Abstract:
An apparatus and related methods for optimizing component separation within a fluid using a direct current electric field. The unique sequence and arrangement of concentrically interleaved electrodes increases reactive surface area, decreases time fluid remains within the reactor, and decreases the size of the reaction vessel.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to the field of fluid phase separation and, more particularly, to water treatment and related methods. More specifically, the present invention relates to a device for separating various components present in a fluid, depending on fluid viscosity and thixotropy. 
       BACKGROUND OF THE INVENTION 
       [0002]    Separating components from Newtonian fluids, such as contaminants from waste water, is necessary for numerous industrial processes. Many methods for component separation exist, such a filtration, chemical treatment, and reverse osmosis. These methods, however, suffer from a number of limitations. 
         [0003]    Chemical treatments are typically extremely pollutant-specific. Additionally, the chemicals used to separate components from the fluid often require removal from the solution or mixture themselves, adding cost and complexity to the process. These methods also involve large and complex mixing and separation devices and procedures. Reverse osmosis generates large amounts of waste run-off, and filters can become clogged and are costly to replace. 
         [0004]    Electrocoalescent treatment of fluids to aid in the separation of components from solutions and mixtures is commonplace in, but not limited to, the industrial waste water treatment field. Electrocoalescence is generally considered an environmentally friendly process for the destabilization and flocculation of suspended, emulsified or dissolved contaminants, as the need for adding exogenous chemicals to the purification scheme is minimized or eliminated and large amounts of excess waste water are also not generated. 
         [0005]    Electrostatic treatment of fluids to aid in the separation of components from solutions and mixtures is commonplace in industrial processes. In such liquid component separation schemes, high voltage electric fields are applied to fluids to augment coalescence of immiscible liquid phases. In general, direct current applied to paired metal electrodes, where sacrificial electrodes causes the attraction of ions in solution which contributes to the removal of undesirable contaminants; either by an in-situ chemical reaction and precipitation or by causing colloidal materials to coalesce so to be readily removed by other available means. Oxidation reactions and hydroxyl radical generation also contribute to aggregate formation and the precipitation of component material. Electric fields also tend to increase the size of coalesced droplets in suspension, and therefore increase the speed in which natural, gravity-based phase separation occurs, and also flotation-based and centrifugation-based methodologies. 
         [0006]    There is a substantial need for rapid, high throughput fluid component separation, which is cost effective, does not generate large amounts of additional waste, and is not highly solute- or contaminant-specific. Electrocoalescence reactors substantially fill these needs, but they tend to be large devices with limited electrode-pair surface area. The trade-off is either an extremely large reactor with adequate electrode surface, or a small unit that has a relatively low efficiency due to lack of electrode-pair surface area. 
         [0007]    Accordingly, there is a need for a high efficiency electrocalescence reactor. This and other objects, features, and advantages in accordance with the present invention are provided by a novel electrocalescence reactor arrangement that efficiently maximizes electrode-pair surface area in a compact reactor assembly. 
       SUMMARY OF THE INVENTION 
       [0008]    This invention is an apparatus and related methods for the electrocoalescent separation of fluid constituents. The invention comprises a first electrode base, a first substantially parallel electrode array, having a first inner concentric fin and a first outer concentric fin and a plurality of intervening concentric fins, attached to the first electrode base that projects distally from the first electrode base. It also comprises a second electrode base, a second substantially parallel electrode array, having a second inner concentric fin and a second outer concentric fin and a second plurality of intervening concentric fins, attached to the second electrode base that projects distally from the second electrode base and having a sufficient size and dimension to complimentarily interleave the first electrode array thereby forming a continuous interstitial channel and forming an intake chamber substantially defined by the first inner concentric fin. Additionally, a first conductor is in continuity with the first electrode array, and a second conductor in continuity with the second electrode array is also part of the apparatus. 
         [0009]    In another embodiment, a reactor vessel surrounds the first electrode base, the first electrode array, the second electrode base, and the second electrode array to define a sealed reaction chamber. A first fastening means attaches the first electrode base to the reactor vessel and a second fastening means attaches the second electrode base to the reactor vessel. The reaction vessel comprises an outlet port situated to allow fluid to exit the reaction chamber. There may also be a second outlet port for draining the reactor vessel. 
         [0010]    In another embodiment, there is an outer wall situated between the first electrode base and second electrode base that sealedly surrounds the first electrode array and second electrode array to define a sealed reaction chamber; and an outlet port situated to allow fluid to exit from the reaction chamber. In another embodiment, there is a second outlet port for draining the reactor vessel. 
         [0011]    An inlet port proximate the intake chamber allows fluid to enter the interstitial channel. In some embodiments, the inlet port is a high turbulence input port to promote fluid agitation and mixture before the fluid enters the intake chamber. 
         [0012]    An electrical circuit between the first conductor and the second conductor generates a voltage potential between the first electrode array and the second electrode array. The apparatus further comprises controls to adjust at least one of voltage and current. The apparatus further comprises an instrument to measure the voltage and current of the system and the electrical continuity between electrodes. 
         [0013]    The arrangement of the first electrode array and the arrangement of the second electrode array are substantially a shape selected from the group consisting of a circle, oval, and polygon. The fins of the first electrode array are equidistantly spaced and the fins of the second electrode array are also equidistantly spaced. The conformation of the electrodes may follow a rectangular, circle, oval, square, rectangle, crescent, star, triangle, polygon, pie or other closed shape while following the same operative principle and advantages outlined in present invention. 
         [0014]    The invention also encompasses methods for augmenting the coalescence of fluid constituents comprising the steps of providing a first electrode array comprising a first plurality of concentric fins, the first plurality of concentric fins projecting generally normally from a first electrode base. Also providing a second electrode array comprising a second plurality of concentric fins, the second plurality of concentric fins projecting generally normally from a second electrode base. The first electrode array is interleaved into the second electrode array, and the resultant electrode assembly is encased into a reactor vessel. Fluid is administering fluid into an inlet port of the reactor vessel, and a voltage potential is generated between the first electrode array and the second electrode array with a power control circuit. The fluid is passed through an outlet port so that the fluid exits the reaction chamber. 
         [0015]    The method also encompasses the step of generating of a voltage potential between the first electrode fin array and the second electrode fin array with a power supply circuit and the passing of fluid through an outlet port so that the fluid exits the reaction chamber. In one embodiment, the power supply circuit comprises controls to adjust at least one of voltage and current. In one embodiment, the power supply circuit comprises an instrument to measure at least one of voltage, current, and resistance of the circuit. 
         [0016]    The pressure applied to the fluid regulates fluid flow and therefore the speed the fluid passes through the interstitial channel. In another embodiment, the fluid is exposed to an electromagnetic field prior to flowing into the reaction chamber. In another embodiment, the fluid is subjected to turbulence prior to the injecting to promote fluid turbulence and mixture before the fluid enters the intake chamber. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    For a fuller understanding of the invention, reference is made to the following detailed description, taken in connection with the accompanying drawings illustrating various embodiments of the present invention, in which: 
           [0018]      FIG. 1  illustrates a perspective semi-wireframe view of an exemplary device according to the present invention showing complimentary electrode fin arrays; 
           [0019]      FIG. 2  illustrates a perspective semi-wireframe view of an exemplary device according to the present invention showing the relationship between interleaving electrode fin arrays; 
           [0020]      FIG. 3  illustrates a cross sectional view taken along the line Y-Y of an exemplary reaction chamber according to the present invention; and 
           [0021]      FIG. 4  illustrates a cross sectional view taken along the line Z-Z of an exemplary device according to the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0022]    The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. 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. Like numbers refer to like elements throughout. 
       Electrode Description 
       [0023]    Referring initially to  FIG. 1 , in one embodiment, a first electrode base  1   a  serves as a mechanical base and electrical conductor for the first electrode  10   a . Attached to the first electrode base  1   a  is a parallel electrode fin array  8   a . This array  8   a  is a series of electrically conductive fins that distally project substantially perpendicularly from the first electrode base  1   a . Each fin of the electrode array  8   a  is substantially parallel to each other fin of that same array  8   a.    
         [0024]    The fins of the electrode array  8   a  are arranged concentrically, and the shape profile of each individual, describing a cross section that is in the same plane as the electrode base  1   a , is that of circle, oval, square, rectangle, crescent, star, triangle, polygon, pie or other closed shape. 
         [0025]    The first electrode base  1   a  is made from a metal chosen from the group comprising of aluminum, iron, magnesium, manganese, molybdenum, gold, rhodium, tin, cobalt, copper, lead, nickel, palladium, platinum, silver, titanium, tungsten, zinc, alloys thereof, and any other electrode material known in the art. In a preferred embodiment, the first electrode base  1   a  is made from iron. The fins of the electrode fin array  8   a  are made from at least one metal chosen from the group comprising of aluminum, iron, magnesium, manganese, molybdenum, gold, rhodium, tin, cobalt, copper, lead, nickel, palladium, platinum, silver, titanium, tungsten, zinc, combinations thereof, and any other electrode material known in the art. In a preferred embodiment, the first electrode fin array  8   a  is made from iron. 
         [0026]    The fins of the first electrode array  8   a  are sealedly attached to the first electrode base  1   a  so that fluid can not leak past the point of attachment. There is electrical continuity between the fins of the first electrode array  8   a  and the first electrode base  1   a . In one embodiment, the fins of the electrode array  8   a  are at least one of bolted, cast, welded, brazed, and soldered to the first electrode base  1   a . In one embodiment, the fins of the first electrode fin array  8   a  are mechanically attached to the first electrode base using at least one of bolts, screws, rivets, adhesive, electrically conductive adhesive, and any other attachment means known in the art. In one embodiment, at least one of gaskets and sealant is used to prevent leakage of fluid past the point of attachment. 
         [0027]    The inner concentric fin  4   a  of the first electrode  10   a  substantially defines the intake chamber  5 . The first electrode fin array  8   a  attached to the first electrode base  1   a  forms a number of separate parallel channels that circumscribe the intake chamber  5 . In one embodiment, each concentric fin is equally spaced in a concentric fashion. 
         [0028]    The second electrode  10   b , is substantially a mirror of the first electrode  10   a , however, the second electrode fin array  8   b  is spatially offset a sufficient distance so that the second electrode array  8   b  interleaves the first electrode array  8   a .  FIG. 2  illustrates one embodiment of the invention wherein electrodes  10   a ,  10   b  are interleaved to form the electrode assembly  20 . The electrode assembly  20  comprises an interstitial channel  11  as a result of the interleaving electrodes  10   a ,  10   b . The outer channel  3  of the second electrode  10   b , after both electrodes interleave, is roughly halved in size by the outer concentric fin  2   a  of the first electrode  10   a , and this splits the outer channel  3  into two sub-channels, the outer sub-channel being referred to as a last parallel sub-channel  7 . The interstitial channel  11  originates at the intake chamber  5 , and continues from a first parallel sub-channel  6  to a last parallel sub-channel  7 . 
         [0029]    The size of the individual sub channels of the interstitial channel  11  of the electrode assembly  20  is determined by the spacing between the concentric electrode arrays  8   a ,  8   b . As fluid travels through the interstitial channel  11 , the pressure drops as a function of distance from the reactor center. If the fins of an electrode array  8   a ,  8   b  are spaced too closely, flow redirection causes a pressure increase. If the fins of an electrode array  8   a ,  8   b  are spaced too far apart, the flow decreases, while the system efficiency increases. For most fluids, the spacing between fins of a sub-channel in the interstitial channel  11  is ideally between 2 mm and 25 mm. 
       Reactor Vessel Description 
       [0030]      FIG. 3  shows the electrocoalescence assembly  30  comprising the electrode assembly  20  encased within a reactor vessel  31 . The reactor vessel  31  is constructed from at least one of plastic, fiberglass, carbon fiber, stainless steel, and any other material known in the art for fabricating such vessels. In one embodiment, the reactor vessel comprises a vessel input port  36  that sealedly communicates with the inlet port  9  of the first electrode  10   a . In one embodiment, a conduit  38  communicates with the inlet port  9  and the vessel input port  36 . In one embodiment, the conduit  38  creates fluid turbulence. 
         [0031]    The electrodes  10   a ,  10   b  are attached to the reactor vessel  31  by at least one of mechanical fasteners, hook and loop, adhesive, sealant, and any other method know in the art. A first conductor  25  is attached to the first electrode base  1   a , and a second conductor  27  is attached to the second electrode base  1   b . The first conductor  25  passes through a first conductor port  26  in the reactor vessel  31 , and the second conductor  27  passes through a second conductor port  28  in the reactor vessel. The conductor ports  26 ,  28  are sealed between the conductors  25 ,  27  and the reactor vessel  31  using at least one of rubber grommets, sealant, friction fit, and any other sealing means known in the art employed to prevent fluid from escaping the reactor vessel around the conductors  25 ,  27 . 
         [0032]    The reactor vessel  31  comprises at least one output port  32 . The reactor vessel  31  comprises at least one drain port  34 . The output port allows fluid in the electrocoalescence assembly  30  to exit and the drain port  34  allows the drainage of fluid from the reactor vessel  31 . In one embodiment, the output port  32  is situated at a height on the side wall  31   a  of the reactor vessel  31  corresponding with the height of the second outer concentric fin  2   b  thereby maintaining an effective fluid level in the reactor and avoiding uncontrolled drainage of the electrocoalescence assembly  30 . 
       Reactor Operation 
       [0033]    Fluid enters the electrocoalescence assembly  30  through the vessel input port  36  and then enters the intake chamber  5  through an inlet port  9  that is connected to the vessel input port by a conduit  38 . Once in the intake chamber  5 , the fluid travels into the first sub-channel  6  of the interstitial channel  11  and travels outwardly from the intake chamber  5  in a sinusoidal-like path towards the last parallel sub-channel  7  and into the extra-electrode assembly space  33  of the reactor vessel  31 . Due to the concentric configurations of the fins of the electrode arrays  8   a ,  8   b  and electrode assembly  20 , the time exposure of fluid increases in a semi-logarithmic fashion and separation efficiency increases for the effective treating surface area of paired electrodes (i.e. parallel sub-channel arrangement) as the fluid progresses through the interstitial channel  11 . 
         [0034]    In one embodiment of the invention, prior to entering the electrocoalescence assembly  30  through the vessel input port  36 , the fluid is exposed to a high-turbulence input nozzle that creates liquid turbulence and mixture before the fluid enters into the intake chamber  5 . This aids in the homogenization of any particles in suspension and minimizes the settling of particles in the electrode assembly  20  and the reactor vessel  31 . 
         [0035]    The electrodes  25 ,  27  are connected to an electrical circuit capable of generating a voltage potential between the electrode fin arrays  8   a ,  8   b  thereby creating a potential between an anode and a cathode for hydrolysis reactions. The voltage potential necessary to produce a reaction to neutralize particle charge and initiate coagulation varies depending on the fluid flow rate, the temperature of the fluid, the pressure of the system, the fluid undergoing decontamination, and the contaminants in the fluid, but the voltage range is well known in the art, and generally from −5 VDC to +5 VDC. 
         [0036]    The electrical circuit comprises a means to adjust at least one of voltage and current. These values are measured by either analog or digital indicators, such as needle gauges and electronic meters. 
       Method of Electrocoalescent Fluid Phase Separation 
       [0037]    By way of example, a method for augmenting the coalescence of fluid constituents begins by introducing a fluid into an electrocoalescence assembly  30  by traveling through a vessel input port  36  through a conduit  38  through an inlet port  9  of a first electrode  10   a , and into an intake chamber  5 . Pressurizing the fluid so that the fluid flows from the intake chamber  5  into a first parallel sub-channel  6 , and travels through a series of interleaving electrode fin arrays  8   a ,  8   b  that define a plurality of sub-channels that together define a single sinusoid-like interstitial channel  11  that is necessary for operation of the system. The fluid travels through the interstitial channel  11  past a last parallel sub-channel  7  and into an extra-electrode assembly space  33  of the reactor vessel  31 . 
         [0038]    Generating a voltage potential between the electrode fin arrays  8   a ,  8   b  is necessary to create a hydrolysis reaction utilizing the fluid flowing through the electrocoalescence assembly  30 . Exposure of the fluid to the electric field and ionizing properties of the hydrolytic circuit causes destabilization and aggregation of smaller particles into larger particles promoting particle coalescence. Additionally, water contaminants, such as ions and colloids are destabilized, therefore promoting aggregation. 
         [0039]    Releasing the fluid from the reactor vessel  31  through an output port  34  after the fluid passes through the electrodes  10   a ,  10   b  within the reactor vessel  31  finalizes one embodiment of the basic method of for augmenting the coalescence of fluid. In another embodiment, fluid exiting the reactor vessel  31  is exposed to a magnetic field to help augment the coalescence of liquid constituents. The liquid may be exposed before it is introduced into the electrocoalescence assembly  30 , after it exits electrocoalescence assembly  30 , or at both points. In one embodiment, the liquid released from the reactor vessel  31  passes into at least one of a settling tank, centrifuge, and filtration apparatus. 
         [0040]    In one embodiment, fluid is exposed to turbulent forces before it is introduced into the either the electrocoalescence assembly  30  or the electrode assembly  20 . In one embodiment, the turbulent forces are generated by a conduit  38  designed to introduce fluid turbulence. 
         [0041]    In one embodiment, regulating pressure is a step in the process utilized to adjust the time in which a fluid is exposed to electrodes  10   a ,  10   b.    
         [0042]    Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.