Abstract:
An apparatus and method for mixing a dry chemical contained within a container. A probe is utilized to puncture an opening in the container and thereafter the probe is extended through the opening. A mixture or liquid is directed to and through the probe and, as the liquid or mixture exits the probe, the dry chemical is dissolved and mixed with the liquid or mixture. Thereafter, the resulting mixture gravitates downwardly through the opening in the container to an underlying tank. Associated with the tank is a concentration controller that is operatively connected to a pump that pumps the mixture from the tank to and through the probe. Effectively, the concentration controller periodically activates the pump so as to maintain the concentration level of the mixture in the tank within a pre-selected range.

Description:
FIELD OF THE INVENTION 
     The present invention relates to systems and processes for mixing chemicals and, more particularly, to a system and process for mixing a chemical in a container with a liquid. 
     BACKGROUND OF THE INVENTION 
     Many chemicals are packaged in containers such as buckets. These chemicals come in various forms, particularly dry and liquid forms. Dry chemicals can assume the form of a dry powder, granules, briquettes, tablets, flakes, etc. However, handling and managing dry-form chemicals can be problematic. One of the problems that arises in handling and mixing dry-form chemicals is that it is difficult in some cases to manage and confine the chemical as it is being transferred from the container to a mixer or mixing tank, for example. Often this transfer and mixing may occur in an outside environment where there is wind and other undesirable weather elements. In the case of a dry-form chemical, especially those chemicals that are presented in a dry powder form, one finds that in transferring the chemical from the container to a mixing tank, for example, that much of the chemical ends up being deposited in the environment around the container and the mixing tank. 
     It is common practice to utilize chemicals such as potassium permanganate in wastewater and potable water treatment processes. Potassium permanganate is normally produced in a dry powder form and containerized in a container such as a 5-gallon bucket. Periodically, personnel at the water or wastewater treatment facility will mix the dry potassium permanganate powder with a liquid in a tank. In transferring the dry powder to the tank, it is not uncommon for the fine granules of powder to end up outside both the container and the mixing tank. Often this is in the form of a fine dust. In any event, the end result is that the potassium permanganate ends up on the worker&#39;s clothes and on system elements outside the mixing tank and the container and, in the final analysis, is simply downright messy. 
     Therefore, there is, and continues to be, a need for a system and process for mixing chemicals, especially chemicals that come in a dry powder form, that avoids the aforementioned problems. 
     SUMMARY OF THE INVENTION 
     The present invention entails a system and process for mixing a chemical within a container with a liquid by directing a liquid or mixture into the container itself and mixing the liquid or mixture with the chemical within the confines of the container and then directing the resulting mixture from the container to a holding tank. 
     In another embodiment of the present invention, the chemical may be held within a holding area as opposed to being held within a conventional container. Here the present invention entails directing a liquid into the holding area where the chemical is held and effectively removing the chemical as a result of the liquid or mixture coming into contact with the chemical within the holding area. 
     More particularly, the present invention entails a probe that is extended into the container containing the chemical. Liquid under pressure is directed to, through, and out the probe. As the liquid is expelled from the probe, under pressure, the liquid causes a portion of the chemical contained within the container to be directed from the container into a holding tank. In one embodiment, the probe is anchored above an opening within the tank and there is provided a supporting structure for holding the container over the probe after the probe has punctured an opening in the container. There the resulting mixture is allowed to gravitate through the opening formed by the puncture into the underlying tank. In another embodiment, the probe is directed into a holding area where the chemical is held or allowed to accumulate. Here the probe extends into the holding area where the chemical is held and a liquid or mixture is expelled from the probe and causes the surrounding chemical to be removed from the holding area. Again, typically the chemical is allowed to gravitate into a mixing tank where the chemical is mixed with a liquid or mixture within the mixing tank. 
     In one embodiment, the system is provided with a recirculating and mixing pump. In particular, the pump is operative to circulate the mixture from the tank to and through the probe. To control the concentration of the mixture within the tank within a pre-selected range, a concentration controller is provided and is operatively coupled to the recirculation and mixing pump. Once the measured concentration of the mixture falls below a pre-selected range, the concentration controller is operative to actuate the pump, causing the pump to pull portions of the mixture from the tank and direct the same through the probe and into the container, mixing with the chemical therein, which results in the mixture formed in the container being directed back to the tank. This has the effect of increasing the concentration of the mixture within the tank. 
     The probe which is inserted into the container includes an inlet and, in one embodiment, a series of outlet or jet ports. These outlet ports are arranged about the probe to efficiently direct a liquid or mixture under pressure into the surrounding chemical. In one particular embodiment, the probe includes at least one vertical cavity formed in the probe with an outlet port disposed about an upper end portion thereof and directed generally downwardly. This outlet port tends to direct a jet of liquid downwardly toward the opening formed within the container and effectively keeps that general area open and unclogged such that the resulting mixture can freely gravitate from the container through the opening formed therein. 
     Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of such invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the chemical mixing system of the present invention shown from one side. 
     FIG. 2 is a perspective view of the chemical mixing system shown from the opposite side. 
     FIG. 3 is a perspective view of the chemical mixing system with the top removed. 
     FIG. 4 is a side diagrammatic view illustrating a container containing a chemical supported on the chemical mixing system. 
     FIG. 5 is a detailed view of the encircled structure shown in FIG.  4 . 
     FIG. 6 is a side elevational view of one side of the probe that forms a part of the chemical mixing system of the present invention. 
     FIG. 7 is another side view of the probe. 
     FIG. 8 is still another side view of the probe. 
     FIG. 9 is a top plan view of the probe. 
     FIG. 10 is a bottom plan view of the probe. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With further reference to the drawings, the chemical mixing system of the present invention is shown therein and indicated generally by the numeral  10 . As will be appreciated from subsequent portions of this disclosure, the chemical mixing system  10  is designed to receive and hold a container, indicated generally by the numeral  12 , that contains a chemical therein. While the texture and form of the chemical may vary, the chemical mixing system  10  of the present invention is particularly adapted to handle a mix of chemicals in a dry form, such as powder, flakes, briquettes, sticks, tablets, etc. 
     Viewing the chemical mixing system  10  in more detail, and with particular reference to FIGS. 1-3, the mixing system includes a mixing tank indicated generally by the numeral  16 . Mixing tank  16  includes a pair of opposed sides  18 , a pair of ends  20 , a bottom  22 , and a removable top  24 . The tank  16  can be constructed of various materials, such as metal, plastic, or any other suitable material. 
     Mounted to the top  24  of tank  16  is a mixer  30 . Mixer  30  is preferably an electric mixer that includes a shaft extending downwardly through the top  24 . About the terminal end of shaft  32  is a propeller  34 . 
     Adjacent the mixer  30 , there is provided an opening in the top  24  of the tank  16 . The purpose of the opening is to receive and accommodate the container  12 . As particularly seen in FIGS. 1-3, the opening formed in the top  24  to accommodate the container includes an inclined band  36  that surrounds the opening. As seen in FIG. 4, the inclined band forms a receiving opening that is particularly sized for the container  12 . Because of the inclination of the sidewalls that form the inclined band  36 , it is seen in FIG. 4 that the entire container  12  is held and confined at an angle with respect to the top  24  of the tank  16 . 
     The mixing tank  10  is provided with a liquid inlet control assembly that is indicated generally by the numeral  50 . The liquid inlet control assembly  50  includes an inlet  52  that is adapted to be connected to a fluid source, such as a source of water. Operatively associated with the inlet  52  is a control valve  54  for controlling the flow of the fluid source, or water, into the inlet  52 . To actuate and control the control valve  54  there is provided, as illustrated in FIG. 3, a float switch  56 . The float switch  56  can be adjusted to actuate the control valve  54  as the fluid level within the tank  16  fluctuates. That is, the float switch  56  is preferably adjusted to maintain a certain level of liquid within the tank  16 . When the level of liquid within the tank  16  falls below a predetermined level, the float switch  56  will actuate the control valve  54  causing the fluid source, such as water, to be directed into the inlet  52 , through the control valve  54 , and through associated piping and into the tank. 
     As will be appreciated from such subsequent portions of this disclosure, the chemical mixing system is adapted to produce a mixture that comprises a chemical contained within the container  12  and a liquid. This mixture is contained within tank  16  and continuously or periodically discharged from the tank. 
     To accommodate discharge, the chemical mixing system  10  is provided with a discharging system indicated generally by the numeral  60 . As particularly seen in FIG. 1, the discharge system  60  includes a discharge pump  62  that is connected to an inlet line  64 , that extends from a control valve  66  to the discharge pump  62 . It is appreciated that control valve  66  is communicably connected to the interior of the tank  16  such that the mixture contained therein can flow from the tank through the control valve  66  and to the discharge pump  62 . Further, there is provided a discharge line  68  that leads from the discharge pump  62 . The discharge pump  62  can be controlled in conventional fashion to discharge a certain flow rate of mixture from the tank continuously, from time-to-time, or in accordance with a pre-programmed scheduled. 
     It is desirable to control the concentration of the mixture within the tank  16 . More particularly, the concentration of the chemical that forms a part of the mixture would be controlled. To achieve this, the chemical mixing system  10  of the present invention includes a concentration controller indicated generally by the numeral  80 . The concentration controller  80  functions to maintain the concentration of the chemical at a certain level, or above a certain level, or within a pre-selected concentration range. Effectively, the concentration controller  80  senses and measures the concentration of the chemical within the mixture. Details of the concentration controller  80  are not dealt with herein because such is not, per se, material to the present invention and, further, because concentration controllers are well known in the art and indeed are commercially available. Briefly, however, it should be pointed out that many concentration controllers will effectively measure a property such as the conductivity of the mixture and, based on the conductivity, the concentration controller will be able to determine the concentration of a particular chemical or chemicals within a mixture. 
     As will be appreciated from subsequent discussions by the foregoing, this pumping system is designed to circulate the mixture from the tank into the container  12  where the mixture mixes with the chemical  14  therein. This mixture formed within the container then flows or gravitates from the container  12  back into the tank  16 . 
     Turning to the pumping system for circulating the mixture to the container  12 , it is seen that the same includes a pump  90  secured on a support  91  adjacent one side of the tank  16 . An inlet line  92  is operatively interconnected between the tank  16  and an inlet associated with the pump  90 . An outlet line  94  leads from the pump  90  to a filter  96 . Extending from the filter  96  is feedline  98  that extends through an opening formed in the sidewall  18  of the tank. As illustrated in FIG. 3, the feed line  98  extends inwardly into the tank  16  and includes a coupler  98 A secured on the remote end thereof. Coupler  98 A is connected to a probe, indicated generally by the numeral  100 . Probe  100  is supported on a cross-bar  102  that is secured between opposed sides  18  of the tank  16 . 
     Pump  90  is operative to pump the mixture from the tank  16  through the inlet line  92  into the pump. The mixture is then pumped through outlet line  94  into the filter  96  and after passing through the filter the mixture is directed through the feed line  98  into the probe  100 . As will be appreciated from the subsequent portions of this disclosure, the probe  100  is operative to dispense the mixture, preferably in a jet form, into the container  12  which, according to the present invention, is supported by the incline band  36  and cross bar  102  and over the probe  100 . 
     Turning to FIGS. 6-9, the probe  100  is shown therein. Formed on one end of the probe  100  is an inlet  107 . Communicatively connected to the inlet  107  is an internal bore or manifold  104 . In the case of the design shown in FIGS. 6-8, the manifold or internal bore  104  extends axially through the probe  100 . 
     Probe  100  is provided with a series of outlet ports that are communicatively connected to the internal bore or manifold  104 . It should be noted, that the number and positioning of the outlet ports can vary. However, in the case of the embodiment illustrated herein, there is provided three (3) horizontally disposed outlet ports  106 ,  108 , and  110 . Further, there is provided two (2) vertically directed ports,  112  and  114 . Further, about the side of the probe  100  shown in FIG. 1, there is provided a pair of vertical cavities  116  and  118 . These vertical cavities  116  and  118  are cut or milled into the probe  100  and in the case of the embodiment shown in FIG. 6 extend generally downwardly from the vertical oriented or directed ports  112  and  114 . Disposed on the side of the probe opposite of that shown in FIG. 6 is one (1) additional horizontal directed port  120 . This is illustrated in FIG.  8 . 
     As seen in FIGS. 6-8, the probe  100  assumes a generally cylindrical configuration and includes an outer cylindrical surface  122 . Formed about the top portion of the probe  100  is a tapered or beveled tip  124 . The tapered tip  124  functions to puncture an opening in the container  12  when the container is placed on the probe  100 . More particularly, the bottom of container  12  is punctured by the beveled tip  124  as the container is dropped into the opening defined by the incline band  36 . 
     Disposed intermediately on the probe  100  is a base  130 . Functionally, the base  130  serves to form a seal or retainer for preventing the chemical in the form of a dry powder from continuously falling through the punctured opening of the container  12  during the period when the probe  100  is inactive. Secondly, the base  130  functions to permit the mixture generated within the container  12  to gravitate or drain downwardly therethrough during periods when the probe is active. As seen in FIGS. 6-9, the base  130  includes a surrounding trough structure that includes a bottom  132  and a surrounding wall  134 . Formed in the surrounding sidewall  134  is at least one (1) drain cut out  136 . 
     With particular reference to FIG. 4, note that once the probe  100  punctures an opening in the bottom of the container  12 , that the probe extends upwardly through the bottom into the container  12 . As noted, the present invention contemplates that the chemical contained within the container  12  would in many instances assume a dry powder form. In such cases, when the probe  100  is inactive or inoperative, meaning that it is not expelling mixture therefrom, the dry chemical will effectively surround the probe  100 . Moreover, the dry chemical will actually gravitate downwardly along the probe and accumulate in the base  130 , and more particularly in the surrounding trough defined by the bottom  132  and surrounding sidewall  134 . The accumulation of the dry powder will effectively seal the punctured opening formed in the bottom of the container  12  by the probe  100 . 
     When the concentration controller  80  calls for an increase in the concentration of the mixture held within the tank, concentration controller  80  will actuate the pumping system for circulating the mixture from the tank into the container  12 . Specifically, the concentration controller  80  will actuate pump  90  and the pump  90  will direct mixture from the tank into the inlet  107  of the probe  100 . The mixture will move upwardly through the internal bore  104  and be expelled through the various outlet ports  106 ,  108 ,  110 ,  112 ,  114  and  120  formed in the probe  100 . Note that the ports  112  and  114  are disposed about the upper portion of the cavities  116  and  118 . These two ports are directed generally downwardly towards the base  130 . The mixture expelled from ports  112  and  114  tends to mix with and dissolve the underlying chemical and generally prevents the area around the probe  100  from becoming clogged. Essentially, the mixture expelled from all of these ports mixes with the surrounding chemical and this resulting mixture drains downwardly through the punctured opening in the bottom of the container  12 , and out the drain cut-outs  136  formed in the sidewall  134  of the surrounding trough. 
     The chemical mixing system  10  of the present invention can be used in a variety of applications. One such application deals with a waste water treatment system where potassium permanganate and is mixed and dispensed into the waste water system continuously or on a periodic basis. The potassium permanganate is particularly effective in controlling hydrasulfide gas. In such a case, potassium permanganate is presented in a dry-powdered form and containerized within the container  12 . The container is loaded into the chemical mixing system by placing the container within the opening defined by the incline band  36 . Once the container is dropped into place, the tapered tip  124  punctures the bottom of the container  12  forming an opening therein, allowing the probe to extend upwardly through the opening. Note in FIG. 5 where the cross-bar  102  effectively supports the bottom of the container  12 , while the incline band  36  generally confines and stations the container  12  about the opening overlying the tank  16 . 
     As discussed above, the mixture held within the tank is periodically or from time to time directed into the probe where the mixture is expelled and mixes with the potassium permanganate contained within the container  12 . The resulting mixture gravitates downwardly through the punctured opening in the bottom of the container and out the drain slots  136  formed in the surrounding wall  134  that forms a part of the base  130 . This resulting mixture simply drains down into the tank where it is held. The mixture held within the tank is dispersed from the tank by the discharge system  60 . In the case of using potassium permanganate to treat waste water, the discharge system is timed or programmed to dispense a certain amount of the potassium permanganate mixture from the tank  16  into the waste water treatment system. The volume and concentration of the potassium permanganate can be varied to accommodate the size and needs of the particular waste water being treated. 
     In the above discussions, it is appreciated that the liquid or mixture expelled from the probe  100 , causes the chemical contained within the container to be directed from the container into the mixing tank. In some instances, it has been noted that the liquid or mixture expelled from the probe mixes with the chemical within the container. It should be noted that the liquid or mixture expelled from the probe in many instances will not completely mix with the chemical within the confines of the container itself. Complete mixing in many instances will not occur until the chemical reaches the mixing tank and is subjected to mixing therein. Basically, the liquid or mixture expelled from the probe  100  acts as a carrier and effectively contacts the chemical within the container and carries the chemical from the container as described above. 
     Further, it should be appreciated that the present invention is not simply confined to dealing with a chemical within a conventional container. Specifically, the present invention and the manner of directing a dry powder chemical into the mixing tank is applicable to other environments besides a conventional container. For example, the dry powder chemical may be directed into a holding area and wherein the probe  100  is directed upwardly into the holding area where the chemical within the holding area effectively surrounds the probe. Here the probe can again be used to expel a liquid or a mixture and cause the surrounding chemical to be transferred from the holding area to the mixing tank via an opening through which the probe extends. In addition, the probe can be extended into a pipe or hopper that continuously receives a supply of chemical and the same process as outlined above can be applied. In short, the present invention is workable not only with conventional containers such as buckets, but is also workable where the chemical is held within a holding area. 
     Further, the term dry chemical has been used here in. The term dry chemical simply means that the chemical is in a dry or liquid form such as powder or granules, as opposed to being in the form of a liquid. 
     From the foregoing specification and discussion, it is appreciated that the pre sent invention presents a very efficient and effective way of mixing chemicals within a container. It is particularly useful with respect to dry chemicals such as chemicals that assume the form of a dry powder. By actually mixing the chemical within the confines of the container and allowing the resulting mixture to drain from the container into an associated tank, chemical mixing operation is greatly simplified. Importantly, the chemical is confined and controlled and the problems associated with having to openly transfer the chemical from the container to a mixing tank are avoided. 
     The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the scope and the essential characteristics of the invention. The present embodiments are therefore to be construed in all aspects as illustrative and not restrictive and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.