The technical field relates generally to wastewater treatment processes, and more particularly, to media filtration in wastewater treatment processes.
Water filtration processes typically include primary, secondary, and tertiary processes to treat wastewater to remove contaminants, such as suspended solids, biodegradable organics, phosphorous, nitrogen, microbiological contaminants, and the like, to provide a clean effluent.
The first or primary treatment process typically involves mechanically separating large solids and other suspended matter in the wastewater from the less dense solids and liquid in the wastewater. Primary treatment processes are typically done in sedimentation tanks using gravity and provide a primary effluent.
Secondary treatment typically includes biological treatment of the primary effluent. The biological treatment units or vessels used for secondary treatment typically include bacteria that break down components of the wastewater, such as organic components. The biological treatment processes in the biological treatment units or vessels may reduce the total organic content and/or biochemical oxygen demand of the wastewater. This is typically done by promoting the consumption of the carbonaceous and nutrient material by bacteria and other types of beneficial organisms already present in the wastewater or mixed into the wastewater.
Tertiary processes typically involve removing suspended solids and any remaining contaminants or pollutants from the wastewater so that the remaining water can be either reused or disposed of safely in the environment. Tertiary processes can include filtration and/or the addition of any one or more of chemicals, UV light, and ozone.
Many wastewater treatment plants utilize a disc filter system to filter water. Such systems typically include a plurality of discs that each comprise a plurality of filter segments. Each filter segment includes a pair of filter panels which are spaced apart and arranged on an outer surface of a central drum. A cap is attached to the top of each pair of filter panels to form a pocket shaped filter segment for receiving water. Each filter panel includes filter media, such as finely woven cloth, for filtering water.
Each filter panel is attached to the drum by a filter support arrangement. Each filter support includes a plurality of support openings which provide fluid communication between adjacent filter segments. This enables water and air to flow circumferentially between adjacent filter segments as the drum rotates.
In operation, the drum is rotated and the water to be filtered is introduced into the drum. The water then exits through ducts in the drum and flows into filter segments inside the filter support. The water in the filter support is then filtered through the media of the filter panels to provide filtered water. The filtered water is then collected in a chamber and exits the disc filter through an effluent pipe. Particulates which are filtered out by the filter panels remain within the filter segments on the inside surface of the filter media of the filter panels. A spray device is used to spray the panels with water to dislodge the particulates and clean the filter media. The particulates are then collected onto a trough and removed from the disc filter system.
Openings in the central drum that function to provide a passageway for the water to be transferred into the interior of the filter discs are typically larger than the openings of the filter media on the filter panels. Influent wastewater having high Total Suspended Solids (TTS) levels will therefore clog the filter media more quickly, which reduces throughput. Furthermore, objects in the wastewater, such as rags and other large objects may flow through the openings in the drum into the interior of the filter panels and become trapped. This results in the loss of effective filter panel filtration area and thus a loss of efficiency. For example, in order to remove these large objects, the disc filter has to be taken offline and the filter panels have to be removed and cleaned, which is both labor intensive and time consuming.
Aspects and embodiments are directed to a two-stage filtration system for filtering wastewater that includes a first stage filter assembly that is disposed sequentially to and upstream from a second stage filter assembly.
According to an aspect of the present disclosure, a filter device for filtering wastewater is provided. The filter device comprises a drum filter including a rotary drum with a filter surface having a first side facing an interior of the drum and a second side facing an exterior of the rotary drum and being fluidly connectable with a source of wastewater, and a disc filter having an inlet fluidly connectable with the first side of the filter surface of the rotary drum.
In some embodiments, the disc filter includes a plurality of disc-shaped filter members attached to a central drum that are configured to receive filtered wastewater passed through the filter surface of the drum filter and to filter the filtered wastewater. In one embodiment, the inlet of the disc filter is fluidly connectable with an interior of the central drum of the disc filter. In another embodiment, the rotary drum of the drum filter and the central drum of the disc filter are positioned along a common longitudinal axis. In some embodiments, the rotary drum of the drum filter is coupled to the central drum of the disc filter.
According to a another embodiment, the disc filter further comprises a housing that at least partially surrounds the drum filter and the disc filter, the housing having an inlet trough fluidly connectable with the wastewater and the second side of the filter surface of the rotary drum filter, an outlet trough fluidly connectable with filtrate, and a sealing plate configured to separate the inlet trough from the outlet trough.
In some embodiments, the disc filter further comprises a drum filter collection trough fluidly connectable with the exterior of the rotary drum.
In some embodiments, the disc filter further comprises a backwashing system. According to one embodiment, the backwashing system comprises a first plurality of spray nozzles configured to spray filtrate onto the plurality of disc-shaped filter members, a disc filter backwash trough configured to collect backwashed filtrate from the plurality of disc-shaped filter members, and a second plurality of spray nozzles configured to spray filtrate onto the first side of the filter surface of the rotary drum, wherein the drum filter collection trough is configured to collect backwash from the filter surface of the rotary drum.
According to at least one embodiment, the filter surface of the rotary drum is configured to retain solids on the second side while permitting the wastewater to filter through the filter material to the first side of the filter material and the interior of the rotary drum as filtered wastewater. In some embodiments, the filter surface of the drum filter has openings with a diameter in a range of about 20 microns to about 800 microns. According to certain embodiments, the filter surface of the drum filter comprises one of wedge wire screen material or woven filter media material. In one embodiment, the plurality of disc-shaped filter members include a filter media with openings having a diameter in a range of about 6 microns to about 300 microns.
According to some embodiments, the wastewater is from one of a secondary or primary treatment process.
According to another aspect of the present disclosure, a two-stage filtration system for filtering wastewater is provided that includes an inlet fluidly connectable with the wastewater, a first stage filter assembly fluidly connectable with the inlet and having a rotary drum with a filter surface configured for radially inward fluid flow, a second stage filter assembly fluidly connectable with the first stage filter assembly and having a plurality of filter discs configured for radially outward fluid flow, and an outlet fluidly connectable with filtrate generated by the second stage filter assembly.
In some embodiments, the plurality of filter discs are attached to a central drum that is fluidly connectable with an interior of the rotary drum of the first stage filter assembly.
According to at least one embodiment, the first stage filter assembly and the second stage filter assembly are rotatable around a common longitudinal axis, and the system further comprises a drive assembly coupled to the first stage filter assembly and the second stage filter assembly. In another embodiment, the two-stage filtration system further includes a backwashing system having a first plurality of spray nozzles configured to spray the filtrate onto the plurality of filter discs and a second plurality of spray nozzles configured to spray the filtrate onto an inwardly facing side of the filter surface of the rotary drum.
In another embodiment, the two-stage filtration system further includes a level sensor configured to provide measurements of a level of wastewater provided by the inlet to the first stage filter assembly. In a further embodiment, the two-stage filtration system further includes a controller operatively coupled to the level sensor, the drive assembly, and the backwashing system, the controller configured to control at least one of the drive assembly and the backwashing system based on measurements from the level sensor. In some embodiments, the filter surface of the drum filter has openings with a diameter in a range of about 20 microns to about 800 microns. In some embodiments, the filter discs include a filter media with openings having a diameter in a range of about 6 microns to about 300 microns.
In some embodiments, the inlet of the two-stage filtration system is fluidly connectable with a secondary clarifier of a secondary treatment process. In other embodiments, the inlet is fluidly connectable with influent to a primary treatment process.
According to one embodiment, the second stage disc filter assembly includes a central drum configured to receive filtered wastewater from the first stage filter assembly, the central drum including a plurality of drum apertures, a frame comprising a plurality of frame supports each having an attachment portion coupled to the central drum and a radial strut portion extending from the attachment portion, each of the plurality of frame supports defining a single frame aperture that extends through the attachment portion and along an entire length of the radial strut portion to correspond with the shape of the frame support, and a plurality of adjacent filter segments positioned around the central drum, each of the plurality of adjacent filter segments defining a cavity in fluid communication with at least one of the plurality of drum apertures and supported at a first side by a first frame support and at a second side by a second frame support, the plurality of frame apertures and cavities arranged to form a circumferential open fluid channel extending continuously around the central drum to enable the filtered wastewater to pass substantially unimpeded through the plurality of drum apertures and through the plurality of adjacent filter segments. In some embodiments, the single frame aperture forms an inverted substantially T-shaped configuration.
According to another aspect of the present disclosure, a method of treating wastewater is provided. The method includes introducing the wastewater to a first-stage filtration operation comprising a barrier filter to produce filtered wastewater, and introducing the filtered wastewater to a second-stage filtration operation comprising a disc filter to produce treated water.
In some embodiments, the method further includes measuring a level of the wastewater introduced to the barrier filter of the first stage filtration operation. In another embodiment, the method further includes backwashing a filter surface of the barrier filter based on the measured level of wastewater. In some embodiments, the barrier filter comprises a rotary drum configured for radially inward fluid flow. In some embodiments, the disc filter is configured for radially outward fluid flow.
Still other aspects, embodiments, and advantages of these example aspects and embodiments, are discussed in detail below. Moreover, it is to be understood that both the foregoing information and the following detailed description are merely illustrative examples of various aspects and embodiments, and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. Embodiments disclosed herein may be combined with other embodiments, and references to “an embodiment,” “an example,” “some embodiments,” “some examples,” “an alternate embodiment,” “various embodiments,” “one embodiment,” “at least one embodiment,” “this and other embodiments,” “certain embodiments,” or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described may be included in at least one embodiment. The appearances of such terms herein are not necessarily all referring to the same embodiment.
Various aspects of at least one embodiment are discussed below with reference to the accompanying figures, which are not intended to be drawn to scale. The figures are included to provide an illustration and a further understanding of the various aspects and embodiments, and are incorporated in and constitute a part of this specification, but are not intended as a definition of the limits of any particular embodiment. The drawings, together with the remainder of the specification, serve to explain principles and operations of the described and claimed aspects and embodiments. For purposes of clarity, not every component may be labeled in every figure. In the figures:
The aspects disclosed herein in accordance with the present invention, are not limited in their application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. These aspects are capable of assuming other embodiments and of being practiced or of being carried out in various ways. Examples of specific implementations are provided herein for illustrative purposes only and are not intended to be limiting. In particular, acts, components, elements, and features discussed in connection with any one or more embodiments are not intended to be excluded from a similar role in any other embodiments. For example, the teachings of this invention apply not only to an “outside-in” type drum filter connected to an “inside-out” disc filter, but also apply to other types of filter configurations, including an “inside-out” type drum filter connected to an “outside-in” disc filter.
Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Any references to examples, embodiments, components, elements or acts of the systems and methods herein referred to in the singular may also embrace embodiments including a plurality, and any references in plural to any embodiment, component, element or act herein may also embrace embodiments including only a singularity. References in the singular or plural form are not intended to limit the presently disclosed systems or methods, their components, acts, or elements. The use herein of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. References to “or” may be construed as inclusive so that any terms described using “or” may indicate any of a single, more than one, and all of the described terms. In addition, in the event of inconsistent usages of terms between this document and documents incorporated herein by reference, the term usage in the incorporated reference is supplementary to that of this document; for irreconcilable inconsistencies, the term usage in this document controls.
While the invention illustrated herein is described as being employed in a wastewater treatment setting, and particularly as a tertiary treatment system, other uses and arrangements are possible. For example, the invention may be used as a primary wastewater treatment system. Other wastewater treatment applications include use as a secondary clarifier in a municipal wastewater treatment plant. In addition to wastewater treatment uses, the present invention can also be used for filtering water used in industrial and manufacturing processes, such as wood, paper, and food industries, as well as production facilities.
As discussed above, rotary disc filters may be used to remove suspended solids from water. Examples of suitable disc filters that may be used in accordance with aspects of the invention are discussed in PCT Application Nos. PCT/US2007/017847 and PCT/US2008/008671, each of which is incorporated herein by reference in its entirety.
The disc filter 115 configuration shown in
Referring back to
The disc filter 115 also includes a drive assembly 170. The drive assembly 170 includes at least two bearings that support the central drum 119 for rotation. A driven sprocket 50 is coupled to the central drum 119 and a drive sprocket 45 is coupled to a motor 55 or other prime mover. In the illustrated construction, a belt engages the drive sprocket 45 and the driven sprocket 50 such that rotation of the motor 55 produces a corresponding rotation of the central drum 119. In preferred constructions, the sprockets 45, 50 are sized to produce a significant speed reduction. However, some constructions may employ a slow speed drive with no speed reduction if desired. While the illustrated construction employs a belt drive, other constructions may employ gears, shafts, chains, direct drive, or other means for transferring the rotation of the motor 55 to the central drum 119.
The disc filter 115 also includes an influent pipe 155 (also referred to herein as an inlet to the housing) that directs influent into an interior 65 (see
The spray bars 190 may be positioned between adjacent filter discs 117 and at the ends of the disc filter 115 to enable the spraying of high-pressure water in a reverse flow direction through the pleated filter media 118 to provide backwashing of the filter media 118. Because the filter media 118 is pleated and thus angled with respect to the plane of the filter discs 117, the use of nozzles (147) that are similarly angled may provide for more efficient backwash cycles. Thus, the nozzles are angled approximately 45 degrees off of a normal direction to the planes of the filter discs 117. In addition, two nozzles may be provided at each spray point, with the nozzles angled with respect to one another at about 90 degrees such that both sides of the pleats are sprayed directly during the backwashing. In some instances, a straight on direct spray may be utilized. In addition, bouncing spray off the filter media at an angle improves the cleaning effect and efficiency for a given amount of backwash flow and spray velocity.
The disc filter 115 of
Referring to
After filtering, and during rotation of the central drum 119, the filter panels 116 exit the liquid and pass the spray bars 190. During a backwash cycle, spray nozzles 147 (see
As illustrated in
Referring to
Referring to
A disc filter backwash trough 142 is positioned beneath the spray bar 190 between adjacent filter discs 117 to catch the spray water or backwash, including any particulate matter removed from the filter panels 116. The backwash and particles are then removed from the disc filter 115 via the backwash pipe 90.
As mentioned above, openings in the central drum 119 (e.g., apertures 158) provide a passageway for water to be sent into the interior of the filter panels (e.g., enclosed space 180). Since the openings or pore size of the filter media 118 is smaller than these openings, solids that are larger than the pore size opening become attached to the filter media. In addition, larger objects such as rags can also flow through the drum openings and become trapped in the interior of the filter panels, which not only reduces filter panel filtration area but also decreases efficiency since the disc filter has to be taken offline to remove these larger trapped objects since the backwash process is ineffective at removing such large objects.
In accordance with one or more embodiments, a two-stage filtration system for filtering wastewater is provided that addresses the problems discussed above related to the trapped solids. The two-stage filtration system includes a drum filter, also referred to herein as a “barrier filter” that functions as a first stage filtration process that is positioned upstream from a disc filter that functions as a second stage filtration process. The drum filter functions as a preceding filter or a pre-filter which provides a certain degree of filtering to a second stage filtration process such as the disc filter. For instance, the drum filter may be configured to remove material that is larger than 100 microns, including large debris from plant upsets caused by storm surges, etc. The drum filter may be directly attached to the disc filter such that the drum filter acts as an extension of the disc filter and functions to protect the disc filter from large debris and foreign objects. Influent wastewater passes through the drum filter first, as a first stage filtration operation. The drum filter removes larger particulates and generates filtered wastewater that is then directed through the disc filter. The disc filter functions as a second state filtration operation by removing finer particulates from the filtered wastewater that passed through the drum filter to generate filtrate.
The housing 125 includes an inlet 155 that is in fluid communication or otherwise fluidly connectable with wastewater to be filtered 102. The wastewater to be filtered 102 may be piped to the inlet from any one of a number of various sources. In some embodiments, the wastewater 102 is from a previous wastewater treatment process, including any one of a primary, secondary, or tertiary treatment process. According to one embodiment, the wastewater 102 is from a secondary treatment process, and the two-stage filtration system 100 may function as at least a portion of a tertiary treatment process. For example, the wastewater 102 may be sourced from a secondary clarifier of a secondary treatment process, as shown in
According to some embodiments, the wastewater 102 has a concentration of total suspended solids (TSS), also referred to herein as simply “suspended solids” in a range of approximately 10-30 mg/L. In other embodiments, the wastewater 102 has a TSS concentration that is greater than 30 mg/L, for example, in primary filtration applications and in instances where the wastewater 102 includes storm water runoff or effluent from a clarifier “burping” process, the wastewater 102 may have a concentration in a range of approximately 100-500 mg/L.
The drum filter 105 includes a rotary drum 110 with a filter surface 112 that has a first side 114a that faces an interior of the rotary drum 110 and a second side 114b that faces an exterior of the rotary drum. According to the embodiments discussed herein, the drum filter 105 is configured as an “outside-in” filter, such that wastewater to be filtered 102 (see
The filter surface 112 of the rotary drum 110 may be any one of a number of different types of filtration media that have openings or pores that allow water to pass through the filter surface but retain solids or other undesirable substances. The size of the openings may depend on the characteristics of the incoming wastewater 102 and/or the type of filter surface 112 used. In some embodiments, the filter surface 112 has openings that are in a range of approximately 1-1000 microns in diameter, and according to one embodiment, the openings in the filter surface 112 have a diameter that is in a range of approximately 20-800 microns, although smaller and larger sized openings for the filter surface of the drum filter are within the scope of this disclosure.
The filter surface 112 may be constructed from any corrosion resistant metal material. In some embodiments, the filter surface 112 is a metal mesh material. Non-limiting examples of metal mesh material include stainless steel, nickel alloys, other metal alloys, brass, bronze, titanium, or any combination thereof. In one embodiment, the filter surface 112 is a wedge wire screen material. In other embodiments, the filter surface 112 is a polymer material. In some embodiments, the filter surface 112 is a woven filter media material.
Referring back to
According to one embodiment, the wastewater 102 flows through the second side 114b of the filter surface 112 to the first side 114a as filtered wastewater 104. Wastewater 102 is forced through the filter surface 112 of the rotary drum 110 by a pressure differential caused by a difference in water height between a high pressure source (water at a higher level) on the outside of the rotary drum 110 (i.e., the presence of the wastewater 102 in the inlet trough 130 that the rotary drum 110 is at least partially immersed in) and the inside of the rotary drum 110, which is at a lower pressure (and lower height water level). The high pressure source on the outside of the rotary drum 110 pushes the wastewater 102 through the filter surface 112 to the inner chamber of the rotary drum 110. The filtered wastewater 104 then flows through one or more openings 150 in the central drum 119 of the disc filter via gravitational forces (see arrows in
Solids 106 too large to pass through the openings in the filter surface 112 adhere to the exterior (second side 114b) of the filter surface 112. A doctor blade 162 or other scraping device functions to scrape off or otherwise remove the filtered-out solid substances 106 from the from the second side 114b of the filter surface 112 as the rotary drum 110 rotates, which is shown in
In accordance with at least one embodiment, the filter device 100 also includes a backwash system. The backwash system functions to clean the filter media 118 of the disc filters 117 and the filter surface 112 of the rotary drum 110 at periodic or predetermined intervals. A schematic of a backwash system 145 is shown in
The backwash system 145 also includes a second plurality of spray nozzles 149 configured spray filtrate 122 onto the filter surface 112 of the rotary drum 110. The second plurality of spray nozzles 149 functions in a similar manner as the first plurality of spray nozzles 147. The second plurality of spray nozzles 149 are also shown in
According to some embodiments, the first plurality of spray nozzles 147 and/or the second plurality of spray nozzles 149 may include one or more features or elements that minimize or reduce clogging. For instance, the spray nozzles may include a retractable element that includes a split spray tip or other element that is configured to retract into an orifice of the housing of the spray nozzle during non-backwashing operations. When retracted, the split spray tip “splits” outwardly such that debris that would otherwise clog the orifice of the spray nozzle is released. Once pressurized, the retractable element extends outward from the opening and the split spray tip merges back together to form a spray pattern. Suitable nozzles having these features include the MOMOJet® nozzles available from Ikeuchi USA, Inc.
As shown in
The size of the drum filter 105 may depend on several factors, including the area and opening size of the filter panel 116 of the drum filter 10, and the flow rate of the wastewater for a given head loss.
Referring now to
Referring to
Referring to
Referring now to
According to at least one aspect, the system may include a level sensor, such as level sensor 178a that is positioned in the inlet trough 130 of the housing 125 that houses the drum filter 105 and the disc filter 115. The level sensor 178a may be configured to measure the level of wastewater 102 (influent water) in the inlet trough 130 of the housing 125. An approximate maximum water level (i.e., a predetermined level) for the influent is show in
The one or more sensors may also include one or more parameter sensors that are configured to measure other process parameters besides the level of influent, which is exemplified at 178b in
In accordance with at least one embodiment, a method of treating wastewater is provided that includes introducing the wastewater (e.g., 102) to a first-stage filtration operation comprising a barrier filter (e.g., 105) to produce filtered wastewater (e.g., 104) and then introducing the filtered wastewater to a second-stage filtration operation comprising a disc filter (e.g., 115) to produce treated water (e.g., 122). The method can also further include measuring a level of wastewater introduced to the barrier filter of the first stage filtration operation and backwashing a filter surface of the barrier filter based on the measured level of wastewater. In one embodiment, the barrier filter comprises a rotary drum configured for radially inward fluid flow and the disc filter is configured for radially outward fluid flow.
The following examples further illustrate the invention, and are not intended to limit the scope of the disclosure.
A pilot plant containing two Forty-X™ filter discs was re-configured to include a drum filter as shown in
A schematic of the placement of the pilot plant within an existing wastewater treatment plant (i.e., test site) is shown in
A 200 micron screen was initially installed on the drum filter. The drum filter was successful in trapping large solids and debris and preventing these items from entering the disc filter, which was fitted with 10 micron filter media. After four months of use, the drum filter showed no signs of wear. TSS data (see left y-axis of
The 200 micron drum filter experiment discussed above in Example 1 resulted in minimal head loss across the drum filter in both tertiary and primary treatment applications (the primary treatment results are discussed further below). Drum filters having screens with various sizes of openings ranging from 25 microns to 220 microns were tested. The results (not shown) from timed draw-down and turbidity tests indicated that a 75 micron screen yielded the best results.
A 75 micron filter material was then installed on the drum filter and a two-stage tertiary filtration process with a 10 micron pleated panel disc filter was commenced.
For purposes of testing the pilot plant in a primary treatment application, a gas powered trash pump was installed in the raw influent stream that fed the test site. The pump was capable of influent flow rates up to 130 gpm and a secondary pump was used to supplement the flow rate to be as high as 400 gpm.
A 200 micron drum filter was paired with two different sized disc filters. The first disc filter tested was a 10 micron pleated panel disc filter, and two-stage primary filtration was performed using this configuration for approximately 6 days.
The results shown in
Combined influent and effluent TSS data from all three examples are also shown in
Having thus described several aspects of at least one example, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. For instance, examples disclosed herein may also be used in other contexts. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the scope of the examples discussed herein. Accordingly, the foregoing description and drawings are by way of example only.
This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 62/374,097, titled “DISC FILTER PRE-SCREEN DUAL MEDIA DISC FILTER,” filed on Aug. 12, 2016, which is herein incorporated by reference in its entirety.
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Number | Date | Country | |
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20230338880 A1 | Oct 2023 | US |
Number | Date | Country | |
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62374097 | Aug 2016 | US |
Number | Date | Country | |
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Parent | 17096226 | Nov 2020 | US |
Child | 18212240 | US | |
Parent | 16320011 | US | |
Child | 17096226 | US |