller tank at the water surface or it may simply be a location within the chiller tank suitable for collecting float. The float holding tank is preferably outside the path of any moving component such as an auger or dasher. 
     The fan  22  and the skimmer box  24  are at a downstream section  26  of the chiller tank  12 . The injection nozzle  36  is at an upstream section  38  of the chiller tank  12 . As used herein, the terms “downstream” and “upstream” refer to the direction of poultry progression during operation of the chiller  10 . According to some embodiments, the fan  22  and the skimmer box  24  are at a first end portion  26  of the chiller tank  12  and the injection nozzle  36  is at a second, opposite end portion  38  of the chiller tank  12 . 
     The saturation pump  32  pulls effluent water  28  from the chiller  10  (e.g., from the skimmer box  24 ). Air is introduced into the water using any of various devices or means familiar to those of ordinary skill in the art such as a compressed air source  31  that may be included with the water treatment system  20  or a venturi that sucks ambient air into the flow of water. The saturation pump  32  mixes the air into the water and increases the water pressure so that some or all of the air dissolves into the water. According to some embodiments, compressed air is introduced downstream of the pump and allowed to dissolve into the water at that point. The saturation pump  32  delivers the saturated water  34  to the injection nozzle  36 . As described above, the injection nozzle  36  is somewhat upstream of the skimmer box  24 . 
     Referring to  FIG.  3   , the water from the injection nozzle  36  “fizzes” out and bubbles  40  (or micro-bubbles) rise to the water surface  42  in the chiller tank  12 . As the bubbles rise to the surface, they adhere to small bits of debris along the way causing the debris to float. A layer of float  44  including foam as well as denser accretions of fats, grease and oil forms on the water surface and auger  14  ( FIG.  1   ) pushes the float downstream. 
     This system is similar to a dissolved air floatation (DAF) process which removes suspended matter such as oil or solids. In prior art DAF applications, dirty water would be removed from the source for treatment in an independent aeration system and separation tank from which clean water returns. As described above, the removal is achieved by dissolving air in the water under pressure and then releasing the air at or near atmospheric pressure at the injection nozzle  36 . The released air forms tiny bubbles which adhere to the suspended matter causing the suspended matter to float to the surface of the water. According to some embodiments, there may be a pressure reduction valve at or adjacent the injection nozzle to reduce the pressure of the water so that the dissolved air is released in the form of micro-bubbles. 
     The fan  22  then blows the float  44  over to the side of the chiller which may be the “dead side” of the chiller  10  (i.e., the side where the auger moves downwardly as it rotates). This is similar to the wind blowing across a pond and pushing scum to one side. The fan  22  may be positioned at or near a top of the chiller tank  12 . In particular, the fan  22  is positioned such that it will blow air to move the float even if the water level in the chiller tank  12  varies. The fan  22  is positioned on a first side  11  of the chiller tank  12  and the skimmer box  24  is positioned on a second, opposite side  13  of the chiller tank  12 . 
     The float is blown through bars  46  and into the skimmer box  24 . The bottom of the skimmer box  24  may be positioned just below the minimum operating water level for the chiller. According to some embodiments, the skimmer box  24  is combined with a suction box. As understood by those of ordinary skill in the art, the suction box provides a space to remove water from the chiller so it can be pumped to a heat exchanger (e.g., re-chiller) and then to the opposite end of the chiller. 
     A rake type skimmer or skimmer assembly  50  according to some embodiments is illustrated in  FIG.  2   . The skimmer  50  includes one or more skimmer paddles  52  that extend vertically down from a drive mechanism (as illustrated, the drive mechanism includes a chain  54  that is driven by sprockets  55 ). The paddle  52  may include a curved bottom edge or portion  56 . The paddle  52  is pivotally attached or connected to the chain  54  such that the paddle is free to pivot about its attachment or connection point (the paddle typically hangs in a vertical orientation due to gravity). 
     The skimmer  50  is configured to accommodate a variation in chiller water level. When the water level is low, the bottom edge of the paddle  52  may be barely submerged in the water in the skimmer box  24 . When the water level is high, more of the paddle  52  is submerged. According to some embodiments, the skimmer  50  is configured to accommodate about an 18 inch variation in chiller water level and the paddle  52  extends about 24 inches down from the chain. 
     One end of the skimmer box  24  includes a ramped surface  58  that slopes upward (perhaps with a fairly shallow slope) to a discharge edge or lip  60 . When the paddle  52  approaches the end of its travel through the skimmer box  24 , the chain  54  lifts the paddle at approximately the same incline as the ramp  58  so that the bottom edge  56  of the paddle  52  drags along the ramp  58  to pull the float  44  up to the discharge lip  60 . The float  44  is sent over the discharge lip  60  to a waste area such as a collection box  62 . On the return transit, the chain  54  is positioned or routed high enough that the paddle  52  (which is hanging downward) does not catch float or interfere with other paddles (where used). 
     Referring to  FIG.  4   , effluent water  28  is removed from the skimmer box  24  by the saturation pump  32 . For example, a stand pipe  66  may be in the skimmer box  24  and in fluid communication with the saturation pump  32 . The water  28  is mixed with air  30  in the saturation pump  32  and the air dissolves into the water in the high pressure discharge of the pump. The saturated water  34  is conveyed to the injection nozzle  36 . The process described above is then repeated. Other methods of dissolving air into the water such as mixing chambers are familiar to those skilled in the art. 
     It will be appreciated that the drag style skimmer described above is only one way to remove the float. Other possibilities include but are not limited to screw conveyors or rotary skimmers. 
     An alternative arrangement for removing float as well as suspended solids is illustrated in  FIGS.  5 - 7   . A rotary screen  70  (or drum) is mounted in a float holding tank that may be the suction box. A drive shaft  80  is coupled to the rotary screen  70  for rotation thereof. As shown in  FIGS.  5  and  6   , water from the chiller  10  flows through the porous wall  76  of the rotary screen  70 . Solids in the water collect on the outside of the screen and form a cake  78 . The cake is scraped off onto a wiper  72  as the screen  70  rotates. According to some embodiments, water or air is sprayed from inside the screen toward the wiper to help remove the cake. 
     Referring to  FIG.  6   , the water level in the chiller  10  and an influent box  82  is higher than the level inside the drum and an effluent box  74 . This level difference provides the pressure difference to push the water through the screen  70 . A pump (which may be the saturation pump  32  or a different pump) removes water from the effluent tank to maintain the reduced water level. In other embodiments, the pump may be a circulation pump supplying water to a heat exchanger for the chiller. 
     A seal  84  may be positioned between the rotary screen  70  and the effluent box  74 . 
     A further alternative arrangement for removing float as well as suspended solids is illustrated in  FIGS.  8 - 10   . A floating weir  90  is positioned in the skimmer box  24  (which may be combined with the suction box as described above). The weir  90  includes a float collar  94  and a tubular portion  92  extending downwardly from the collar  94 . The tubular portion  92  is received around a drain chute (e.g., the stand pipe  66 ) in the skimmer box  24 . A sliding seal  95  may be provided between the tubular portion  92  and the stand pipe  66  (e.g., at or adjacent a lower opening  93  of the tubular portion  92 ). As used herein, the term “tubular portion” is meant to encompass an elongated hollow member having a variety of cross-sectional shapes (e.g., circular, elliptical, polygonal). In other embodiments, the tubular portion  92  may be received inside the drain chute. 
     The weir  90  is configured such that the float collar  94  floats at the surface of water in the skimmer box  24 . The floating weir  90  travels up and down as the water level fluctuates. Float  44  in the skimmer box  24  flows over a weir edge  97  at or adjacent an upper opening  99  of the tubular portion  92  and down the tubular portion  92  of the weir  90  and drains in the direction indicated by the arrow in  FIG.  9   . The drained float may be collected in a collection box  62  ( FIG.  8   ). 
     More specifically, referring to  FIG.  10   , the float collar  94  may include a plurality of spaced apart segments  96  with a gap  98  defined between adjacent ones of the segments  96 . The gaps  98  provide a flow path for the float  44  to flow therethrough and into the tubular portion  92  of the weir  90 . 
     Another embodiment of a floating weir  100  of the tubular form is illustrated in  FIGS.  11  and  12   . The floating weir  100  may be used in place of the floating weir  90  illustrated in  FIGS.  8 - 10    (e.g., the floating weir  100  may be in the skimmer box  24  of  FIG.  9   ). The floating weir  100  includes a tubular portion  102  and one or more floatation chambers or members  104 . According to some embodiments, a plurality of floatation members  104  are employed. For example, as illustrated, the floating weir  100  includes two floatation members  104 , although it will be appreciated that more than two flotation members may be used. According to some embodiments, the floating weir  100  may include a single floatation member  104  (e.g., the floatation member  104  may be shaped as a polygon or a ring and surround an upper portion of the tubular portion  102 ). 
     Like with the weir  90 , float  44  flows over a weir edge  107  at or adjacent an upper opening  109  defined by the tubular portion  102  and down the tubular portion  102  of the weir  100  and drains through the drain chute (e.g., the stand pipe  66 ). A sliding seal  105  may be between the tubular portion  102  and the stand pipe  66  (e.g., at or adjacent a lower opening  103  of the tubular portion  102 , or at or adjacent an upper end of the stand pipe  66 ). 
     A floating weir  120  having a linear configuration is illustrated in  FIG.  13   . The weir  120  includes at least one floatation chamber or member  122  that is configured to float on the water surface. The weir  120  includes a chute  124  that is defined by chute sidewalls  126  and a chute front wall  128 . As illustrated, the chute  124  is hingedly or pivotally attached to the tank sidewall  15  by, for example, hinge  130 . Those skilled in the art will appreciate that the floatation member  122  may have a geometric form that maintains the weir edge  132  in consistent proximity to a surface of water in the tank as the weir  120  pivots in response to higher or lower water level. Alternatively, the weir  120  may be in a separate vessel such as the float holding tank  24  illustrated in  FIG.  4   . With such an arrangement, the chute  124  may be hingedly or pivotally attached to a sidewall  25  of the tank  24 . 
     The flotation member  122  floats at the surface of the water and travels as indicated by the arrow as the water level fluctuates. The weir  120  includes a weir edge  132  at an upper opening  134  of the weir  120 . The weir edge  132  is configured to allow float  44  on a surface of the water to pass over the weir edge  132  into the upper opening  134  and through the weir  120  to a lower opening  136  thereof. The float therefore exits the tank and can be collected as described above (e.g., using the collection box  62  illustrated in  FIG.  5   ). 
     A seal  138  may be provided between the chute  124  and the tank sidewall  15 . The seal  138  may be between the chute sidewalls  126  and the tank sidewall  15 . If a separate float holding tank is used as described above, the seal  138  may be between the chute  124  and the tank sidewall  25  ( FIG.  4   ). 
     In some embodiments, the fan  22  may be positioned on the same side of the chiller as the float holding tank  24 . For example, referring to  FIG.  8   , the fan  22  may be positioned on the same side of the chiller as the float holding tank  24  in order to be closer to the weir  90  so that a stream of air directed toward the weir will have sufficient momentum to assist pushing the float over the weir edge  97  ( FIG.  10   ). This same configuration could be used with the weirs  100  and  120  ( FIGS.  11 - 13   ). The fan  22  may be coupled to the tank  12  or the tank sidewall  15  using any suitable connection feature (e.g., a hook). Alternatively, the fan  22  may be suspended from a separate structure to be positioned over the tank  12 . 
     The examples described herein illustrate water treatment systems integrated with an auger style chiller. It will be appreciated that the water treatment systems can also be applied to rocker style or drag style chillers or other immersion type chillers in a similar fashion. 
     Embodiments of the present invention treat water in poultry chillers to reduce the concentration of fats, oil and grease in order to improve the efficacy of anti-microbial treatment to the water and increase the length of time such water is suitable for use in chilling poultry products. The water treatment systems described herein allow the water to be (continuously) treated and kept in use for days. This is in contrast to the “cold hold” process sometimes used in the industry in which the water is held in the tank for days without proper treatment. It is likely that a regulatory agency such as the USDA will put rules in place requiring treatment of water held for extended processing intervals. 
     Embodiments of the present invention also reduce the capital cost of the water treatment system by integrating the active components of the treatment system into existing features of the poultry chiller. In this regard, some components of known treatment systems may be eliminated. For example, as described above, certain features of the present invention are similar to those of DAF systems. However, embodiments of the present invention eliminate components of the DAF system such as the separation tank. Instead, the separation takes place in the chiller itself. 
     Further, the problem of moving contaminants that float on the surface of the water in the chiller to a location where they can be removed is solved by blowing air across the surface of the chiller water to move contaminants in the desired direction. Blowing air as described herein advantageously does not interfere with the movement any structure (e.g., auger or rocker) in the tank. Further, blowing air across the surface of the water has minimal impact on the flow of product and water in the tank. 
     According to some embodiments, the injection nozzle may be omitted from the water treatment systems and methods described herein. The saturation pump may be replaced with a standard pump for directing the water to a heat exchanger such as a re-chiller. Therefore, water treatment systems and methods according to some embodiments include the fan and a float removal mechanism such as the paddle, rotary screen, or weir described above. Such an arrangement may be sufficient to satisfy water cleaning or treatment regulations in certain jurisdictions. 
     The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.