Patent Description:
A particle separation system according to claim <NUM> is provided, Some examples provide a particle separation system that may comprise a vessel having at least one side wall and a bottom wall forming an internal chamber within the vessel, a filtration unit positioned within the vessel and including a first filtration pack including a first plurality of filter elements, an inlet for moving pre-separated fluid into the vessel, and an outlet in fluid communication with the filtration pack for moving processed fluid out of the vessel, a rate of pre-separated fluid flow into the vessel and a rate of processed fluid flow out of the vessel each being between about <NUM> liters per minute and about <NUM> liters per minute (LPM) (about <NUM> and about <NUM> gallons per minute (GPM)) and a flux within the filtration unit is less than or equal to about <NUM> liters per minute per square meter (LPM/m<NUM>) (about <NUM> gallons per minute per square foot (GPM/ft<NUM>)).

Other embodiments provide, a particle separation system comprising, a vessel having at least one side wall and a bottom wall forming an internal chamber within the vessel, a filtration unit positioned within the vessel and comprising a first filtration pack comprising a first plurality of filter elements having a first plurality of outlets, a first hollow manifold having a first plurality of inlets, a number of the first plurality of inlets being equal to a number of the first plurality of outlets, the first plurality of outlets and the first plurality of inlets being capable of coupling such that a flow through each of the first plurality of filter elements enters the first manifold, the first hollow manifold including a first outlet channel for flow from the first manifold to a processed fluid conduit, a second filtration pack comprising a second plurality of filter elements having a second plurality of outlets, a second hollow manifold having a second plurality of inlets, a number of the second plurality of inlets being equal to a number of the second plurality of outlets, the second plurality of outlets and the second plurality of inlets being capable of coupling such that a flow through each of the second plurality of filter elements enters the second manifold, the second hollow manifold including a second outlet channel for flow from the second manifold to the processed fluid conduit, wherein the first plurality of outlets of the first filtration pack are positioned and aligned such that all of the first plurality of outlets are capable of coupling to all of the first plurality of inlets of the first single manifold at the same time and wherein the second plurality of outlets of the second filtration pack are positioned and aligned such that all of the second plurality of outlets are capable of coupling to all of the second plurality of inlets of the second single manifold at the same time.

Still other examples provide a method of separating particles from fluid, the method comprising the steps of moving pre-separated fluid through an inlet into a vessel at atmospheric pressure, the vessel having at least one side wall and a bottom wall forming an internal chamber within the vessel, wherein the pre-separated fluid is moved into the vessel at a rate of between about <NUM> liters per minute and about <NUM> liters per minute (LPM) (about <NUM> and about <NUM> gallons per minute (GPM)), moving the pre-separated fluid into and through a filtration unit utilizing a downstream pump, the filtration unit including a plurality of filtration packs each having a plurality of filter elements, thereby creating a flux in the filtration pack of less than or equal to about <NUM> liters per minute per square meter (LPM/m<NUM>) (about <NUM> gallons per minute per square foot (GPM/ft<NUM>)), and moving fluid processed by the filtration unit to an outlet and out of the vessel.

The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

Referring now to <FIG>, an exemplary particle separation system <NUM> is depicted. The particle separation system generally includes a source tank(s) <NUM> holding pre-separated fluid to be processed by the particle separation system <NUM>, a pump system <NUM> that is configured to move fluid through the particle separation system <NUM>, and a separation vessel <NUM> for separating solids from fluids. While a source tank <NUM> is depicted, a pressurized flow (e.g., at a varying flow rate) of pre-separated fluid can be received from some other process or any other suitable source.

Pre-separated fluid is transferred into the source tank(s) <NUM>, for example, by trucks <NUM>. In the depicted embodiment, the trucks <NUM> are filled with pre-separated fluid at a remote location and transported to the location of the particle separation system <NUM>. The pre-separated fluid can be transferred from the trucks <NUM> to the source tank(s) <NUM> in any suitable manner. In other illustrative embodiments, the pre-separated fluid can be transferred to the source tank(s) <NUM> is other manners, for example, through a pressurized flow from another location. Alternatively, the pre-separated fluid can be transferred by any suitable vehicle, vessel, or fluid transfer system. Still further, while the fluid in the source tank(s) <NUM> is referred to herein as being pre-separated fluid, the fluid can be any pre-separated fluid capable of separation into solids and fluids. More particularly, pre-separated fluid refers to any fluid, for example, water, an amine, or any other fluid, that is contaminated by dirt or other debris, hydrocarbons, chemicals, and/or any other contaminants regardless of the form (e.g., solid, liquid, etc.). In some embodiments, the pre-separated fluid is produced water, which is a by-product of hydrocarbon extraction methods and consists of water mixed with oil and particulate of various concentrations. In some embodiments, the pre-separated fluid is waste water, for example, from a refinery, chemical plant, gas plant, or other similar location. In still other embodiments, the pre-separated fluid is industrial waste water, run-off, or construction de-watering. Produced and waste water are both by-products of chemical processes that must be treated before reuse or disposal.

Referring to <FIG> and <FIG>, the flow of fluid in the particle separation system <NUM> is also depicted. Arrow <NUM> depicts the transfer of pre-separated fluid from, for example, the trucks <NUM> to the source tank(s) <NUM>. Pre-separated fluid in the source tank(s) <NUM> is pumped through a first transfer or inlet line <NUM> (arrow <NUM>) to the pump system <NUM> and through a second transfer or outlet line <NUM> (arrow <NUM>) to the separation vessel <NUM>. After the pre-separated fluid is filtered in the separation vessel <NUM>, processed fluid (i.e., pre-separated fluid that has been processed by the separation vessel <NUM>, for example, water, amine, or any other suitable fluid) is pumped through a third transfer or inlet line <NUM> (arrow <NUM>) to the pump system <NUM> and through a fourth transfer or outlet line <NUM> (arrow <NUM>) back to the source tank(s) <NUM>. While the source tank <NUM> for produced and processed fluid is shown as being the same, different tanks or different compartments within the same tank can be utilized.

While a single source tank <NUM>, a single pump system <NUM>, and a single separation vessel <NUM> are depicted in <FIG>, the particle separation system <NUM> can include any suitable number of source tanks <NUM>, pump systems <NUM>, and/or separation vessels <NUM>.

The pump system <NUM> and the separation vessel <NUM> are shown in more detail in <FIG>. The pump system <NUM> is depicted as having a pump outlet <NUM> in fluid communication with a separation vessel inlet <NUM> by way of the second transfer or outlet line <NUM> to move pre-separated fluid into the separation vessel <NUM>. The pump system <NUM> includes an inlet pump <NUM> that pumps pre-separated fluid from the source tank(s) <NUM>, through the second transfer line <NUM> into the separation vessel <NUM>. The pump system is also depicted as having a plurality of pump inlets <NUM> connected to a manifold <NUM>, wherein each of the pump inlets is in fluid communication with a respective separation vessel outlet <NUM> by way of the third transfer or inlet lines <NUM>. Processed fluid is moved through each of the third transfer lines <NUM> into the manifold <NUM> and through the fourth transfer line <NUM> to the source tank(s) <NUM> by an outlet pump <NUM>. The manifold <NUM> streamlines each of the third transfer lines <NUM> into a single fluid stream to the source tank(s) <NUM>.

The separation vessel <NUM> generally includes a top wall or covering <NUM> (optional), a bottom wall <NUM>, and one or more side walls <NUM> forming an internal or main filtration chamber <NUM> within the separation vessel <NUM>, as seen in <FIG> and <FIG>. One or more portions of the separation vessel <NUM> can be made of fiberglass or another suitable material that can prevent corrosion when pre-separated fluid containing harmful chemicals is processed by the separation vessel <NUM>. In illustrative embodiments, the separation vessel <NUM> is not pressurized (i.e., is at atmospheric pressure). In other illustrative embodiments, the separation vessel <NUM> can be pressurized. The separation vessel <NUM> can include a weir <NUM> spaced from the separation vessel inlet <NUM>. The separation vessel inlet <NUM> can be positioned adjacent a bottom of the weir <NUM> such that pre-separated fluid must travel upwardly and over the weir <NUM>. The weir <NUM> extends from the bottom wall <NUM> of the separation vessel <NUM> and ends short of a fluid height <NUM> in the separation vessel <NUM>. The weir <NUM> functions to provide "bulk knock out" of very large particles or bulk oil/immiscible liquid content (that will sink to the bottom of the weir <NUM> and not enter the main filtration chamber <NUM>) and serve as a strong physical barrier to the filtration technology (e.g., filtration unit, filtration pack, filter elements, etc.) in the event a strong pressurized stream enters the separation vessel <NUM>. In some embodiments, the weir <NUM> is not utilized.

As seen in <FIG> and <FIG>, a filtration unit <NUM> is positioned within the internal chamber <NUM> of the separation vessel <NUM> after the weir <NUM> (in a flow path between the separation vessel inlet <NUM> and the separation vessel outlet <NUM>). The filtration unit <NUM> is positioned on a suction side of the pump system <NUM> and can include at least one filtration pack <NUM> including a plurality of filter elements <NUM>. The filtration pack <NUM> can include a frame <NUM> or other structure to which the filter elements <NUM> are attached. The frame can include a plurality of top struts <NUM>, a plurality of bottom struts <NUM>, and a plurality of side struts <NUM> connecting the pluralities of top and bottom struts <NUM>, <NUM>. The frame <NUM> can be constructed of, for example, polyvinyl chloride (PVC), polypropylene, polyethylene, or any other suitable material(s). While a particular frame <NUM> is depicted, one skilled in the art would understand that different types of frames could be used to support a plurality of filter elements <NUM> and allow the filtration pack <NUM> to be replaced, as will be discussed in greater detail below. For example, only one of the top struts <NUM>, the bottom struts <NUM>, and the side struts <NUM> can be utilized, two of the top struts <NUM>, the bottom struts <NUM>, and the side struts <NUM> can be utilized, or any other configuration can be utilized to hold and position the filtration packs <NUM>. In illustrative embodiments, the frame <NUM> provides spacing between the filtration unit <NUM> and the bottom wall <NUM> of the separation vessel <NUM>, which allows for accumulation of solids adjacent the bottom wall <NUM>, as will be discussed in greater detail below. In some embodiments, the filtration unit <NUM> and/or the filtration packs <NUM> are self-supporting in that they can be set within the separation vessel <NUM> without being attached to any portion of the separation vessel <NUM>.

Each filtration pack <NUM> can include any suitable number of filter elements <NUM>, for example, between about <NUM> and about <NUM>, between about <NUM> and about <NUM>, between about <NUM> and about <NUM>, between about <NUM> and <NUM>, or about <NUM> filter elements <NUM>. In an illustrative embodiments, multiple filtration packs <NUM> each having <NUM> filter elements <NUM>, can be utilized. In one such embodiment, <NUM> filtration packs <NUM> each having <NUM> filter elements <NUM> (with a total of <NUM> filter elements) can be utilized.

While the filter elements <NUM> are depicted as being vertical, the filter elements <NUM> can optionally be horizontal or one or more filtration packs <NUM> can include filter elements <NUM> that are vertical and one or more filtration packs <NUM> can include filter elements <NUM> that are horizontal. In illustrative embodiments, each of the filter elements <NUM> in the filtration pack <NUM> can be parallel to one another. Additionally, while the filter elements <NUM> are shown as being nested in a square-shape with parallel rows and columns of filter elements <NUM>, as seen in the top elevational view of <FIG>, the filter elements <NUM> can be nested in other configurations. For example, the filter elements <NUM> of individual rows can be aligned, but the filter elements <NUM> in adjacent rows can be offset, as seen in <FIG>, the filter elements <NUM> can be formed into a hex ring, as seen in <FIG>, or the filter elements <NUM> can be arranged in any other suitable configuration. Still further, while the filtration packs <NUM> are shown as being arranged in parallel, the filtration packs <NUM> can be arranged in series and/or in parallel.

As best seen in <FIG>, each filter element <NUM> can generally include filter media <NUM>, which can be for example, cylindrical surrounding a central hollow core <NUM>, a top, open end cap <NUM> partially enclosing a top end <NUM> of the filter media <NUM>, and a bottom, closed end cap <NUM> enclosing a bottom end <NUM> of the filter media <NUM>. A filter element outlet tube <NUM> can extend through, for example, the top, open end cap <NUM> to allow fluid to flow therethrough. The filter media <NUM> can be non-woven and can be made of, for example, glass blown fibers or any other suitable material. In some embodiments, pore size for the media can be between about <NUM> and about <NUM> micrometers. The top, open end cap <NUM> can be made of, for example, polyester or any other suitable material. In addition, the top, open end cap <NUM> can include a compression fitting for creating a fluid-tight seal with the filter element outlet tube <NUM>. The bottom, closed end cap <NUM> can be made of, for example, glass-filled nylon or any other suitable material.

Pre-separated fluid moves from an outside of the filter media <NUM>, through the filter media <NUM>, into the central hollow core <NUM>, and out the filter element outlet tube <NUM>, as shown by arrows 155a-155c, as seen in <FIG>. Each of the filter element outlet tubes <NUM> combine into an outlet manifold <NUM> for movement out of the separation vessel <NUM>. Each of the outlet manifolds <NUM> is in fluid communication with a respective third transfer line <NUM> to transfer fluid through the manifold <NUM> to the source tank(s) <NUM>. Each filtration pack <NUM> can include any suitable number of outlet manifolds <NUM> in fluid communication with any suitable number of filter elements <NUM>.

In illustrative embodiments, the filtration unit <NUM> includes at least two filtration packs <NUM>. In illustrative embodiments, the filtration unit <NUM> includes two filtration packs <NUM>, each including <NUM> filter elements <NUM>, as seen in <FIG>. As described above, each of the filtration packs <NUM> includes a frame <NUM>, wherein adjacent frames <NUM> can be removably attached to one another.

While the separation vessel <NUM> is shown as being generally rectangular in shape, one skilled in the art will understand that the separation vessel <NUM> can have any suitable shape, for example, square-shaped, cylindrical, or any other suitable geometric shape. In illustrative embodiments, the separation vessel <NUM> can include sloped inner surfaces <NUM> (<FIG>) to allow solids separated by the filter elements <NUM> to collect in a central collection region <NUM>. In other illustrative embodiments, the bottom wall <NUM> can be sloped, as seen in <FIG>. In still other illustrative embodiments, the separation vessel <NUM> can be cylindrical in shape with an inverted cone bottom <NUM>, as seen in <FIG>. In illustrative embodiments, the separation vessel <NUM> can include one or more drains <NUM> in the bottom wall <NUM>, adjacent the bottom wall <NUM>, or in any other suitable location to remove collected solids from the separation vessel <NUM>.

The filtration unit <NUM>, including the filtration packs <NUM> and the individual filter elements <NUM> of the filtration packs <NUM>, in combination with the rate of flow through the separation vessel <NUM> create a low flux through the filtration unit <NUM>. More particularly, by increasing the number of overall filter elements <NUM> (e.g., by including a number of filtration packs <NUM> or a single filtration pack <NUM> with multiple filter elements <NUM>), a total square footage of filter media is increased or maximized. In illustrative embodiments, the flux through the filter elements <NUM> can be less between about <NUM> liters per minute per square meter and about <NUM> liters per minute per square meter (about <NUM> gallons per minute per square foot (GPM/ft<NUM>) and about <NUM> GPM/ft<NUM>). In other illustrative embodiments, the flux through the filter elements <NUM> can be less than or equal to about <NUM> liters per minute per square meter (<NUM> GPM/ft<NUM>). In still other illustrative embodiments, the flux through the filter elements <NUM> can be less than or equal to about <NUM> liters per minute per square meter (about <NUM> GPM/ft<NUM>). In yet other illustrative embodiments, the flux through the filter elements <NUM> can be less than or equal to about <NUM> liters per minute per square meter (about <NUM> GPM/ft<NUM>). In some embodiments, the flux through the filter elements <NUM> can be between about <NUM> liters per minute per square meter and about <NUM> liters per minute per square meter, or about <NUM> liters per minute per square meter (about <NUM> GPM/ft<NUM> and about <NUM> GPM/ft<NUM>, or about <NUM> GPM/ft<NUM>). To achieve the desired flux, the flow of pre-separated fluid into the separation vessel <NUM> and processed fluid out of the separation vessel <NUM> can be the same. In some illustrative embodiments, the flow of pre-separated fluid into the separation vessel <NUM> and the flow of processed fluid out of the separation vessel <NUM> can be between about <NUM> liters per minute and about <NUM> liters per minute (LPM) (about <NUM> gallons per minute (GPM) and about <NUM> GPM). In other embodiments, both flows can be between about <NUM> liters per minute and about <NUM> liters per minute or between about <NUM> liters per minute and <NUM> (about <NUM> GPM and about <NUM> GPM or between about <NUM> GPM and about <NUM> GPM). In yet other illustrative embodiments, the flow can be about <NUM> or about <NUM> liters per minute (LPM) (about <NUM> or about <NUM> GPM). The flow rate can vary, so an overall surface area of the filter elements <NUM> can be varied to achieve a flux within the ranges desired herein. In some illustrative embodiments, the flow of pre-separated fluid into the separation vessel <NUM> and processed fluid out of the separation vessel <NUM> can be different.

In some embodiments, the flow rate through the vessel <NUM> (and thus, through the filtration unit <NUM>) is variable (per the ranges discussed above). In such embodiments, the filter element surface area can be varied in order to achieve the target flux rates discussed above. In this manner, the number of filtration packs <NUM> and/or the dimensions of the filter elements <NUM> within a filtration pack <NUM> can be varied to achieve the target flux rates for a particular flow rate. In this manner, the filtration packs <NUM> are modular, as will be discussed in greater detail below, in that each pack can be individually inserted and removed from the vessel <NUM>.

An increased square footage of filter media minimizes the flow rate per media area (or flux). At very low flux rates per unit of media area, the dirt or particle holding capacity of the filtration unit <NUM>, the filtration packs <NUM>, and the individual filter elements <NUM> increases exponentially, which leads to longer operation time before the filtration unit <NUM>, the filtration pack(s) <NUM>, and/or the individual filter elements <NUM> need to be changed due to limited differential pressure. The mechanism of ultra-low flux theory is that particles do not have a large enough face velocity to penetrate or clog pores in the filter media <NUM> of the filter elements <NUM>. More particularly, solid particles hit the filter media <NUM> and fall to the bottom of the separation vessel <NUM>, rather than collecting in the filter media <NUM>. Conversely, at a higher flux, the particles would have a large enough face velocity to penetrate and clog the pores in the filter media <NUM> of the filter elements <NUM>. The systems described herein capitalize on the ultra-low flux theory by increasing the number of filter elements <NUM> through which the pre-separated fluid flows, thereby decreasing the flux to a low enough number that filter element <NUM> life (and, thus, filtration unit <NUM> and filtration pack <NUM> life) is lengthened from several days to months. This increased life decreases operational expenditures dramatically, as will be discussed in more detail herein.

The particle separation system <NUM> can include a control system <NUM> for controlling operation of the system <NUM>. In some embodiments, as seen in <FIG>, the pump system <NUM> includes inlet and outlet pumps <NUM>, <NUM>, which can be controlled by variable frequency drives. In some embodiments, the control system <NUM> can include electronically actuated ball valves <NUM>, <NUM> that control flow of pre-separated fluid through the first and second transfer lines <NUM>, <NUM> into the separation vessel <NUM> and through the third and fourth transfer lines <NUM>, <NUM> out of the separation vessel <NUM>, respectively. In some embodiments, the control system <NUM> can include one or more flow meters <NUM>, <NUM>, for example, within the first and/or second transfer lines <NUM>, <NUM> and/or within the third and/or fourth transfer lines <NUM>, <NUM> for monitoring flow into and out of the separation vessel <NUM>, respectively. In some embodiments, the control system <NUM> can include a pressure sensor <NUM> within the first and/or second transfer lines <NUM>, <NUM> to monitor a pressure of pre-separated fluid into the separation vessel <NUM>. In some embodiments, the control system can include one or more level sensors <NUM> within the separation vessel <NUM> for monitoring a level of fluid within the separation vessel <NUM>. One or more level sensors <NUM> can also be included in the source tank(s) <NUM> for monitoring a level of fluid. The control system <NUM> receives feedback from the various sensors within the particle separation system <NUM> and changes parameters of the system based on such feedback. The feedback can include, but is not limited to, inlet flow rate, outlet flow rate, sensing of different conditions, alarms, notifications, or any other suitable feedback.

Referring now to <FIG>, a further embodiment of a separation vessel <NUM> is depicted. The separation vessel <NUM> can be included in any of the systems disclosed herein, can include any of the features described above with respect to <FIG>, and can function in the same manner (i.e., at a high flow rate and/or low flux). The separation vessel <NUM> includes a filtration unit <NUM> with a plurality of filtration packs <NUM> including a plurality of filter elements <NUM>. The filtration unit <NUM> will now be described in detail, it being understood that all other components and features of the separation vessel <NUM> (and the system in which the separation <NUM> vessel is employed) can be as disclosed with respect to the vessel <NUM> of <FIG> and the system in which the vessel <NUM> is employed, for example, as seen in <FIG>.

The separation vessel <NUM> includes a plurality of walls <NUM> forming the separation vessel <NUM> that form an internal or main filtration chamber <NUM>. The filtration packs <NUM> of the filtration unit <NUM> occupy at least a portion of the internal chamber <NUM>. Referring to <FIG>, each filtration pack <NUM> can generally include a plurality of filter elements <NUM> arranged in a parallel manner. In some embodiments, the filtration unit <NUM> includes <NUM> filter elements <NUM>, for example, in a five by five orientation. In other embodiments, any number of filter elements in any orientation can be utilized.

First ends <NUM> of the filter elements <NUM> can be positioned in a frame <NUM> and second ends <NUM> of the filter elements <NUM> can be connected to a manifold <NUM>. The frame <NUM>, which can be made of steel or another suitable material, can include a plurality of slots (not shown) for insertion of a second end <NUM> of each filter element <NUM> in each of the slots to retain the filter elements <NUM> within the frame <NUM> and in relation to one another. In other embodiments, the filter elements <NUM> can be retained within the frame <NUM> in any suitable manner. The manifold <NUM>, as seen in <FIG> and <FIG>, is a hollow structure with a plurality of input ports <NUM> for connection of an outlet tube <NUM> of each filter element <NUM> and an outlet port <NUM>, as will be discussed in greater detail below. In some embodiments, each outlet tube <NUM> can fit within a corresponding port <NUM> of the manifold <NUM> through an interference fit. In such an embodiment, an O-ring <NUM> can be positioned around the outlet tube <NUM> to further the interference fit, create a seal, and prevent leakage between the outlet tube <NUM> and the port <NUM>. The ports <NUM> and the outlet tubes <NUM> are positioned and aligned such that each of the filter elements <NUM> of the filtration pack <NUM> can be connected to the manifold <NUM> at the same time. In other embodiments, the input ports <NUM> and the outlet tubes <NUM> can be formed in any suitable manner that would provide for quick and easy attachment of a plurality of outlet tubes <NUM> of a plurality of filter elements <NUM> to a plurality of input ports <NUM> of a single manifold <NUM> at the same time.

As further seen in <FIG>, the filtration pack <NUM> can include a number of arms <NUM> connecting the frame <NUM> and the manifold <NUM> and including looped ends <NUM> that allow for connection of an apparatus for lifting the filtration pack <NUM>. In some embodiments, the arms <NUM> can be in the form of straps or another suitable flexible elements. In other embodiments, the arms are made of a more rigid material. The arms <NUM> hold the filter elements <NUM>, the frame <NUM>, and the manifold <NUM> together. Further, each filtration pack <NUM> can be lifted by the looped ends <NUM> of the arms <NUM> to insert and remove the filtration packs <NUM> from the separation vessel <NUM>. In other embodiments, the arms <NUM> can include any other suitable structure for holding and moving the filtration packs <NUM>. As seen in <FIG>, a plurality of filtration packs <NUM> (that are the same or different) can be inserted into the separation vessel <NUM>. While the filtration packs <NUM> are shown as occupying most of the separation vessel <NUM>, the filtration packs <NUM> may not occupy the entire separation vessel <NUM> (i.e., there can be open space within the vessel <NUM>).

As best seen in <FIG>, a bottom perspective view of the filtration pack <NUM> is depicted. Each filtration pack <NUM> includes a molded end cap structure <NUM> that is separate from or an integral part of the frame <NUM>. The end cap structure <NUM> is molded in a square shape and can include a number of alignment structures <NUM> (e.g., circular slots, apertures, or other aligning structures) for holding ends of each of the filter elements <NUM> in position. The alignment structures <NUM> can further include connecting structures <NUM> that couple the alignment structures <NUM> to individual square-shaped members <NUM> that together form the end cap structure <NUM>. While one particular member of providing alignment features to ends of the filter elements <NUM> is depicted, any other suitable alignment feature can be utilized. Further, the shape of the frame <NUM> and/or molded end cap structure <NUM> can be varied to accommodate filtration packs <NUM> of different shapes and/or sizes.

Referring back to <FIG>, the separation vessel <NUM> further includes processed fluid conduits <NUM> on opposing sides of the separation vessel <NUM>. The conduits <NUM> can be attached to an inner surface of a wall <NUM> of the separation vessel <NUM> by brackets or any other suitable manner. The conduits <NUM> are configured to transport clean fluid (i.e., by pulling the fluid through the vessel <NUM> utilizing a downstream pump) from the filtration packs <NUM> out of the separation vessel <NUM>. More particularly, pack conduits <NUM> are connected between each of outlet portion <NUM> and a respective processed fluid conduit <NUM>.

When the filtration packs <NUM> are first inserted into the separation vessel <NUM>, the filter elements <NUM> are clean and dry and, thus, create an upward buoyant force. In order to retain the filtration packs <NUM> in place within the separation vessel <NUM> (in a vertical direction), retention straps <NUM> can be attached, for example by brackets or any other suitable mechanism, to opposing walls <NUM> of the separation vessel <NUM>. In some embodiments, the retention straps <NUM> are positioned immediately above the manifolds <NUM> when the frame <NUM> is positioned on a bottom wall of the separation vessel <NUM>. In other embodiments, the retention straps <NUM> can be located at any suitable position. While the retention straps <NUM> are shown as being made of a flexible material, the straps <NUM> may alternatively be made of a rigid material or a combination of flexible and rigid materials.

Still referring to <FIG>, the manifold <NUM> of each of the filtration packs <NUM> is coupled to the conduits <NUM> by the pack conduits <NUM>. As described in detail above, the contaminated is pulled through the separation vessel <NUM> by a pump downstream of the separation vessel <NUM>. In this manner, the systems disclosed herein are non-pressurized or lack a pressurized vessel (i.e., the system is at atmospheric pressure). Instead, the systems disclosed herein utilize a suction-side pump that draws fluid through the system. One advantage of a non-pressurized system is cost. Pressurized systems require specific vessels that cost significantly more for the same amount of filtration. Utilizing a non-pressurized system eliminates the need for such expensive vessels.

In some embodiments, as seen in <FIG> and <FIG>, any of the separation vessels herein can be included as part of a two (or more) stage filtration system <NUM>. For example, the separation vessels discussed herein are utilized to separate particles from a pre-separated fluid and/or to skim oil from an oil/water emulsion. It may also be desirous to provide a coalescing stage to remove oil and/or to provide other filtration steps. Some systems <NUM> can include any number of separation vessels <NUM> (which can be any of the separation vessels disclosed herein). Pre-separated fluid is provided from a tank or other site (see <FIG>) through a distribution manifold to a number of different separation vessels <NUM>. The pre-separated fluid is pulled through each of the separation vessels <NUM> by a respective pump <NUM> positioned, for example, on a pump skid <NUM>. The pumps <NUM> can then pump processed or treated fluid from the separation vessels <NUM> to additional treatment stages, for example, coalescers <NUM>, which remove oil from the treated fluid. A collection manifold <NUM> can be positioned between the pumps <NUM> and the additional filtration stages <NUM> to control the flow therebetween and to monitor the fluid (e.g., the quality, pressure, etc.) flowing therebetween. While coalescers are discussed, any additional filtration treatment process(es) can be utilized in combination with the separation vessels <NUM> and/or numerous additional filtration treatment processes can be utilized. In some embodiments, absorption beds can be utilized. In other embodiments, the other filtration or treatment processes can be pre-treatment processes in that they can be positioned upstream (i.e., before) the separation vessels <NUM>.

In any of the embodiments discloses herein, one or more aerators or bubblers can be disposed, for example, on the bottom wall <NUM>, one or more side walls <NUM>, or at any other suitable location within the separation vessel <NUM>. The aerator or bubbler would act to inject air (or possibly a fluid, such as water) into the separation vessel <NUM> to create a disturbance, which may assist in moving fluid through the separation vessel <NUM> and/or in the filtration process.

In any of the embodiments discloses herein, a back-pulsing operation may be implemented within any of the systems. More particularly, the flow through the separation vessel may be reversed to remove solids from the filter elements of one or more filtration packs, and then may be returned to the original flow direction. The back-pulsing operation may improve the life of the individual filter elements.

As can be seen from the foregoing figures, the separation vessels <NUM>, <NUM> of the particle separation system can be portable and replaceable. More particularly, the separation vessel <NUM>, <NUM> can be on wheels or can be capable of being placed on a trailer or other structure for moving the separation vessel <NUM>, <NUM>. The separation vessel <NUM>, <NUM> can be connected and unconnected from the source tank(s) <NUM> (or other location) and the pump system <NUM> and can be removed from the particle separation system <NUM> and a new separation vessel <NUM>, <NUM> can replace the original separation vessel <NUM>, <NUM>. Use of the separation vessel <NUM>, <NUM> causes buildup and soiling of the filter elements <NUM>, <NUM> within the separation vessel <NUM>, <NUM>. In current systems, the system must be stopped and the filter elements must be cleaned, which takes a long time, thereby resulting in significant downtime, which leads to higher costs. In the present particle separation system <NUM>, the separation vessel <NUM>, <NUM> can be disconnected from the source tank(s) <NUM> (or other location) and the pump system <NUM>, <NUM> and immediately replaced with a new separation vessel <NUM>, <NUM>, resulting in very little downtime. The old separation vessel <NUM>, <NUM> can then be transported to a facility for cleaning of the filter elements <NUM>, <NUM> and other components within the separation vessel <NUM>, <NUM>. The separation vessel <NUM>, <NUM> is, therefore, also portable. More specifically, the vessel can be transferred to, for example, a flatbed truck or another vehicle for transport thereof and/or can include wheels or other mobilizer for moving the separation vessel <NUM>, <NUM> short distances.

In some embodiments, the separation vessel <NUM>, <NUM> can be modular. More specifically, the separation vessel <NUM>, <NUM> can be equipped to hold any suitable number of outlet manifolds <NUM>, <NUM> for accommodating a number of slots X for up to X filtration packs <NUM>, <NUM>. The separation vessel <NUM>, <NUM> can also be equipped with appropriate shutoff valves or other equipment to deactivate one or more of the outlet manifolds <NUM>, <NUM>. In this manner, dependent upon a particular application, any number of the slots X can include filtration packs <NUM>, <NUM>. For example, if the separation vessel <NUM>, <NUM> includes six slots to accommodate up to six filtration packs and the separation vessel <NUM>, <NUM> is utilized for a first application, filtration packs <NUM>, <NUM> can be installed in each of the six slots and all six filtration packs <NUM>, <NUM> may be active. In another application, filtration packs <NUM>, <NUM> may be installed in each of the <NUM> slots, but less than six of the filtration packs <NUM>, <NUM> may be active. In yet another application, filtration packs <NUM>, <NUM> may be installed in less than all six slots (for example, three). In situations where filtration packs <NUM>, <NUM> are installed and not utilized or not installed at all, the respective manifolds may be deactivated. The above-described modular system allows for customization of a system by installing a suitable number of filtration packs <NUM>, <NUM> and by further allowing for selective activation and deactivation of filtration packs <NUM>, <NUM> dependent upon the particular application.

In some embodiments, the systems disclosed herein can be offered as a rental model. In this manner, site personnel do not need to remove and replace hundreds of filter elements at once. Rather, the entire separation vessel may be removed from a particular site and replace with a new separation vessel. This model also greatly reduces downtime, as it takes significant time to remove and replace hundreds of filtration elements.

Claim 1:
A particle separation system (<NUM>), comprising:
a vessel (<NUM>) having at least one side wall (<NUM>) and a bottom wall (<NUM>) forming an internal chamber (<NUM>) within the vessel (<NUM>);
a filtration unit (<NUM>) positioned within the vessel (<NUM>) and comprising:
a first filtration pack (<NUM>) comprising a first plurality of filter elements (<NUM>) having a first plurality of outlets (<NUM>);
a first hollow manifold (<NUM>) having a first plurality of inlets (<NUM>), a number of the first plurality of inlets (<NUM>) being equal to a number of the first plurality of outlets (<NUM>), the first plurality of outlets (<NUM>) and the first plurality of inlets (<NUM>) being capable of coupling such that a flow through each of the first plurality of filter elements (<NUM>) enters the first manifold (<NUM>);
the first hollow manifold (<NUM>) including a first outlet channel (<NUM>) for flow from the first manifold (<NUM>) to a processed fluid conduit (<NUM>);
a second filtration pack (<NUM>) comprising a second plurality of filter elements (<NUM>) having a second plurality of outlets (<NUM>);
a second hollow manifold (<NUM>) having a second plurality of inlets (<NUM>), a number of the second plurality of inlets (<NUM>) being equal to a number of the second plurality of outlets (<NUM>), the second plurality of outlets (<NUM>) and the second plurality of inlets (<NUM>) being capable of coupling such that a flow through each of the second plurality of filter elements (<NUM>) enters the second manifold (<NUM>);
the second hollow manifold (<NUM>) including a second outlet channel (<NUM>) for flow from the second manifold (<NUM>) to the processed fluid conduit (<NUM>);
wherein each of the first and second filtration packs (<NUM>) is modular in that each of the first and second filtration packs (<NUM>) can be individually inserted and removed from the vessel (<NUM>) such that each of the first plurality of filter elements (<NUM>) are insertable and/or removable together and each of the second plurality of filter elements (<NUM>) are insertable and/or removable together.