Patent Application
20050054507
This invention relates to centrifuges, and more particularly to centrifuges used for separation of waste materials.
Centrifuge technology has long been used to separate mixtures of materials into their heavy and light components. Centrifuge technology is useful in many fields, including, but not limited to, medical, industrial, and public service sectors, all within various specific applications where separation technology is beneficial.
The effectiveness of presently known centrifuge technology is dependent upon factors such as the magnitude of the separating force (centrifugal force) that is generated by the centrifuge and the residence time during which the material to be separated is subjected to the separating force. Virtually all centrifuges rely on some type of rotary motion to generate a separating force. Thus, the magnitude of the separating force that is generated depends on the size (moment arm) of the centrifuge and the speed at which the centrifuge rotates. To generate a given magnitude of separating force, a small-size centrifuge must be driven at higher revolutions per minute (RPM) than is required of a large-size centrifuge.
The residence time during which the material to be separated is subjected to the separating force depends upon the flow-path of the material through the centrifuge. This flow-path is defined by the internal structure of the centrifuge, and its length is sometimes limited by the type of centrifuge. Typically, the longer the residence time of a material under a given separation force, the better the separation of the light material from heavy material.
Existing centrifuge technology is limited in its ability to allow a change to be made in the separation force and/or in the residence time.
While existing relatively large-size centrifuge technology is capable of handling relatively large inflow rates, such as 100 gallons per minute (GPM), it is not conducive to portable use in a self-contained unit. Such large size centrifuge structures are difficult to transport, require frequent skilled maintenance, and often do not allow simple modification of the separation force and/or the residence time in order to adjust the centrifuge as input material conditions or output material requirements vary.
Further, present centrifuge designs may suffer from a variety of issues during operation. For example, input mixture flow into the centrifuge arms may stream or clump at specific arm segments, rather than uniformly distribute about the arm. Similarly, solids and/or particulates may cake onto the end of the arm, restricting flow therethrough and minimizing the reaction zone for separating heavy and light materials from one another in the arm.
Additionally, resonance and vibration in the centrifuge may be an issue, especially when high operating speeds are reached. Such resonance may result from overloading the drive shaft of the centrifuge, load imbalances between arms, and/or lack of adequate support for the shaft.
It is with the foregoing issues in mind that the centrifuge of the present invention was developed.
This invention provides a centrifuge having at least one arm assembly that rotates in a generally vertical plane and that extends outward on a common radius from a generally horizontal axis of rotation (spin axis).
The present invention pertains to a centrifuge for accepting an input mixture and for separating a light material that is within the mixture from a heavy material that is within the mixture. The centrifuge has a housing having a central member that is rotatable on an axis of rotation and also has at least one arm assembly used for separation of the light material from the heavy material. The housing is constructed such that the lower half of the housing can be placed below ground level, if desired. The arm assembly has an outer tube with a first end operably connected to the central member and a closed second end extending away from the central member. The arm assembly has an intermediate tube operably connected to the central member that is located within the outer housing. This location defines a first annular flow path between the outer housing and the intermediate tube. The arm assembly also has an inner tube that is operably connected to the central member that is located within the intermediate tube. This location with respect to the intermediate tube defines a second annular flow path between the intermediate tube and the inner tube as well as a tubular flow path within the inner tube. An input mixture flow path is provided to receive the input mixture. This input mixture flow path extends through the drive shaft, through the housing and is in communication with one of the first and second annular flow paths. There is also a light material flow path communicating with the other of the first and second annular flow paths and a heavy material flow path communicating with the tubular flow path.
According to another aspect of the present invention, the outer tube housing is operably connected to the central member by a first mounting ring. The intermediate tube is operably connected to the central member and the first mounting ring by a second mounting ring and the inner tube is operably connected to the central member and the second mounting ring by a third mounting ring. The first mounting ring has an overhanging portion that overlies a portion of the second mounting ring, the second mounting ring has an overhanging portion that overlies a portion of the third mounting ring.
A first speed-controllable drive means drives a hollow drive shaft that defines the centrifuge's horizontal axis of rotation. One end of this drive shaft is bolt connected to a central member that rotates on the axis of rotation. The arm assembly is mounted onto this central member and is contained within a relatively large annular housing that is formed generally concentric with the axis of rotation. The centrifuge's separation force is a direct function of the speed of this first drive means and this force is varied by varying the speed of the motor. The residence time of the centrifuge is related to the length of the arms and the number of cylindrical tubes, which can be changed as desired.
The inner tube of each centrifuge arm assembly is a long tube having a small diameter. This inner tube may contain an elongated conveyer screw or auger that aids in the transport of heavy material radially inward toward the axis of rotation. The auger may have flighting along its entire length, a portion of the length, or in a discontinuous manner. A flow of heavy material enters the far end of this inner tube, moves inward toward the central member, enters the central member and makes a 90° degree turn in a direction away from the drive shaft, flows into the apex of a heavy-material discharge cone, through the discharge cone, and then into a small-size annular housing that is formed concentric with the axis of rotation.
This heavy material discharge cone extends outward from the central member. The horizontal axis of the discharge cone is generally coincident with the centrifuge's axis of rotation, and the discharge cone is located on the opposite side of the central member from the drive shaft.
A second speed-controllable drive means is mounted onto the central member, generally coincident with the centrifuge's axis of rotation. This second drive means is connected to drive the conveyor screw. Speed-control of this second drive means enables the speed of conveyor screws to be controlled independent of the speed at which the centrifuge's arm assemblies are rotated by the first drive means.
The intermediate tube of the centrifuge arm assembly is of an intermediate length and an intermediate diameter. An input mixture that is to be separated, and that contains both heavy and light material, flows through the hollow drive shaft and into the central member where it makes a 90° turn, flows into the inner end of an annular space that exists between the inner tube and the intermediate tube, and then flows outward from the axis of rotation to the outer end of the arm assembly.
The outer housing of each centrifuge arm assembly has the shortest length and the largest diameter. Light material that has been separated from the input mixture flows into the outer end of a cylindrical space that exists between the intermediate tube and the outer housing, inward toward the axis of rotation, into the central member where it makes a 90° degree turn, through conduits that are formed in a side wall of the heavy material discharge cone, and then into an intermediate size annular housing that is formed concentric with the axis of rotation.
As a feature of the invention, the two centrifuge arm assemblies provide for selective replacement of components that are within the arm assembly(s), and provide for modification of the arm assemblies in order to change the separation characteristics of the centrifuge. This is achieved by including a removable plug and/or a removable end cap on the end of the outer tube housing.
According to another aspect of the present invention, a method of using a centrifuge to separate a light material that is within an input mixture from a heavy material that is within the input mixture, while at the same time independently controlling a speed of rotation of the centrifuge and a speed of removal of the heavy material from the centrifuge is provided. The method includes the following steps: providing a first and a second arm assembly aligned on an arm-axis and that are rotatable in a plane extending generally perpendicular to a rotation-axis; providing that each of the arm assemblies includes a tubular-housing having a closed outer end, an intermediate tube having an open outer end, and an inner tube having an open outer end; providing that the inner tube of each arm assembly is of a given length; providing that the intermediate tube of each arm assembly is of a length that is less than the given length; providing that an outer end of the tubular-housing of each arm assembly is spaced from the outer end of the intermediate tube and from the outer end of the inner tube; providing an input mixture flow path that communicates with a cylindrical space between the intermediate tube and the inner tube of each arm assembly; providing a heavy material flow path that communicates with a space within the inner tube of each arm assembly; providing a light material flow path that communicates with a cylindrical space between the intermediate tube and the tubular-housing of each arm assembly; providing a conveyer screw within the inner tube of each arm assembly; providing a first speed controllable drive means connected to effect rotation of the first and second arm assemblies about the rotation-axis; and providing a second speed controllable drive means connected to effect rotation of the conveyer screws.
In an embodiment of the invention, but without limitation thereto, the input mixture to the centrifuge of the invention is a water-containing liquid that is not potable, and the light material output from the centrifuge comprises potable water.
The present invention includes a novel system and method for oxidizing materials. In both the system and method embodiments, an oxidation reaction is contained within a centrifuge.
The system for oxidizing materials includes an entry zone, a thickening zone, a reaction zone, a cooling zone, and an exit zone. The entry zone includes a centrifuge influent manifold and beginning portion of a centrifuge arm, the reaction zone encompasses the end portion of a centrifuge arm, the cooling zone is contained in the center channel of a centrifuge arm, and the exit zone includes the centrifuge effluent manifold. Influent materials are introduced to the system via the entry zone. The influent materials are then thickened in the thickening zone before being transported to the reaction zone. In the reaction zone, the materials are oxidized in an oxidation reaction. The oxidation by-products (effluent) are next cooled in the cooling zone before exiting the system via the exit zone.
The method for oxidizing materials involves passing an influent material through the various system zones (entry zone, thickening zone, reaction zone, cooling zone, and exit zone) described above. In addition to oxidizing the influent materials, lighter fluids present in the influent materials may be decanted during the normal operation of the centrifuge if desired. By controlling the system probe, the volume of centrate produced can be controlled.
The centrifuge can be used as a supercritical oxidation reactor or a subcritical oxidation reactor, depending on the conditions inside the reactor, as controlled by the user. Given the extreme pressure built up in the end of each arm of the centrifuge as described herein, the end of each arm can act as the reaction zone for the supercritical oxidation reactor with the proper addition of an oxidant into the system and with the proper addition of heat to create the ideal reaction zone parameters.
One embodiment of the centrifuge desecribed herein can be used as an oxidation reactor, both for subcritical and supercritical conditions. In this embodiment, the centrifuge includes a main body having at least one inlet and at least one outlet and being rotatable about an axis, at least one hollow arm extending from said main body, said arm having a distal end and a proximal end, said arm defining at least an interior inlet flow path communicating with and leading from said inlet at said proximal end outwardly to said distal end, and at least a first exit flow path leading from said distal end to said proximal end and communicating with said outlet, and a heat source at said distal end, and a reactor region formed at said distal end of said arm.
In greater detail, the oxidation reactor could also include a flow path for inserting an oxidant into to said reactor region.
In further detail, the oxidation reactor could also include a second exit flow path leading to a second outlet, said first exit flow path for the flow of the incoming material after passing through said reactor region, and said second exit flow path for liquid separated from the incoming material.
In further embodiments, the oxidation reactor can be suspended from a frame so as to rotate about a vertical axis, and the outlet of the oxidation reactor can be positioned in a tank below the frame. The tank can have liquid, such as water, therein to assist in handling the reaction by-products.
The centrifuge may employ a variety of shafts to intake the aforementioned input mixture. The input mixture or sludge may flow through a rotary union, into a rotary shaft, through a flexible seal joining the rotary shaft to a drive shaft, along the drive shaft, into a shaft coupler affixing the drive shaft to an output shaft, and into the centrifuge body and arms. Multiple bearing blocks may support one or more of the aforementioned shafts.
In some embodiments of the present invention, the arm structure may be reinforced with threaded rods having a shoulder formed at one end. The threaded rod may be seated in a mating threaded cavity at the arm base, with the shoulder abutting the cavity exterior. The shoulder acts to spread stress and shear forces about a larger cross-sectional area of the reinforcing, threaded rod, thus reducing the likelihood of rod failure.
Certain embodiments may also modify the arm structure by adding a flow distributor within the arm. The flow distributor generally prevents the input mixture from flowing along a single path of least resistance in the arm, instead spreading the mixture about the interior cavity defined by the inner and intermediate tubes of the arm relatively uniformly. The centrifuge arm may also be equipped with one or more scrapers located in a void space defined beneath the end cap. The scrapers may be affixed to, and rotate with, the auger. The scrapers generally remove solid buildup from the interior walls of the end cap defining the void space, and may further chop such solid material into finer chunks or particulate for further processing and disposal by the centrifuge.
Additionally, some embodiments of the present invention may employ a centrate shroud and one or more labyrinth seals designed to minimize centrate flow beyond the shroud. The centrate shroud collects centrate leaving the main body of the centrifuge during operation, while the labyrinth seals channel centrate to the shroud. Each labyrinth seal is generally formed of a series of interconnected disks made of rubber, plastic, metal, or another suitable material. Grooves are formed along the longitudinal axis of the disks to catch and collect centrate thrown from the body by centrifugal force. These grooves channel the centrate to a seal passage communicating with the centrate shroud interior. Thus, centrate collected by the labyrinth seal is channeled back into the shroud interior.
Other aspects, features and details of the present invention can be more completely understood by reference to the following detailed description of various embodiments, in conjunction with the drawings, and from the attached claims.
In the figures of this application an X-Y-Z coordinate system is shown as an aid to orienting the figures one to another.
This invention will be described relative to the separation of an input mixture that contains heavy solids and relatively light liquids. However, the invention can be used with virtually any generally liquid input mixture that contains both heavy and light material, for example a mixture of oil and water. Also, the input mixture can be filtered prior to being introduced into the centrifuge of the invention.
The input mixture can be introduced into the centrifuge by way of gravity feed or by way of pressure feed as achieved by pumping. The centrifuge 10 of the present invention is relatively insensitive to the flow-rate of its input mixture, to the solid content of its input mixture, and to the volumetric weight of its input mixture.
With particular reference to
Centrifuge 10 includes at least two laterally opposed and axially aligned rotating-arms 12 and 14 that extend perpendicularly outwardly from one end 38 of a hollow drive shaft 28. The internal volume of drive shaft 28 carries input mixture 16 from input end 26 to the inner ends of arm assemblies 12, and 14.
The opposite end portion 26 of drive shaft 28 into which input mixture 11 is introduced is bearing-supported by two shaft-bearings 42 and 44 that are mounted on and supported by a rectangular frame 46 and its generally centrally located flat plate 48. A relatively large annular housing 50 is also supported by frame 46. Housing 50 surrounds, protects, and contains the centrifuge's rotating arm assembly 12, 14.
Drive shaft 28 and its end-supported arm assembly 12, 14 are driven by an electric motor 52 that is mounted on frame 46. Motor 52 and its drive belt 54 cause drive shaft 28 to continuously rotate in one direction about a rotational or Y-direction axis 24 that is coincident with the center of drive shaft 28. Rotation of drive shaft 28 develops the centrifugal forces that are necessary for material separation.
While physical dimensions are not a limitation on the spirit and scope of the invention, centrifuge 10 is relatively large. For example, the total length of rotating arm assembly 12, 14 may be in the range of from 7 to 8 feet, the diameter of each arm 12, 14 may be in the range of from 1 foot to 1.5 feet, and the rotational speed of shaft 28 may be about 3000 revolutions per minute (RPM). In addition, in an embodiment of the invention, but without limitation thereto, the centrifuge's frame 46 occupies a horizontal plane, and a lower portion of housing 50 may extend below ground level.
With particular reference to
While the radial spacing between the tubes can be any distance depending on the application, the radial spacing between tubes 30, 32, 34 is approximately from about 1 inch to about 4 inches, preferably 1.9 inches, and the axial lengths of tubes 30, 32, 34 can be any of a variety of different lengths that maintain outer tube 34 as the shortest tube, that maintain intermediate tube 32 as an intermediate length tube, and that maintain inner tube 30 as the longest tube. The tubes can be made of any material that has sufficient strength to withstand the forces of the centrifuge, such as but not limited to, metal or plastic.
The length of innermost tube 30 is preferably adjustable. The outer end can include a sleeve portion (not shown) that slides along the length of the rest of the tube to allow length adjustment. The sleeve portion is fixed to the rest of the tube 30 by a set screw, or other attachment mechanism. This allows for a fine adjustment of length of the innermost tube 30 without having to replace the entire tube 30. This can be helpful to match the tube to the plug size, as is discussed in more detail below.
While all three of the tubes 30, 32, 34 are rigid tubes that have a circular cross section, it is preferred that outer tubular housing 34 be made of a thicker or a stronger material than are tubes 30 and 32. In accordance with the invention, inner tube 30 is a relatively longer tube that has a relatively small diameter, intermediate tube 32 is a relatively shorter tube that has a relatively larger diameter. The three tubes 30, 32, 34 are mounted such that their inner ends occupy a common flat plane 62 (shown in
As perhaps best seen in
Each of the innermost and axially aligned tubes 30 contains a conveyer screw or auger 36 that aids in the removal of heavy material 24 that builds up at end-cap ends 56 of arms 12, 14 during use of centrifuge 10 to separate light material 22 from heavy material 24, both materials being contained within input mixture 16. The heavier material 24 builds up to form a plug around the end of the innermost tube 30 and covers a portion of the end cap 56. Conveyor screws 36 rotate about the central axis 64 of arms 12, 14 and aid in the movement of heavier material 24 radially inward and through innermost tube 30 toward the centrifuge's axis of rotation 72, whereas the heavier material 24 enters the heavy output chamber 70 within driven member 60. This heavy material 24 then moves out of centrifuge 10 by way of an exit cone 74 that is formed about rotational axis 72.
The apex of cone 74 lies on rotational axis 72, and its broad base 76 terminates at an X-Z plane that is within a small-size annular housing 78. The conveyor screws 36 can have different flighting 80 designs on them to facilitate the removal of the heavier material. As shown, the flighting 80 at the outer ends of the arms 12, 14 is small and extends for a short distance, for example 6 inches, to assist in breaking up the compacted heavier material 24 and help it begin moving toward the exit cone 74. The middle length of the conveyor screw 36 preferably has no fighting, as the heavier material 24 is pushed to some point there along by the head pressure created by the spinning of the centrifuge 10. The inner end of the conveyor screws are flighted 80 to help pull the heavy material 24 towards the exit 82, and push it through the change of direction in the transition between the inner end of the inner tube 30 and the exit cone 74. The length of the flighting preferably extends a distance that meets the heavy material once the head pressure is no longer sufficient to advance the heavy material through the inner tube 30.
In one embodiment of the invention, and as shown in
Input mixture 16 moves through the hollow center of shaft 28 and along rotational axis 72 as arm assembly 12, 14 rotates about axis 72. Input mixture 16 then enters input chamber 68 within driven member 60. As best seen in
Heavy-material flow 24 first compacts at the end of the arms 12, 14 and moves radially inward through innermost tube 30, this flow 24 being assisted by conveyor screw 36, enters chamber 70, enters exit cone 74, and then enters housing 78 wherein the heavy material 24 exits centrifuge 10 at 82 as best shown in
As perhaps best seen in
As input mixture 16 is forced to the distal ends of arms 12, 14 by the rotation of the arm assembly about axis 72, the solid or heavy material 24 that is within input mixture 16 compacts or compresses to form a plug of heavy material 24 adjacent to and abutting the inside surface of end cap 56. As a result, light-material flow 22 is forced back toward the center of rotation 72 in the outer tube 32. As this plug of heavy material 24 builds up in size, heavy-material flow 24 is also forced back toward the center of rotation 72 in the inner tube 30.
More particularly, at the distal end of each of the two arms 12 and 14, the end of long-tube 30 extends beyond the end of shorter-tube 32. As solids are deposited at the distal end of arms 12 and 14 a relatively solid plug of heavy material 24 is formed, this plug increases in thickness, along arm axis 64, until such time as the plug seals the end of long-tube 30. However, this plug thickness parameter does not increase enough to seal off the end of shorter tube 32. Thus, the plug partially defines the boundary of the two output flow paths 18 and 20.
The thickness of the plug is regulated in part by the action of conveyer screw 36. While not a limitation on the spirit and scope of the invention, the elongated shaft of conveyor screw 36 does not have fighting or threading 80 along its entire length, but preferably has flighting 80 only adjacent to its inner end, as best shown in
Centrifugal forces on the heavy material 24 at the distal end of arms 12, 14 combined with the hydrostatic head of the overlying liquids and solids and assist in forcing the solids 24 through flow path 18, in a direction toward the center of rotation 72. The distance that solids 24 move inward through tube 30 depends on the operating parameters of centrifuge 10 (for example the moment arm and the RPM), and on the type of input mixture 16 that is provided to centrifuge 10. Usually, solids within input mixture 16 require the assistance of flighting 80 on conveyor screw arm 36 to move the solids along flow path 18. It is possible, however, to have an input mixture 16 with a heavy material content that does not require the presence of conveyor screws to assist the heavy material through the inner tube towards the exit cone 74.
The thickness of the heavy-material plug that forms at the distal end of each arm 12, 14 is determined by an equilibrium condition that is established by the growth of the plug and the removal of the plug by way of flow path 18 through the inner tube 30. Basically, the amount of flighting 80 adjacent to the inner end of conveyor screw 36 determines the equilibrium size of the plug. Assuming an input flow 16 having relatively constant amounts of heavy 24 and light materials 22, a greater amount of flighting 80 reduces the equilibrium plug size, whereas less flighting 80 increases the equilibrium size of the plug. This relationship is due to the effect that flighting 80 has on the removal of the heavier material 24 by way of flow path 18.
The plug size is preferably at least at a minimum size or radial thickness to insure that the plug contacts only the ends of the inner tubes 30 that define the input flow path 40, the light-material output flow path 20, and the heavy material output flow path 18. This plug size should be relatively conservatively designed to accommodate a temporary reduction in the amount of heavy material 24 within input mixture 16 (which reduction would cause the size of the plug to grow more slowly). If the heavier/lighter material composition of input mixture 16 is to be changed for more than a temporary period, such as when a different type of input mixture 16 is to be separated, the length of flighting 80 that is provided on conveyer screw 36 may require modification to accommodate this change. This modification is accomplished by removing an existing conveyer screw 36 and replacing it with a conveyer screw having a different fighting configuration 80. Other changes may also need to be made, such as changing the RPM of the centrifuge or the length or spacing of the tubes 30, 32.
An important feature of the present invention is a mechanical interlocking construction and arrangement within the two arm assemblies 12, 14 that enables the arm assemblies to be easily cleaned, to be easily repaired by the selective replacement of components that make up the arm assemblies, and to be easily modified, for example in order to change the separation characteristics of centrifuge 10 to in order to accommodate a change in input mixture 16.
With particular reference to
By virtue of a mechanical interlocking arrangement in accordance with the invention, this radially inward force that is thus produced by housing-tube 34 when bolts 58 are tightened also securely mounts intermediate tube 32 and inner tube 30 to driven member 60 in a cantilever manner.
More specifically, and with particular reference to
In addition, the corresponding end of intermediate tube 32 integrally carries a second annular ring 114 having an overhanging ring-portion 116, and having a ring portion 118 that underlies the overhanging ring portion 110 that is carried by housing-tube 34. Thus, when housing-tube 34 is secured to main body member 60 by operation of bolts 58, overhanging ring-portion 110 operates to physically trap the underlying-ring portion 118 of intermediate tube 32, thus securing intermediate tube 32 to driven member 60.
In addition, the corresponding end of inner tube 30 integrally carries a third annular metal ring 120 having an underlying ring-portion 122. When intermediate tube 32 is secured to driven member 60 as above described, overhanging ring-portion 116 that is carried by intermediate tube 32 operates to physically trap the underlying-ring portion 122 of inner tube 30, thus securing inner tube 30 to driven member 60.
In operation, should it become necessary to repair, service and/or modify arm assemblies 12, 14, all that need be done is to remove bolts 58, disassemble the arm assemblies by removing the end caps 56 and tubes 30, 32, 34, perform the needed operations, and then reassemble the arm assemblies 12, 14.
When new and/or different tubes 30, 32, 34 are to be placed within centrifuge 10, the old tubes are removed and the new tubes are placed within the arm assemblies 12, 14, the new tubes corresponding to the old tubes in the manner in which they are mounted to driven member 60 as above described.
With particular reference to
With particular reference to
As shown in
Another important feature of the present invention is the construction and arrangement whereby the speed of rotation of arm assembly 12, 14 can be varied independent of the speed of rotation of the conveyor screws 36 that are within each of the two arms 12, 14. For example, but without limitation thereto, this unique two-motor construction of centrifuge 10 enables the speed of motor 52 to be varied as a function the centrifugal force that is required to separate a given input mixture 16, whereas the speed of motor 84 can be independently varied as a function of the amount of heavy material 24 that is within a given volume of the given input mixture 16.
As perhaps best seen in
There are several benefits gained by a centrifuge 10 constructed and arranged in accordance with the present invention. The concentric tubular rotating arms 12, 14 of the present invention provide an extremely long residence time during which an input mixture is subjected to centrifugal separating forces. The longer this residence time, the larger the amount of heavy material 24 that is removed from the input mixture. In addition, heavy material 24 is deliquefied by means of the compaction that occurs at the distal ends of the centrifuge's rotating arm assemblies 12, 14. The centrifuge arm assemblies 12, 14 are easily disassembled for maintenance, part replacement, and/or performance modification. A centrifuge 10 in accordance with the present invention generates tremendous centrifugal force in a machine having a relatively small physical size, and the centrifuge can be easily adjusted to handle a wide variety of input materials and flow rates. Since two separate drive means 52, 84 are provided, the rate of arm rotation and the rate of removal of the heavy material 24 from the centrifuge 10 can be independently varied, and removal of heavy material 24 from the centrifuge 10 is by way of a relatively large exit cone 74.
The centrifuge of the present invention can be utilized as an oxidation reactor with some structural modifications. The wet oxidation centrifuge reactor disintegrates waste containing sludge in a supercritical oxidation reaction. A centrifuge is used to house the supercritical oxidation reaction to create a more efficient environment for generating supercritical conditions (i.e., high pressure, high temperature). The influent is typically in the form of a sludge slurry injection. After undergoing the oxidation reaction, the resulting effluent is comprised of ash, CO2, and H2O, and other by-products depending on the constituents of the incoming slurry. FIGS. 13 provides a schematic overview of the various process zones and related reactor parameters for an embodiment of the supercritical wet oxidation centrifuge reactor.
Several identifiable zones exist within the centrifuge reactor 200 during processing. Referring to
Referring to
The centrifuge arms include a beginning portion 210 and an end portion 212. The centrifuge arm beginning portion 210 includes three concentric tubes that define three concentric channels. The outer channel 214 (or outer annular region) is in communication with the effluent manifold 638, the middle channel 216 (or intermediate annular region) is in communication with the influent manifold 644, and the center channel 218 (inner tube) is in communication with the effluent manifold 638. In an alternate embodiment, the outer channel 214 may be in communication with a centrate outflow channel (not shown) or port or no outer channel 214 may be present. The outer channel 214 generally has a consistent cross-sectional area. The middle channel 216 cross-sectional area increases from the end 220 nearest the main body 602 portion to the center portion of the middle channel 216 and then decreases from the center portion to the end 222 nearest the end portion of the centrifuge arm. The center channel cross-sectional area decreases from the end 224 nearest the main body portion to the end 226 nearest the end portion of the centrifuge arm 604.
Central to the center channel is a cooling tube or probe 228. The probe 228 introduces cooling water 230 to the center channel. The probe 228 is connected to a cooling water supply pipe 230 that extends from the side of the discharge chamber and up the center of the effluent manifold 638. The probe(s) 228 extend outwardly from the center of the effluent manifold 638 into the center of the center channel 218. The probes 228 can be mutually or independently adjustable and can also be configured to automatically adjust depending on the pressure in the center channel 218.
The end portion 212 of the centrifuge arm 604 includes two concentric tubes that define two concentric chambers: an outer chamber 232 and an inner chamber 234. The outer chamber 232 is in communication with the middle channel 216. The inner chamber 234 is in communication with the center channel 218. The outer chamber 232 is also in communication with the inner chamber 234. The outer chamber 232 cross-sectional area increases from the end 236 nearest the main body portion 602 to the opposite end 238. The inner chamber 234 cross-sectional area decreases from the end 240 nearest the main body portion 602 to the opposite end 242. The probe 228 extends from the middle channel 216 into the inner chamber 234 and acts a plunger to partially block and control the flow of effluent from the inner chamber 234 to the middle channel 216.
A flow path is defined through the main body portion 602 and centrifuge arm 604 during operation of the centrifuge reactor 200. The influent sludge slurry injection enters the influent manifold 644 at the top of the centrifuge main body 602 and flows down to openings defined by the centrifuge arm middle channels 216. The forces exerted by the rotation of the centrifuge 200 causes the slurry to enter the middle channels 216. The influent slurry flows along the middle channel 216 to the beginning of the outer chamber 232 on the end portion 212 of the centrifuge arm 604. The area from the beginning of the influent manifold 644 to the beginning of the outer chamber 232 on the end portion 212 of the centrifuge arm is known as the entry zone 201.
Centrate 246 flows out of the middle channel 216, into the outer channel 214, and back into the effluent manifold 638 in the center of the main body portion 602 (centrate is the resulting separated liquid from a centrifuge process). In alternate embodiments, the centrate 246 may exit the centrifuge 200 via a centrate port (not shown) or no outer channel may be present. In the middle channel 216, the influent begins to thicken. This area is known as the sludge thickening zone 202.
The influent continues into the outer chamber 232 and to the end 212 of the centrifuge arm. The end portion 212 of the centrifuge arm 604 is heated by a heating element 244. The influent/effluent next flows into the inner chamber. The influent sludge is disintegrated in oxidation reactions in the outer 232 and inner 234 chambers. This region is known as the oxidation reaction zone 204.
The oxidized influent (now effluent) mixes with cooling water 230 from the probe 228 and flows into the center channel 218 of what is called the cooling zone 206. The effluent finally flows into the effluent manifold 638 in the center of the main body portion 602. The effluent manifold 638 and surrounding regions are known as the exit zone 208. In some embodiments, the effluent in the effluent manifold 638 mixes with any centrate 246 present and flows down into the discharge chamber 654 at the base of the centrifuge 200. In other embodiments, the centrate 246 may be separately removed from the centrifuge 200 or no centrate 246 is present.
The centrifuge arm 604 length is an important factor as it relates to the pressure within the centrifuge arm 604. The centrifugal forces generated by the centrifuge 200 are related to the distance measured from the center axis 248 of the centrifuge 200 to the particular point within the centrifuge arm (“R” in
In greater detail, as the sludge slurry is injected into the main body 602 and travels down the influent manifold 644 and into the beginning portion 210 of the centrifuge arms 604, the slurry is not under any appreciable pressure (see Table 1). Both the velocity and temperature of the sludge slurry remain constant in the beginning portion 210 of the centrifuge arm 604. In addition, because the density of the influent remains constant in the beginning portion 210 of the arm 604, the specific volume also remains constant (specific volume is the inverse of density). As the sludge slurry moves from the influent manifold 644 to the middle channel 216 of the centrifuge arm 604, the cross-sectional area of the middle channel 216 begins to decrease as the overall diameter of the middle channel 216 decreases. As the middle channel 216 narrows in diameter, the sludge slurry begins to thicken. This area of the centrifuge arm is known as the sludge thickening zone 202.
In one embodiment, as the sludge thickens, centrate 246 or lighter fluids flow away from the sludge through exit ports in the middle channel 216 into the outer channel 214 and back toward the center of the main body portion 602. The centrate 246 ultimately flows into the effluent manifold 638 and into the discharge chamber 654 in the base of the centrifuge reactor 200. The presence of an outer channel 214 allows the lighter fluid 246, if any, to exit the centrifuge 200 without being part of the oxidation reaction. This lighter fluid 246 is decanted from the sludge by the centrifuge 200 in its normal operation prior to reaching the reaction zone 204. In some circumstances, the influent may not have a high fluid content. In those instances the exit ports and outer channels 214 may not be necessary.
As illustrated in the graph in
The end portion 212 of the centrifuge arm 604 is typically heated using an external heating coil 244. In other embodiments, an electrode internal to the end portion of the centrifuge arm 604 may also be used. The end portion 212 of the centrifuge arm 604 is also known as the oxidation reaction zone 204. The oxidation reaction occurs in this area. The oxidation reaction disintegrates the sludge and creates an effluent mixture of ash, CO2, and H2O. Other by-products may also be present depending on the constituents in the influent material. A combination of high temperatures created by the heating coil 244 and high pressures created by both and the centrifuge 200 and the centrifuge arm 604 geometry act together to create an environment with supercritical conditions. The oxidant enriched sludge undergoes an oxidation reaction in the supercritical environment.
The oxidation reaction zone 204 portion of the centrifuge reactor 200 includes outer 232 and inner 234 chambers. The cross-sectional area of the outer chamber 232 increases and the cross-sectional area of the inner chamber 234 decreases as the influent sludge flows toward the end 212 of the centrifuge arm 604. In the oxidation reaction zone 204, the influent is primarily comprised of materials in the solid and gas phases. As a result, the influent in the oxidation reaction zone 204 responds at least partially according to the ideal gas law (Pv=nRT, where P=pressure, n & R are constants, and T=temperature). If the ideal gas law applies, the pressure and specific volume are directly proportional to the temperature. Regardless of whether the ideal gas law applies, the centrifugal forces generated by the centrifuge 200 cause the pressure to rise steadily as the distance (“R”) from the center 248 of the centrifuge 200 increases.
The resulting pressures from the centrifuge 200 and from the increasing temperature in the oxidation reaction zone 204 cause the pressure to increase from the beginning of the outer chamber 232 to the end of the outer chamber 232 in the middle portion of the oxidation reaction zone 204 at the end of the centrifuge arm (see
The pressure decreases after the sludge flows reverses direction and flows beyond this pinch point 250 and into the inner chamber 234. Although the temperature continues to rise, because substantially all of the influent sludge has been disintegrated in an oxidation reaction in the outer chamber 232, the geometry of the inner chamber 234 begins to have an effect on the pressure of the effluent oxidized sludge mixture. In addition, the centrifugal forces on the effluent sludge decrease as the value of R decreases and the effluent moves closer to the axis of rotation 248. The side section of the inner chamber is generally funnel-shaped 252 and the diameter of the inner chamber 234 includes a constant portion 254 from the end of the centrifuge arm 604 to a portion near the middle of the end portion 212 of the centrifuge arm 604, and a portion 252 with an increasing diameter from the middle 256 of the end portion 212 of the centrifuge arm 604 to the beginning of the centrifuge arm 604 adjacent the main body 602. This increasing diameter helps cause a reduction in pressure (pressure=F/A, F=force in pounds, A=area in square inches, increase in diameter increases cross-sectional area, thus decreasing pressure).
The specific volume of both the thickened sludge and oxidized sludge steadily increases throughout the oxidation reaction zone 204 (see
The velocity of the sludge increases slightly as it moves toward the inlet 250 of the inner chamber 234 (see
As the oxidized wastes travel further along the inner chamber 234 toward the effluent manifold 638 in the main body 602, the oxidized wastes (effluent) flows around the cooling tube or probe 228 that extends into the inner chamber 234 from the cooling zone 206 center channel 218. The probe 228 introduces cooling water 230 to the ash and CO2 mixture exiting the oxidation reaction zone 204. As a result, the velocity again increases due to the diminished cross-sectional area within the inner chamber 234 (see region “D” in
The diameter of the center channel 218 in the cooling zone 206 increases from the beginning of the cooling zone to the end of the cooling zone adjacent the effluent manifold. The geometry of the cooling zone 206 center channel 218 (increasing diameter) causes the pressure in the cooling zone to steadily decrease. The pressure decreases as the effluent moves from the constricted inlet 258 of the center channel 218 to the larger diameter portion of the center channel 218.
As mentioned above, the length of each probe 228 may be adapted to manually or automatically adjust depending on the pressure in each centrifuge arm 604 cooling zone 206. The head 229 of the probe 228 serves as a throttle block 229 to help maintain pressure levels in the reaction zone 204 and to generally help control the entire process. If the probe 228 were substantially removed from the oxidation reaction zone 204 inner chamber 234, the oxidation reactions would discontinue. By substantially removing the probe 228 from the oxidation reaction zone 204, the CO2 gases within the reaction zone 204 are allowed to expand into the cooling zone 206 thereby increasing the volume and decreasing the density. The drop in density correspondingly causes the pressure within the reaction zone 204 to decrease thereby causing the oxidation reaction to discontinue. If the probe 228 is inserted too far into the oxidation reaction zone 204, the cooling water 230 can cause the oxidation reaction to discontinue by quenching the reaction. The cooling water 230 can cause the temperature within the reaction zone 204 to drop low enough to cause the oxidation reactions to cease. The probe 228 can also be adjusted to manipulate the amount of centrate 246 that flows out of the outer channels 214. The further the probe 228 is inserted into the reaction zone 204 (without quenching the reactions), the greater the pressure is within the reaction zone 204. As a result, the pressure in the sludge thickening zone 202 is also increased and the amount of centrate 246 that escapes via the outer channel 214 is increased. If the probe 228 is only inserted far enough into the reaction zone 204 to maintain the oxidation reactions, the pressure levels in the reaction zone 204 will be toward the lower end of acceptable pressure levels to maintain oxidation reactions. As a result, the pressure levels in the sludge thickening zone 202 will also be reduced thereby allowing potentially all of the fluids to pass into the reaction zone 204. In such a case, the centrate 246 flow rate may be greatly reduced or even stopped.
As illustrated best in
The velocity of the effluent increases throughout the cooling zone 206. In the beginning of the cooling zone 206, the center channel 218 cross-sectional area is reduced greatly by the presence of the probe 228 within the channel 218. As a result, the velocity greatly increases through that region (see region “D”). The velocity drops 206 through most of the cooling zone as the cross-sectional area increases (velocity=area/area). At the end of the cooling zone, the expanding CO2 gases cause the velocity to increase as the effluent enters the effluent manifold (see “F” in
Because of the injection of cooling water 230, the temperature within the cooling zone 206 is significantly less than the temperature in the oxidation
reaction zone 204. Also because of the injection of cooling water 230, the temperature within the cooling zone 206 remains substantially constant.
After exiting the cooling zone 206, the cooled effluent mixes with any centrate from the sludge thickening zone and flows into the effluent manifold 638 in the main body 602 portion and down into the discharge chamber 654 at the base of the centrifuge reactor 200. The effluent mixes with cooling water in the discharge chamber 654 to further lower its temperature. As an additional step, the effluent solids may be sent to a filtering process to separate the effluent solids from the effluent fluids.
Table 2 includes parameters for one embodiment of the reactor (also see corresponding
In addition to parameters related to the area and the influent characteristics delineated in Table 2, Table 3 includes parameters related to the geometry of the centrifuge arm internal channels and chambers. The location of the various zones in the centrifuge arms with respect to the axis of rotation of the centrifuge is important in relation to the centrifugal forces generated by the centrifuge. Table 3 and
Referring first to
Referring first to
The structure of
An inflow channel 328 is formed by the inlet pipe 318 and extends from the inlet pipe 318 into both of the arms 304, 306. The inflow channels 328 in both arms are identical, so only the flow channels 328 in one arm are described herein. Inside the arm 304 there is a central tube 330 that acts as an exit path and is in communication with the outlet aperture of the main body 316. Spaced concentrically outwardly from the central tube 330 and attached to the main body 316 is an intermediate tube 332, which forms an annular space around the central tube 330. This inner annular space 334 is part of the inflow channel 328 incoming flow path for the incoming sludge material. The arm housing 336 forms an annular space 338 around the intermediate tube 332. This outer annular space 338 forms part of the exit path for the decanted liquids as described above. The outer annular space 338 is in communication with the high fluid (decanted liquid) exit channel 340 formed in the main body as described above. The central tube 330 can be somewhat longer than the intermediate tube 332 for reasons described above.
The end 342 of the arm 304 forms a cavity 344, which is the reaction zone for the oxidation reactor. The curved cavity 344 is defined by an end cap 312, which is held in place by a series of elongated bolts 346, which extend from the end cap 312 to the main body 316. Each tube has its own base frame 348 which fits into the main body 316 and interlocks with the base ring 350 of the adjacent tube, and under the compressive force of the attachment bolts 346, each of the base rings 350 form a tight seal with the main body 316, as described above. The interlocked base rings 350 allow the sectional formation and removal of the arm 304 and its inner parts. The end cap 312 seats on the outer end 342 of the arm housing 336 and under the compression of the elongated bolts 346, compressing the arm housing 336 towards the main body 316. The base ring 350 of the arm housing 336 interlocks with the base ring 350 of the intermediate tube 332, which in turns interlocks with the base ring 350 of the inner tube 330, and thus holds all of the tubes in sealed engagement with the main body 316.
A set of bearings 352, only one of which is shown, supports the inlet pipe 318, and thus also the cantilevered centrifuge 300. As the centrifuge 300 spins, preferably with the arms 304, 306 moving in a vertical plane, great pressures are formed at the ends 342 and each arm 304, 305 in the reaction zone area. The pressure is determined primarily by the revolutions per minute (spin speed) and the length of the arm 304, and is easily controlled. As noted above, a motor (not shown) is used to spin the centrifuge 300, preferably by turning the inlet pipe 318.
A heating element 326, such as an electrode 308, is positioned in the reaction zone to provide the heat required for the supercritical oxidation reaction process. The temperature required for the oxidation reaction to occur is described above in detail, and is generally above 700° F. and 3200 psi.
Oxygen is required, along with heat and pressure, to cause the oxidation reaction to occur. Oxygen can be fed directly into the reaction zone by a separate piping system (not shown in this embodiment) or can be permeated in the incoming sludge material as it enters the centrifuge 300. In either manner, oxygen is brought into the reaction zone in addition to the heat and pressure in the reaction zone, helping facilitate the oxidation reaction taking place.
Generally, when the sludge plug forms in the reaction zone, and the sludge is subjected to extreme pressures, heat, energy and oxygen, the oxidation reaction process occurs. The by-products of the reaction oxidation process are typically mainly ash, CO2 or H2O. The reaction by-products can also include other elements which are not entirely transformed during the reaction process to ash, CO2 or H2O, depending upon the constituents of the incoming sludge. The reaction by-products exit the centrifuge through the inner tube 330, as is described in more detail below. Because the reaction zone is at very high pressure and the exit aperture 314 is at ambient pressure, the reaction products will somewhat automatically flow through the inner tube 330 toward the outlet aperture 314 due to the pressure drop. As the reaction products flow through the inner tube 330, at some intermediate position 356 of the inner tube 330, there is a flash steam zone where the pressure has decreased sufficiently to allow the H2O reaction by products to transition to a steam state. This further helps expel the reaction by products out the outlet aperture 314, which is a atmospheric pressure.
In more detail, in the instant invention, with respect to
Generally, a temperature of approximately 800 to 1200 degrees Fahrenheit is required for the oxidation process to occur. The pressure generated at the end 342 of the centrifuge arm 304 in the reaction zone should be approximately 3,000 to 3,500 psi, and the required oxidant level depends on the volatility of the material in the mixture being oxidated in the reaction. While the oxidant can be included in the incoming material, it is more efficient if it is added to the heavier material as it is compacted. The compaction (drying out) process removes some of the oxidant from the material. If the oxidant is added after the majority of the compaction has occurred, then only the necessary level of oxidant is required to be added to the material. These values are representative only, as are the values described elsewhere herein.
In using the centrifuge 300 of the present invention as an oxidation reactor, the pressure can be easily controlled by the length of the arm 304 extending from the main body 316 and the spin speed of the centrifuge 300 itself. This is a significant advantage over the existing supercritical oxidation reactor processes which require complex pressure generation, release and control equipment. Further advantages are described hereinafter. The reaction products from this process can be taken directly from the outlet aperture 314 and disposed of as desired, such as being encased in concrete or handled by any other known type of disposal techniques.
It is contemplated that the centrifuge 300 of the present invention can be connected in series with at least a second centrifuge, if desired. For instance, a first centrifuge can be used to de-water the sludge to a sufficient level for the oxidation reaction process, with the outlet of the first centrifuge being connected to the inlet of the second centrifuge. If the second centrifuge is modified to act as an oxidation reactor, then the outlet of the first centrifuge can flow into the inlet of the second centrifuge where the oxidation reaction process takes place. Several centrifuges can also be hooked together if desired.
During the oxidation reaction process, whether critical, subcritical, supercritical, or any other reaction process performed in the centrifuge 300 of the present invention, the process parameters can be monitored and controlled by the placement of appropriate sensors in the centrifuge 300, combined with automatic feedback of the sensor data to either a human-controlled center, or to an automated center including a computer, microprocessor, and the desired programming software to interpret and respond to the feedback from the sensors. The sensors can be placed in several places in the centrifuge 300 for monitoring the critical process characteristics, such as along the inside 358 or outside 360 of the arm 304, in the reaction zone, in the exit tube 330 and outlet aperture 314 areas, and in the inlet path 328 as well as the inlet pipe 318. The sensors allow the measurement of the physical characteristics such as, but not limited to, the heat level, the oxidant content and the pressure. The control system, whether human or automated, can react to the sensor data to decrease, increase or maintain the various input data, such as spin speed, temperature, oxidant content and possibly even sludge chemical makeup to help optimize the oxidation reaction.
The centrifuge 300 of the present invention used as an oxidation reactor is not limited to two diametrically opposed arms 304, 306. It is contemplated that any number of arms can be implemented as long as the proper balance is created to allow the spin speeds required to generate the desired pressure.
It is also contemplated that the outlet flow path 334 for the decanted liquid can be blocked to make all of the input sludge material in the inlet pipe 318 go through the reaction zone in a case requiring the entire content of the sludge to be reacted. The decanted liquid outlet apertures (not shown) can be permanently covered up or selectively covered up so that the same reactor can decant the liquid to force mainly solids through the oxidation reaction process, or can force both liquids or solids (preferably in a slurry form) through the reaction zone. Each has its benefits for different kinds of sludge material, and can be selected as desired.
Another benefit of the current invention is that the inlet sludge is subject to a gradually increasing pressure gradient when entering the reaction zone, and a decreasing pressure gradient when exiting from the reaction zone to ambient pressure through the outlet aperture 314. The pressure drop from the reaction zone to ambient pressure in the outlet aperture 314 facilitates in flushing the reaction products through the center tube 330 and out of the centrifuge 300.
The oxidant inlet path 426 extends from the base 448 of an annular region 450 formed by the sheath 418, through a channel 451 in the main body 402, and is connected to an outer annular space 452 formed on the inside 454 of an inlet pipe 456. This outer annular space 452 is formed by a tube 458 welded or connected inside the inlet path 460 to the inner walls 454 of the inlet pipe 456. The outer annular space 452 in the inlet pipe 456 is in fluid connection with an oxygen manifold 462 rotatably mounted on the exterior 464 of the inlet pipe 456. The manifold 462 is attached to an oxidant source, such as a tank or oxidant line 468. The oxidant thus flows into the oxidant manifold 462, through the apertures 466 formed on the wall 454 of the inlet pipe 456, and into the outer annular region 452 of the inlet pipe 456. The oxidant flows along the inlet pipe 456 in the outer annular region 452 to the oxidant channel 451 flowing through the central body 402 of the centrifuge 400 to the base 448 of the annular region 450 formed between the sheath 418 and the inner tube 412. The oxidant then flows along the length of the inner tube 412 to the perforated holes 430, where it then mixes with the incoming sludge to add oxidant the sludge and prepare it for the oxidation reaction.
The arms 404 of the tubes are shorter in this embodiment than in the previous embodiments described to allow for the elongated end cap tube 406, with the total centrifuge 400 diameter remaining approximately the same. The arms 404 could be longer or shorter as desired and the end tubes 406 could be longer or shorter as desired to define the proper external dimensions of the centrifuge 400 as well as the proper size of reaction chamber 416. Currently, as described herein, the reaction chamber 416 or zone is approximately one-quarter to one-half of the total length of the arm 404 of the centrifuge 400.
The tubular end cap 406 is formed of a material, such as metal, that is sufficiently strong and resilient enough to withstand the high pressure and temperature of the oxidation reaction occurring with the end cap 406. The tubular end caps 406 are effectively bell-jar shaped with an internal flange 470 that wedges against the semi-conical, frusti-conical end cap collar 472. The centrifugal force from spinning causes a positive engagement between the angular flange 470 around the bottom 474 of the tubular end cap 406 and the inner wall 476 of the semi-conical end cap collar 472.
A heating element 478 is positioned around the tubular end cap 406, preferably around its entirety, about which an insulated layer 480 is positioned and held in place by fasteners 482 attaching to the end cap collar 472. The heat source 478, as noted above, can be any suitable heating element. The heat source 478 can be inside the arm 404 and end cap 406 or outside the arm 404 and end cap 406, and can cover all of or part of the arm 404 and end cap 406 surrounding the reaction zone. For instance, the heat source 478 could be a band formed around the circumference of the arm 404 or end cap 406, or can be a stripe extending longitudinally along the arm 404 or end cap 406. The heat source 478 is preferably covered by an insulating material to assist in energy efficiency. As noted above, the heat source 478 can be turned off or otherwise controlled as needed after the oxidation reaction has begun.
Oxidant is added to the sludge through the oxidant source that flows from the annulus 462 surrounding the inlet pipe 456 to the pathway 450 through the central body 402, which in turn leads to the sheath 418, which forms the annular space 420 around the inner tube 412. A length of the sheath 418 near its distal end 428 is perforated 430 to allow the oxidant to permeate the sludge that passes over the sheath 418 as the sludge flows towards the end 434 of the reaction chamber 416 to form the plug. The sheath 418 is preferably perforated 430 around its circumference for the oxidant to be evenly dispersed into the sludge. The amount of oxidant dispersed into the sludge depends on the pressure of the oxidant in the in-feed line 468 and the compaction level of the dewatered sludge. The level of oxidant to be diffused into the sludge depends on which type of sludge is to be incinerated in the oxidation reaction process. The oxidant is preferably diffused into and around the sludge after it is de-watered substantially in order to efficiently use the oxidant. If added prior to the compaction step, some of the oxidant is lost in the compaction process.
The oxidant can be inserted through injectors (not shown) placed through the wall 488 of the housing 438 at the desired location. These injectors can be positioned as desired and needed, and can be replaced, removed and maintained. The injectors are fed oxidant by a different source path than that described above for the sheath 418, such as by individual lines running to each injector. Other oxidant insertion means can be used also.
In
In this embodiment, an auger/choke arm 500 is positioned inside each of the inner tubes 412. The arm 500 is similar to the augers described above with flighting 502 positioned at its distal end 504 to help draw material into the center 506 of the inner tube 412, and flighting 502 attached near the proximate end 508 of the arm 500 where the arm 500 attaches to the central hydraulic motor 510. The positioning of this flighting 502 can be varied depending on the particular oxidation reaction and the requisite desired output characteristics. At a mid-portion 512 of the arm 500, a choke 514 is formed which is an enlarged region 514 of the arm 500, which takes up a majority of the space within the inner tube 412.
The de-watered sludge then passes beyond the end 428 of the sheath 418 and contacts the inner tube 412 at which point it flows to the end 434 of the reaction chamber 416 in its de-watered, concentrated condition. At this location in the reaction chamber 416, the temperature, pressure and oxygen content are all established to support the oxidation reaction process.
As described above, after the oxidation reaction occurs, the by-products of the oxidation reaction process are initially augured out by the central auger 500 down the inner tube 412 towards the main body 402 of the centrifuge 400. The flighting 502 at the distal end 504 of the auger 500 helps the reaction by-products begin the path towards exiting the centrifuge 400. Flighting 502 at the proximate end 508 of the auger 500 helps push the waste products out the exit aperture 490.
The choke 514 formed along the central part 512 of the auger 500 controls the pressure of the reaction chamber 416, that is, it maintains the pressure in the reaction chamber 416 to control the flash of the pressurized water to steam as it exits past the choke 514. The choke 514 is mainly an enlarged portion 512 of the auger 500 that consumes the volume of the space inside the inner tube 412. The volume of the choke 514 depends on the amount of control of the flashpoint of the pressurized water to steam as is desired. The choke 514 can take many forms, such as that shown, being an area of increased diameter with gradual front 520 and rear 522 edges, or it can be an area of increased diameter with abrupt front and rear edges, such as a disk mounted transversely inside the inner tube 412. The shape and position of the choke 514 depends on the pressure to be controlled and the physical characteristics of the “flash to steam” process. The choke 514 can have grooves formed longitudinally therein, or other such features, as an additional manner to help control the pressure on either side of the choke 514.
The augers 500 are driven in the inner tube 412 by the hydraulic motor 510 positioned in the center 516 of the main body 402, as is described above. The auger 500 is driven by a hydraulic motor 510, which drives the auger 500 at a selected speed independent of the spin speed of the centrifuge 400. The hydraulic motor 510 is driven by pressurized hydraulic fluid and is fed by a separate shaft 524 inserted into the main body 402 from the end 526 opposite the inlet channel 460.
The heat transfer from the inner annular space 422 to the inside 528 of the inner tube 412 is (through the wall 530 of the inner tube 412 or the combination of the sheath 418 and the inner tube 412) is preferably minimized. The sheath 418, if used, helps provide an insulating layer. Otherwise some sort of insulation is used on the inner tube walls 530.
As in the embodiment described above, the end cap collar 472 is held in place by bolts 532 that when tightened pull the entire arm 404 towards the main body 402.
In this embodiment, the oxidant is inserted by injectors 622 at the inner end 624 of the tubular end cap 626, near the end cap collar 628.
The auger 500, extending into each of the arms 604 inside the inner tubes 606 in the previous embodiment, is replaced by a water dispersion probe 630 having a hollow shape for carrying water. The water dispersion probe 630 extends at least partially into the inner tube 606 and extends towards the distal end 620. The probe 630 is provided with water through a piping system, one version of which is shown in
The probe 630 is a hollow tube with a curved spray end 634 having apertures 636 formed adjacent the end 634 for spraying water into the inner tube 606. The water acts as a coolant for helping control the temperature of the reaction by-products in the inner tube 606 as they flow towards the exit aperture 638, near the location of the flash point between the pressurized water and the steam. The curved end 634 of the probe 630 is an enlarged tip 631 which also acts as a choke (as described above) to help physically control the pressure as well as the resultant velocity of the reaction by-product as it passes the choke 631 towards the exit aperture 638. The water exits the probe 630 through apertures 636 formed adjacent the head 634 of the probe 630.
The centrifuge 600 in
The closed chamber 654 is intended to hold a liquid, such as water, which acts as a heat sink for the reaction by-products exiting the centrifuge 600. The chamber 654 has at least one outlet 670 for the water positioned on the sidewalls 656. The chamber 654 also has at least one outlet 672 for the reaction by-products that settle to the bottom 662 of the chamber 654 for removal therefrom. The water supply line 632 for the probes 630 can pass through the sidewall 656 of the chamber 654 and attach to the bottom 674 of a water inlet feed 676 for the probe 630. The top of the water inlet feed 676 for the probe 630 is attached to the probe 630 in a fluid connection to allow the probe 630 to supply water into the inner tubes 606 as desired, for each of the instances where the probe 630 is stationary, the probe 630 is floating, or the probes 630 are independently adjustable within each arm 604.
A gas volume 678 is positioned between the top surface 680 of the water 681 and the cover 682 of the closed chamber 654. At least one gas inlet aperture 684 is formed in the sidewall 656 of the chamber 654 to allow gas to be added to or removed from that volume 678. The gas aperture 684 can be left to the atmosphere if desired. The pressure in the system can be affected by the water level on the collar 652. As the water level is raised, the back pressure on the system is increased, and as the water level is decreased in the chamber 654, the back pressure on the system is decreased. All the gas can be removed from the chamber 654 and replaced with water to maximize the back pressure adjustment. Additional water head pressure can be created by extending the chamber 654 to surround the frame 646 up along the sides 686 of the centrifuge 600 if so desired.
The collar 652 to which the centrifuge 600 is attached can be rigidly attached to the centrifuge 600 in order to spin in the water. In this instance, the cover 682 of the closed chamber 654 is sealingly yet rotatably engaged to the circumference of the collar 652. The spinning of the collar 652 can actuate the water and create a vortex which in turn can further assist in drawing the by-products from the outlet 672 and also helps mix the by-products with the water.
The back pressure particular to each arm 604 and acting on the oxidation reaction zone, is affected by the position of the probe 630 along the inner tube 606. Thus the adjustment of each of the probes 630 within each of the tubes 606 respectively is an option that is helpful for fine tuning the oxidation reaction in each of the arms 604. Alternatively, with the “floating” probe 630, the probe 630 can self-adjust based on the pressure in each arm 604, with the arm 604 having the higher pressure pushing the probe 630 towards the other arm 604 to the point where the pressures are balanced at the opposing heads 634 of the floating probe 630. The oxidation reaction can be halted by moving the probe 630 away from the reaction zone and towards the main body 602 a sufficient amount to allow the pressure to drop below the critical pressure.
The frame 646 is shown having five outwardly and downwardly extending legs 702 each attached at their bottom 704 to a base frame 706, and attached at their tops 708 together to support the centrifuge 600 by its shaft 696. One side 710 of the frame 646 is open with no legs 702 to allow the centrifuge 600 to be positioned in and removed from the frame 646.
The instant invention as used as an oxidation reactor provides several benefits, as listed below.
The oxidation reactor of the present invention can treat waste having a more solid form, such as sewage sludge, where liquid can be neutralized by other means. It can also handle waste in liquid or mixed-liquid form, such as animal waste-where all material, solid and liquid needs to be processed in a centrifugal machine modified to block the liquid exit. This would allow one tube to be removed, and might require adjustment of the reaction chamber size.
The term gas as used herein is intended to include all phases of a material, including but not limited to, liquid, compressed gas, or low pressure gas. While oxygen is specifically mentioned as an oxidant, it is not exclusive, and any other gas that is useful in subcritical or supercritical oxidation reactions is sufficient.
Still with respect to
Generally, sludge flows from the inlet 726, through the rotary union 714, along the rotary shaft 728, and into the centrifuge drive shaft 730. When the rotary union 714 and centrifuge operate 712, however, two problems may arise. First, the weight and rotation of the union at one end of the shelf may give rise to a resonance. Second, the rotary shaft's 728 center of rotation may be slightly misaligned with the drive shaft's center of rotation. Either issue may result in a feeding a resonance or vibration into the device shaft, and ultimately the centrifuge body and arms, if the rotary shaft 728 and drive shaft 730 are directly inflexibly coupled.
Accordingly, a flexible seal 716 or coupling is placed about the adjacent ends of the drive shaft 730 and rotary shaft 728. In the present embodiment 712, the flexible seal overlies both the drive and rotary shafts. In some embodiments, the flexible seal 716 may include a threaded aperture at both ends for receiving a threaded male segment of both the drive and rotary shafts, although any connection preventing an input mixture from leaking beyond the flexible seal may be used (including a friction fit or post-and-channel type structure).
The sidewalls of the flexible seal 716 are generally formed from a material permitting sufficient lateral flexing or motion to at least partially dampen any vibration or resonance originating in the rotary union 714 or rotary shaft 728, or caused by misalignment of the centers of rotation of the drive and rotary shafts. For example, the present embodiment employs a flexible seal having rubber or polymer sidewalls. In the present embodiment, the flexible seal generally covers an approximately two-inch gap between ends of the rotary and drive shafts 728, 730.
A flexible tube 732 is located within the drive shaft 730, and threadedly attached at a first end to the drive shaft and a second end to the input shaft 734. The threaded connection 736, 738 between the tube 732 and drive shaft 730 and tube and input shaft 734 is shown to best effect in the cross-sectional view of
The drive shaft 730 is supported at a first, or outer, end by a first bearing block 740. The first bearing block interior rotates with the drive shaft, while the exterior remains stationary. The first bearing block provides stability to, and minimizes vibration of, the drive shaft.
The drive shaft 730 generally connects to an input shaft 734, which accepts the input mixture from the drive shaft and coveys the mixture to the centrifuge main body 742 (shown in
Returning to
The input and drive shafts 730, 734 are joined by a shaft coupler 750, shown generally in
The shaft coupler 750 body is manufactured from carbon or stainless steel, although alternative embodiments may manufacture the shaft coupler body from any of a number of other metals or alloys, such as aluminum, titanium, and so forth. The body includes a drive hub 754 and input hub 756, bolted together through a disc pack 758. Generally, and as also shown in
A disc pack 758 is placed between the shaft coupler hubs 754, 756, and secured to the hubs by the aforementioned bolts 760. The disc pack generally consists of a series of thin steel layers, although for convenience the disc pack is shown as a single layer in the cross-sectional view of
As previously mentioned, the input shaft 734, main body 742, and output shaft 748 are all connected to form a main shaft. The output shaft passes through, and is supported by, an output bearing block 718. The output bearing block exterior remains stationary while a portion of the bearing interior rotates with the output shaft. The output bearing block serves to provide additional stiffness to the output shaft by supporting one end. Since the output shaft 748 is supported by the output bearing block 718 and the input shaft 734 is supported by the second bearing block 752 (see
Accordingly, the present embodiment employs three separate shafts: the rotary shaft 728, the drive shaft 730, and the main shaft. The rotary shaft is supported at a first end by the rotary union 714 and flexibly coupled at the opposite end to the drive shaft by the flexible seal 716. The drive shaft 730 is supported adjacent the flexible seal by the first bearing block 740. The opposing end of the drive shaft is received in, and supported by, the shaft coupler 750. The shaft coupler also receives a first end of the main shaft (i.e., the input shaft 734). This first end of the main shaft passes through the second bearing block 752. The second end of the main shaft (i.e., the output shaft 748) extends slightly beyond the exterior of the output bearing block 718, which is located on the side of the shroud 722 opposite the second bearing block. The output bearing block serves to stiffen the main shaft. Essentially, the various bearing blocks 740, 752, 1718 minimize vibration in the respective shafts passing therethrough, and thus enhance operation of the present embodiment.
As previously mentioned, a shroud 722 may cover the central body 742 and centrifuge arms 744, 746. The shroud generally obscures the arms during operation of the centrifuge 712 and prevents debris or foreign objects from impacting the arms and/or body during centrifuge operation, which may damage the present embodiment. The shroud 722 may be divided into an upper and lower shroud, as shown in
Since the shroud 722 encloses the arms 744, 746, access to the arms would typically require the shroud be disassembled. This is a time-consuming process. The arms might require access during operation, for example, to unclog the arms if sludge cake builds up in or around the end cap, to check for sludge leakage out of the arms and into the shroud, to check the arms for wobble or deviation from the standard plane or rotation, and so forth.
The present embodiment defines an access port 720 in the shroud body 722 to permit access to the shroud interior, and thus the arm 744, 746. In this fashion, the shroud may remain in place while the arm is examined by an operator. A removable access cap 764 generally covers the access port during operation of the embodiment.
In some embodiments, the access cap 764 may be sealed to the access port 720 until centrifuge operation ceases as a safety measure. In yet other embodiments, the arms 744, 746 may be electronically or mechanically synched or programmed to rotate in such a fashion that the end cap of the arm aligns with the access port 720 when either the centrifuge 712 ceases operation or the access cap is removed.
As mentioned in more detail above, each arm 744, 746 typically includes a removable end cap 766. The access port 720 is sized such that the end cap may be opened through the port without removing the shroud 722.
Turning now to
The rods 768 shown in
Each short threaded rod 770 is threaded at both ends 772, 774. The distal end 772 engages an exterior arm collar 776. The threaded portion of the distal end passes through an aperture 778 in the collar, and is secured thereto by a nut 780 on either side of the collar. This arrangement is shown in cross-section in
In the present embodiment 712, flat planes 784 are formed on a portion of the threaded rod 770 approximately one-third of the length of the rod from the shoulder 782. These flat planes create a relatively square profile in lateral cross-section. The square profile provides a surface for a wrench to grasp and tighten the rod 770 into the threaded cavity 780. Alternate embodiments may omit such flat surfaces, or may vary the number of surfaces and profile created thereby (for example, providing six such surfaces to form a hexagonal profile).
Imbalances between arms 744, 746 may result not only from varying amounts of sludge in each arm, but also from the release of entrained gases in the sludge. Sufficiently large imbalances may result in the centrifuge 712 terminating operation. The dynamic balancer 786 counteracts such imbalances by circumferentially moving a weight affixed to a disk. Moving the weight in a plane parallel to the plane of rotation of the centrifuge arms 744, 746 offsets imbalances, properly loading the arms with respect to one another. Electrically-activated actuator coils rotate the disks within this plane to position the weighted portion as necessary. In the present embodiment, the disks are oriented in-line with each arm's longitudinal axis of rotation.
The dynamic balancer 786 includes a stationary segment (stator) 788 and a rotating segment (rotor) 790. In the present embodiment, the stator is mounted to the stator mounting bracket 792, as shown in
The present embodiment may employ dynamic balancers 786 manufactured by a variety of suppliers and operating in a variety of manners. The foregoing description is intended to be exemplary, rather than limiting. Alternate embodiments, for example may not employ dynamic balancers at all.
Unlike previously-described embodiments, it should be noted that the present embodiment 712 employs an auger 790 having flighting 791 along only a portion of its length. (It also should be noted any of the augers or stirrers described herein may be used with any of the embodiments described herein.) Generally, the centrifugal force generated by the rotational motion of the arm 746 increases with distance from the center of rotation (i.e., base of the arm). Accordingly, more force acts on sludge flowing along any or all of the tubes 792, 794, 796 depicted herein the closer the sludge is to the end cap 760. Thus, where sludge or heavy, semi-solid particulate enters the inner tube 792 in the manner described above, it is under the least force at the portion of the tube closest the arm base or main body 742. Thus, the auger 790 is provided with partial flighting 791 along the segment of the auger shaft proximate the arm base to facilitate movement of sludge at this segment. Alternate embodiments may employ augers having flighting along the entire length of the auger shaft, discontinuous flighting, or partial flighting along a different segment of the auger, such as the portion nearest the end cap or along the middle segment. Further, the flighting may be either left-hand or right-hand flighting. Yet other embodiments may employ variable-diameter flighting 791 to enhance solid movement in certain areas of the inner tube 792. For example, where choke points or dead spots in sludge or heavy material motion are common, the radius of the flighting may be extended to provide additional lift and movement as well as chop caked solids.
Returning to
Although the embodiment in
Yet other embodiments may vary the scraper 790 profile or otherwise change the scraper. For example, some embodiments may employ planar scrapers rather than the angled scrapers 804 shown in
As discussed above in greater detail, the input mixture 16 generally enters a cylindrical-shaped volume 86 through an input chamber 68. In order to prevent input material 16 entering from the input chamber from flowing only along the inner sidewall of the middle tube defining the cylindrical-shaped volume, a flow distributor 806 is placed within the cylindrical-shaped volume. The flow distributor acts to evenly distribute the input mixture flow about the volume 86.
As shown to best effect in
During operation, centrate may collect in the centrifuge 712. Such centrate is generally emitted from a centrate nozzle 814 associated with the output shaft through a series of nozzles. The centrate is collected in a centrate shroud. However, the shroud alone may permit centrate to leak into a different section of the present embodiment, such as the nearby solids collection area. The centrate nozzles and shroud are shown in cross-section in Gif. 37.
To minimize such leakage, a labyrinth seal 816 may be placed on either side of the centrate shroud.
The seals 816 extend completely about the output shaft 748, but do not contact the shaft. Rather, a slight clearance exists between seal and output shaft. This clearance is shown to best effect in
Centrate emitted from the nozzle 814 sprays into the shroud 752. Some centrate may fall onto the output shaft 748 exterior (or main body 742 exterior) and spread therealong. Generally, centrifugal force will scatter the centrate from the output shaft (or main body) outward. Some amount of centrate, however, may escape the shroud 752 before being scattered since the shroud does not touch the output shaft exterior. The labyrinth seal 816 is formed from a series of relatively thin disks 820 of plastic, metal, rubber, or other suitable material. Grooves 822 are formed in several of the disks comprising the labyrinth seal. In the present embodiment, each groove 822 is formed by ending every other disk 820 some distance prior to the interior circumferential edge, so that the groove base is defined by the inner edge of the prematurely-terminated disk and the sidewalls of the disks to either side (see
Each groove 822 communicates with a seal passage 818. The seal passage extends through all disks 820 forming the labyrinth seal 816, with the exception of the outermost disk 824 (i.e., the disk furthest from the shroud wall). In the present embodiment, a single seal passage 818 is formed at the bottom of each seal, beneath the output shaft 748 or main body 742. Alternate embodiments may employ multiple seal passages.
During operation of the present embodiment 712, centrate may be thrown from the output shaft 748 or main body 742 onto the labyrinth seal 816. The centrate generally flows into and along the grooves 822. Gravity collects the centrate at the base of the grooves, beneath the output shaft, where the seal passage 818 is located. The centrate then may flow out the seal passage 818 and into the centrate shroud interior. This ensures most or all centrate escaping the centrate shroud 752 is collected by the labyrinth seal 816 and channeled, via the grooves and passage, back into the shroud.
While the invention has been particularly shown and described with reference to certain embodiments thereof, it will be understood by those skilled in the art that various other changes in structural form and detail may be made without departing from the spirit and scope of the invention.
Embodiments of the present invention and many of its improvements have been described with a degree of particularity. It should be understood that this description has been made by way of example, and that the invention is defined by the scope of the following claims.
This application claims the benefit of U.S. Provisional Application Ser. No. 60/546,666, filed Feb. 20, 2004, entitled THICKENING AND DEWATERING CENTRIFUGE and U.S. Provisional Application Ser. No. 60/498,977, filed Aug. 30, 2003, entitled THICKENING AND DEWATERING CENTRIFUGE and is a continuation-in-part patent application of copending U.S. patent application Ser. No. 10/723,366, filed Nov. 26, 2003, entitled CONCENTRIC TUBULAR CENTRIFUGE; which is a divisional patent application of copending U.S. patent application Ser. No. 09/828,296, filed Apr. 6, 2001, entitled CONCENTRIC TUBULAR CENTRIFUGE, which claims the benefit of U.S. Provisional Application Ser. No. 60/215,499, filed Jun. 30, 2000, entitled CONCENTRIC TUBULAR CENTRIFUGE and U.S. Provisional Application Ser. No. 60/195,686 filed Apr. 7, 2000, entitled CENTRIFUGAL OXIDATION REACTOR and is a continuation-in-part of copending U.S. patent application Ser. No. 09/707,430, filed Nov. 6, 2000, entitled CONCENTRIC TUBULAR CENTRIFUGE; which is a continuation of U.S. patent application Ser. No. 09/298,272, filed Apr. 23, 1999, entitled CONCENTRIC TUBULAR CENTRIFUGE, now U.S. Pat. No. 6,142,924; which is a continuation application of U.S. patent application Ser. No. 08/950,377, filed Oct. 14, 1997, entitled CONCENTRIC TUBULAR CENTRIFUGE, now U.S. Pat. No. 5,944,648; which claims the benefit of U.S. Provisional Application Ser. No. 60/028,556, filed Oct. 15, 1996, entitled CONCENTRIC TUBULAR CENTRIFUGE; all of which are incorporated herein by reference as if fully set forth herein.
| Number | Date | Country | |
|---|---|---|---|
| 60546666 | Feb 2004 | US | |
| 60498977 | Aug 2003 | US | |
| 60215499 | Jun 2000 | US | |
| 60195686 | Apr 2000 | US | |
| 60028556 | Oct 1996 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 09828296 | Apr 2001 | US |
| Child | 10723366 | Nov 2003 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 09298272 | Apr 1999 | US |
| Child | 09707430 | Nov 2000 | US |
| Parent | 08950377 | Oct 1997 | US |
| Child | 09298272 | Apr 1999 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10723366 | Nov 2003 | US |
| Child | 10931056 | Aug 2004 | US |
| Parent | 09707430 | Nov 2000 | US |
| Child | 10723366 | Nov 2003 | US |
