The present application pertains to an apparatus for drying sludge and like viscous substances and to a method for drying sludge, for example, in the context of waste management, micro-plastic recovery, among others.
In waste management, it is common to have to dispose of viscous substances such as sludge that incorporate a mixture of liquids and solids, for example. In an embodiment, such sludge may have water, and pollutants, solids, mixed up. As water or other liquids represent a sizable portion of the mass of the sludge, it may be desired to dry the sludge so as to separate solids from the liquid. The challenge remains to separate the water from the solids in an ecological manner.
In one aspect, there is provided an apparatus for treating a substance comprising: a structure; a dryer system including drums rotatably mounted to the structure, the drums arranged on the structure to form a throat therebetween, a drive system to rotate the drums, and a heating system for heating an outer cylindrical surface of the drums.
Still further in accordance with the aspect, for example, at least one feed conveyor may be configured to feed the substance to the throat.
Still further in accordance with the aspect, for example, each of the drums has a respective one of the feed conveyor.
Still further in accordance with the aspect, for example, the at least one feed conveyor includes a feed plate directing a substance to the throat.
Still further in accordance with the aspect, for example, the feed plate has troughs.
Still further in accordance with the aspect, for example, a sieve may be in the at least one feed conveyor.
Still further in accordance with the aspect, for example, including at least one feed screw may be in the feed conveyor.
Still further in accordance with the aspect, for example, a wiper may be between the feed conveyor and at least one of the drum.
Still further in accordance with the aspect, for example, the heating system includes a hollow cavity in the drums configured to receive a heating fluid.
Still further in accordance with the aspect, for example, the heating system includes at least one heating element in the hollow cavity configured to heat the heating fluid.
Still further in accordance with the aspect, for example, the at least one heating element is at least one electrically powered resistive element.
Still further in accordance with the aspect, for example, each of the drums has a plurality of the electrically powered resistive element, the plurality of the electrically powered resistive element being circumferentially distributed.
Still further in accordance with the aspect, for example, assemblies of brushes and slip rings may be configured to power the plurality of the electrically powered resistive element.
Still further in accordance with the aspect, for example, a hydraulic system may be in fluid communication with the hollow cavity.
Still further in accordance with the aspect, for example, the hydraulic system may include a tank, the tank being located at least partially above a top of the drums.
Still further in accordance with the aspect, for example, the tank is an atmospheric tank.
Still further in accordance with the aspect, for example, the hydraulic system has a conduit network extending from the tank to the drums, the conduit network in fluid communication with a conduit portion of a central shaft of the drums.
Still further in accordance with the aspect, for example, the rotational axis of the drums lie in a common plane, the common plane being generally horizontal.
Still further in accordance with the aspect, for example, a scrubbing member may be adjacent to outer cylindrical surface of at least one of the drum.
Still further in accordance with the aspect, for example, the scrubbing member is located within a 6 o'clock and a 9 o'clock position relative to a clockwise direction of rotation of the drum.
Still further in accordance with the aspect, for example, the drive system includes a chain and sprocket transmission and a motor.
Still further in accordance with the aspect, for example, a collecting system may be under the throat configured to collect the substance.
Still further in accordance with the aspect, for example, the collecting system includes a trough and a conduit at a bottom of the trough.
Still further in accordance with the aspect, for example, a hood unit may be mounted above the dryer system and configured to collect steam and/or emissions from the dryer system.
Still further in accordance with the aspect, for example, the hood unit includes a fan.
Still further in accordance with the aspect, for example, at least one of the drums is mounted to the structure with a translational joint.
Still further in accordance with the aspect, for example, a biasing mechanism may bias the drum mounted to the structure with the translational joint toward another of the drums.
Still further in accordance with the aspect, for example, a controller may be configured to control the heating system and the drive system
In accordance with another aspect, there is provided a method for treating a substance comprising: rotating at least a pair of drums having a throat between the drums; heating an outer cylindrical surface of the drums; feeding a substance in the throat to vaporize at least part of a liquid content in the substance; and collecting solids at a bottom of the throat.
Further in accordance with the other aspect, one of the drums from the pair may be biased toward the other of the drums of the pair.
Still further in accordance with the other aspect, heating the outer cylindrical surface includes operating resistive elements in the drums to heat a heating fluid in the drums.
Still further in accordance with the other aspect, heating the outer cylindrical surface includes heating the outer cylindrical surface to a temperature above a melting point temperature of a solid in the substance.
Reference is now made to the accompanying figures in which:
Referring to the drawings and more particularly to
The apparatus 10 has one or more of a structure 20, a hood unit 30, a feed conveyor 40, a dryer system 50, a collecting system 60, and/or a controller unit 70, or any combination thereof.
Referring to
Referring to
Still referring to
Referring to
Referring to
In an embodiment, the pillow blocks 52 or like support for both drums 51 are mounted to the structure 20 by translational joints 52A, though this is not necessary. As shown as an exemplary embodiment, the translational joint 52A may include a bracket 53A fixed to the structure 20, and another bracket 53A mounted to the structure 20 with a set of guides and slots so as to be displaceable in translation, along direction Y. A biasing device 53 may be present in order to bias the drum 51 toward the other drum 51, along direction Y, by acting on the brackets 53A. For example, the biasing device 53 in an embodiment has the pair of brackets 53A with a bolt 53B and spring 53C therebetween. The bolt 53B may be fixed to one of the brackets 53A, such as by a pair of nuts as shown, and other components such as washers, etc). The bolt 53B and the brackets 53A act as stops to delimit the movement of the drums 51 relative to one another. The spring 53C is compressed between the head of the bolt 53B and one of the brackets 53A as shown, but could be at other locations, such as between the brackets 53A. Other configurations are considered as well. The action of the spring 53C biases the drums 51 toward one another, but with the possibility of the drums 51 distancing from one another against the action of the spring 53C, when a pressure is present between the drums 51. In an embodiment, a set of the translational joint 52A and biasing device 53 is present on each side of the drive system 50, for a mirroring biasing action on both sides of the drum(s) 51. Accordingly, a translational degree of freedom may be provided between the drums 51 as an option. In another embodiment, the plane of the axes X is not horizontal, for gravity to bias a translating one of the drums 51 toward the other drum 51.
In order to perform the drying process, the drums 51 are heated. More particularly, in an embodiment, the outer cylindrical surface of the drums 51 is heated for the substance to be heated by contact with the drums 51. In an embodiment, the outer cylindrical surface is heated by a fluid such as oil that is inside the inner hollow cavity of the drum(s) 51 (one or both drums 51 being heated in the embodiment shown). For simplicity, reference is made herein to oil being the fluid inside the drum 51, but other fluids may be used, as identified above. Moreover, as an alternative to a heated fluid, heating cartridges may be used, which heating cartridges may be heated electrically, for example. As another alternative, gas burners may be provided inside the drums 51, or may be fed by conduits. If heated by oil, the drums 51 are sealed so as to receive the oil. In an embodiment, a hydraulic system is present to ensure that the drum(s) 51 is(are) filled with oil. Referring to
Referring to
Referring to
Referring to
Referring to
Now that the apparatus 10 has been described, a method for drying a substance such as a viscous substance, or for separating solids (e.g., plastics, micro-plastics) from a fluid (e.g., water) is described, using for example the apparatus 10. A substance to be treated, including sludge, waste, substances that are liquid with solid particles in suspension, is fed to the dryer system 50. In an embodiment, this is achieved via the feed conveyor 40 that controls a feed of the substance to a throat between the drums 51 of the dryer system 50. The feed may be a continuous feed or in batches, and the volumetric flow may be controlled during the process, for instance by adjusting the speed of the feed screws 42. This may be done by the controller 70.
The dryer system 50 has its drums 51 heated to a temperature specific to the substances to be treated. The drums 51 are rotated, for example in the direction shown in
The presence of oil in an embodiment is well-suited for a control of the temperature, as the heat capacity of the oil ensures that the outer cylindrical surfaces of the drums 51 is at a relatively constant temperature, taking into consideration the volumetric flow of substance reaching the drums 51. As the substance falling between the drums 51 is heated and exposed to the pressure of the rotating drums 51, it accumulates in the throat and causes the water to boil and evaporate via the hood unit 30, if present. The solid contents are, on the other hand, kept between the drums 51 by gravity. The solid contents are therefore compressed and may consequently gather in a cake. The translating arrangement of the drums 51, if present, may contribute to the compression and throughput, via the biasing action allowing a greater volume of substance to pass, as a function of pressure in the throat. The cake may have a reduced moisture content, in contrast to the sludge that is fed to the drying system 50. By gravity, the solids falls into the collecting system 60 with the rake 59 removing any material gathered onto the surface of the drums 51. In an embodiment, if water is still present in the substance of the collecting system 60, the collected substance may be cycled back to the feed conveyor 40 for another pass. The drums 51 may compact the substance and may consequently squeeze out additional liquids.
The apparatus 10 and the method related to the apparatus 10 may be said to be continuous, in that the substance to be treated is continuously fed to the system, though batch operation, semi-continuous operation are possible. The controller 70 may operate the apparatus 10 and/or perform a method for treating or drying a substance in an automated way. The controller 70 may have one or more processors of a processing unit 70A, and a non-transitory computer-readable memory 70B communicatively coupled to the processing unit and comprising computer-readable program instructions executable by the processing unit. Sensors 71 of various kinds may be provided to monitor the process. For example, temperature sensors (e.g., thermocouples) may be present to monitor drum temperature, substance temperature at the outset. Hygrometers may be used downstream of the drums 51, so as to measure the moisture content in the matter exiting the drying system 50. Force sensors may monitor the pressure on the drums (e.g., via the translational joints 52A for example). The controller 70 may consequently control the speed of rotation of the drums 51, and adjust the feed of substance via the feed conveyor 40. The controller 70 may also control and adjust the temperature in the drums 51 depending on the process. For example, if the substance to be treated is water with micro-plastics, the temperature of the drums 51 may be set to be above a melting point of the plastic. Moreover, the temperature may be in proximity to but below a combustion temperature of the plastic. As a result, the plastic in the water may begin melting and may adhere to the surface of the drums 51, while the water vaporizes. The controller 70 may control speed of rotation as a function of temperature and throughput. For example, an aim of the controller 70 may be keep the speed of rotation as high as possible to maintain a high throughput, and this may require maintain the temperature high as well. However, the controller 70 may keep the temperature below given thresholds to limit the emission of fumes by the dryer system 50.
The apparatus 10 may be described as being for treating a substance and may have a structure; a dryer system including drums rotatably mounted to the structure, the drums arranged on the structure to form a throat therebetween, means to rotate the drums, and a heating system for heating an outer cylindrical surface of the drums; and a feed conveyor configured to feed the substance to the throat.
The apparatus 10 may alternatively be described as being for treating a substance (e.g., being a mixture of substances, a sludge, a liquid with solids in suspension), the apparatus 10 including among other components a structure; a dryer system including drums rotatably mounted to the structure, the drums arranged on the structure to form a throat therebetween, a drive system to rotate the drums, and a heating system for heating an outer cylindrical surface of the drums.
The method described herein may be for treating a substance comprising: rotating at least a pair of drums having a throat between the drums; heating an outer cylindrical surface of the drums; feeding a substance in the throat to vaporize at least part of a liquid content in the substance; and collecting solids at a bottom of the throat.
The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims.
The present application claims the benefit of U.S. Patent Application No. 63/025,029, filed on Jun. 5, 2020 and incorporated herein by reference.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/CA2021/050777 | 6/7/2021 | WO |
Number | Date | Country | |
---|---|---|---|
63035029 | Jun 2020 | US |