Patent Application
20150053628
The invention relates to a filter cleaning head and to a related method of cleaning a filter, for example for cleaning a filter element of a water filtration device.
Filtration is a preparatory step in many fluid treatment processes and in particular in water treatment processes. Such processes are typically aimed at improving water quality and to reducing risks associated with water or other liquids containing unwanted elements. Filtering processes are also used to remove solids and liquids from a process gas. The filtering may be to enable effective use of the fluid in a subsequent process, for example as a process fluid in a cleaning, cooling or manufacturing process. Improved filtration technologies will benefit currently applied treatment methods regardless of media and applications and further open up for the development of improved processes and technologies.
Filtering is conventionally used in numerous applications such as fresh water applications, potable water production including recirculation of water from domestic and industrial processes, cooling-water intake for power plants, produced water treatment applications from oil/gas exploration, sea water applications, waste water applications and aquaculture applications on land or on floating units such as floating aquaculture installations (fish farms), air conditioning and gas purification, installations associated with the production of oil and gas as well as on-board ships, ballast water management on-board ships, food and drink processing, mineral and slurry processing, pharmaceutical processing, chemical processing and power generation applications such as pre-processing of power station cooling water or processing of electrical transformer oils. Whilst many of these uses for filtration involve water based liquids the use of filters of the type described herein is not limited to water based liquids alone but could also be used to treat acids and alkalis or other fluids where it is desirable to remove unwanted elements from the fluid.
Many of these uses require filtration of a high volume of water at high flow rates. An example of this is the filtration of ship ballast water, for example during treatment of the ballast water to kill micro-organisms, and this is of increasing importance to ship builders and fleet operators. Transferring large volumes of sea water between distinct geographical locations is known to be damaging to marine biodiversity. Regulatory requirements and environmental concerns make it important to effectively treat ship's ballast water before it is discharged in order to remove contaminants and organisms, including micro-organisms. Regulations set onerous requirements for the size of organism that must be removed or disabled and this gives rise to a need for effective filtration and micro-filtration of large volumes of water. The scale of modern ships means the volumes of ballast water tanks is large and consequently the time taken to load and unload ballast tanks is of commercial importance to fleet operators. Additionally, space is surprisingly scarce on-board ships. As a result, efficient filtration systems or more specifically micro-filtration systems that are space efficient and still capable of filtering large volumes of water and removing a considerable amount of matter (organic as well as in-organic) are highly desirable.
A range of filter systems are available to that can filter fluids in these applications. Such systems generally comprise a conventional filter element through which the fluid, raw sea water, for example, flows. All filter systems naturally require the material that is filtered out to be removed. In a typical system, as the liquid flow passes through the wall of the filter elements any dirt, particles or organic matter greater in size than the filter size specification may not pass through the filter element and are trapped on the internal wall of the filter element and begin to form an accretion of filter residue, known as a ‘cake’. As the cake of matter builds-up the pressure loss over the filter element increases. It is necessary for the accreted filter residue to be cleaned off the interior wall of the filter element in order to maintain efficiency. Even the best filter designs will suffer from build-up of residue and this problem increases as the effectiveness of the filter in removing solids from the liquid is increased. Thus, to provide an effective filtering of liquid it is necessary to not only provide an improved filtration but also to ensure effective cleaning of the filter.
This cleaning process can be achieved by stripping down the filter to gain access to the filter elements. This has obvious disadvantages in relation to the need for maintenance personnel, access to the filter, and down time for the filter apparatus. A more self-sufficient filtration mechanism can be provided by the use of a backwashing process. Such a process uses a backwashing mechanism that may be configured for continuous cleaning or triggered only when the pressure loss over the filter reaches a certain monitored level or triggered at present intervals or manually. The pressure loss will increase as the ‘cake’ of filter residue builds-up. Various filter cleaning heads have been employed in various backwashing mechanisms which allow the filter element to be cleaned through reverse water flow through the filter wall. The reverse flow dislodges filtered material, which can then be removed from the filter apparatus.
WO 2006/008729 and WO 2011/058556 describe known backwashing processes, in which a cleaning head is passed over the filter wall to clean the filter and remove filter residue. The cleaning head uses a local flow reversal in a relatively small part of the filter wall to dislodge the residue and to remove it from the filtration apparatus. This backwashing process can be performed whilst the filter is in use thus allowing the filter to continuously filter water whilst being cleaned. The cleaning head is arranged to move over the filter surface so that all areas can be cleaned. Typically the filter surface is a cylinder and the cleaning head is arranged to move over the cylindrical surface following a helical path in order to clean the whole surface. The cleaning head must be in close contact with the filter surface during the cleaning operation in order to maintain the pressure difference for reverse flow. This means that some device is required for holding the cleaning head against the filter surface. In addition, the contact portion of the cleaning head will suffer wear due to sliding contact with the filter surface. This means that it is necessary to either adjust the device constantly or to provide some mechanism for automatically adjusting the position to the cleaning head in order to maintain close contact with the filter surface as the contact portion wears away.
In WO 2006/008729 adjustment of the cleaning head position is achieved by the use of a spring element in the cleaning head, which pushes the cleaning head against the filter wall. However, the spring must provide a sufficient force to hold the cleaning head against the cleaning wall under the highest expected pressure differential. This has the result that the cleaning head is generally pushed too hard against the wall during normal operational pressure differences, which can be considerably lower than the maximum design pressure difference. The increased force increases wear and results in undesirable deformation of and damage to the filter wall.
WO 2011/058556 attempts to improve the device of WO 2006/008729 by the use of a resilient bellows with a different elastic deformation characteristic to the spring of WO 2006/008729. However, the bellows arrangement creates further problems, since when there is a high pressure differential then the suction pressure can cause the bellows to retract. This requires an arrangement for equalisation of pressure to ensure that the cleaning head remains in contact with the filter wall. The pressure equalisation uses specially introduced holes in order to equalise pressures in and around the filter cleaning head. These holes are prone to blockage by dirt since the holes are necessarily located on the dirty side of the filter element.
Thus, with the spring device of WO 2006/008729 the force applied between the cleaning head and the filter wall at low pressure differentials is too high, whereas the bellows device of WO 2011/058556 requires pressure equalisation to avoid loss of contact with the filter wall at high pressure differentials.
Viewed from a first aspect, the present invention provides a cleaning head for a filter backwashing mechanism, the cleaning head comprising: a nozzle for contact with a filter element wall and for receiving a flow of backwash fluid, wherein the nozzle comprises a rotor for generating a torque when exposed to the flow of backwash fluid, and wherein the cleaning head is arranged such that at least a part of the nozzle will move toward and/or apply a force to the filter element wall as a result of the torque generated by the rotor.
With this arrangement the nozzle or a part of the nozzle can be pushed against the filter wall by a force that is produced based on the flow of backwash fluid. The torque generated by the rotor will vary in accordance with the flow rate of the fluid, which itself will vary dependent on the pressure differential. As a consequence the force that keeps the nozzle part in contact with the filter wall is dependent on the pressure differential. This avoids the problems with the prior art systems described above. At low pressure differentials a lower torque is generated and hence the pressure applied to the wall is not excessive as in WO 2006/008729. Higher pressure differentials are matched by higher torques and there is no need for a pressure equalisation mechanism as in WO 2011/058556. This reduces the risk of fouling functional parts of the cleaning head by debris.
In a preferred embodiment the torque generated by the rotor produces a linear movement of the nozzle or a part of the nozzle in a direction that is toward the filter element wall, in use, and/or results in a linear force applied by the nozzle or part thereof in a direction that is toward the filter element wall, in use. The rotor may be mounted in any fashion with any suitable mechanism being used to convert rotation of the rotor into a linear motion/force. However, the rotor is preferably mounted in the cleaning head with an axis of rotation that is generally perpendicular to the surface of the filter element wall. The torque generated by the rotor may be converted into a linear force and/or movement by a screw thread arrangement.
In a preferred embodiment the rotor is mounted to the cleaning head via a screw thread arrangement and the screw thread has an axis of rotation that is generally perpendicular to the surface of the filter element wall. This means that the rotor itself will move linearly as it rotates and hence may comprise the part of the nozzle that moves toward the filter element wall. For example, there may be a threaded shaft directly connected to the rotor or to the cleaning head, with the other end of the rotor or the cleaning head being provided with a threaded hole or nut. Preferably the thread mechanism is enclosed and sealed to prevent fluid ingress and to thereby avoid fouling of the thread with debris from the unfiltered process fluid. The rotor may form at least an end part of the nozzle, so that an inlet of the rotor forms the contact part of the nozzle that is intended to contact with the filter element wall.
In an alternative preferred embodiment, the nozzle comprises the rotor and a separate contact part arranged for linear movement driven by rotation of the rotor, the contact part being for contact with the filter element wall during backwashing. With this arrangement, the rotor may be mounted to the cleaning head for rotating movement only, for example via a bearing or similar. The contact part may be a threaded part slidably mounted with respect to a main body of the nozzle and connected to a threaded part that rotates driven by rotation of the rotor, such as a threaded part of the rotor itself. One particular arrangement for the contact part may comprise a threaded rod slidably mounted along the axis of rotation of the rotor and engaged with a complementary threaded hole along the rotor axis, whereby rotation of the rotor moves the contact part in a linear manner so that an end of the contact part is pushed against the filter element wall during backwashing.
With this type of arrangement since the contact part moves linearly without rotation then wear of the contact area is reduced in comparison to the above arrangement where the rotating rotor moves toward and makes contact with the filter element wall. The trade-off is a potentially more complex mechanism since there are at least two moving parts, these being the linearly sliding contact part and the rotating rotor.
Preferably the rotor comprises an inlet that receives backwash fluid and an outlet that discharges backwash fluid to downstream parts of the backwashing mechanism.
The cleaning head may be arranged so that all of the backwash fluid for the cleaning head passes through the rotor before being passed to downstream parts of the backwashing mechanism. This maximises torque production and maximising the flow rate through the rotor also minimises fouling of the rotor and build-up of filter residue within the rotor and associated parts of the cleaning head.
As the contact part at the tip of the nozzle is moved over the inner wall of the filter element in contact with the wall then wear may take place. It is preferred that a relatively soft material such as plastic or PTFE or a slightly deformable material is used for the contact part of the nozzle in order to reduce friction and reduce wear of the expensive filter element and absorb small manufacturing tolerances. Thus, the material of the contact part is preferably softer than the material of the filter element wall. As wear takes place, the contact part of the nozzle will be allowed to move further toward the filter wall propelled by the torque from the rotor, increasing its linear movement until the tip of the nozzle once again creates a seal between the inner wall of the filter element and the nozzle. Therefore, the nozzle automatically compensates for wear of the nozzle up to a predetermined limit. Once this predetermined limit is reached the nozzle may be easily replaced.
Preferably the filter cleaning head includes a hollow conduit for passage of backwash fluid from the nozzle to downstream parts of the backwashing mechanism. The hollow conduit may support the rotor and/or nozzle, for example the hollow conduit may hold a bearing that supports the rotor or a threaded shaft or nut that supports a corresponding nut or threaded shaft of the rotor.
The filter cleaning head may be designed to be retro-fitted onto an existing backwashing mechanism, for instance the hollow conduit may comprise a joint or interface for fitting to a conduit of an existing backwashing mechanism.
Alternatively, the filter cleaning head may be designed together with other parts of the backwashing mechanism and manufactured as a part of a backwashing mechanism designed for use with this filter cleaning head. In this case one preferred embodiment comprises a hollow conduit including a part of a main flow path for the backwashing mechanism and a branch extending from the part of the main flow path for supporting the nozzle. The hollow conduit may be a T-shape. Multiple cleaning heads may hence be connected together by joining the parts of the main flow path in order to produce a backwashing mechanism including multiple cleaning heads on branches extending from a common main flow path.
The part of the main flow path preferably comprises a segment arranged to be joined to another similar segment, for example via two tubes interconnecting in a plug and socket fashion, optionally with a ‘snap fit’. This allows a backwashing mechanism to be made up of a plurality of filter cleaning heads spaced along the length of any size of filter element and separated by a predetermined distance. Plastic ‘hooks’ and seals may be included in the hollow conduit to facilitate the assembly and sealing of each segment. The assembled hollow conduits then hold the plurality of filter cleaning heads in their correct respective locations relative to each other. The hollow conduits may be rotated relative to one another about the axis of the main flow path so that the branches and hence the nozzles extend away from the main flow path in different directions. The backwashing mechanism may further include suitable end pieces for the main flow path of the multiple hollow conduits in order for connection to the remainder of the backwashing mechanism.
The rotor preferably comprises one or more helical rotor blade(s) with a pitch that decreases in the direction of flow of backwash fluid. Thus, the blade(s) may have a pitch that is larger at the and of the rotor closest to the filter element wall, in use, and smaller at the other end of the rotor.
The rotor may have a conic shape, with blades formed between two conic surfaces.
The nozzle may be formed by the rotor and an outer housing or cowling of the rotor that moves with the rotor as it moves linearly relative to the filter element wall.
In a preferred embodiment the rotor comprises: at least one blade arranged to rotate about an axis of rotation, the blade being formed by a surface extending between inner and outer conic helixes; an inner surface and an outer rim enclosing the blade, the inner and outer surfaces following inner and outer generally conical surfaces of revolution corresponding to the paths of the conic helixes, wherein the conic helixes each have a pitch that decreases along the flow direction and wherein the blade extends between the outer rim and the inner surface and is mounted to at least one of the outer rim and the inner surface. The use of a rotor as described above has been found to give an effective mechanism for the required movement of the nozzle. In one example arrangement the radius of the helix increases along the flow direction and the rotor is arranged with the small diameter end of the conic shape forming an inlet for flow of backwashing fluid. Thus, the small diameter end of the cone faces the filter element wall, in use, with the large diameter end of the cone forming the outlet for backwashing fluid as it passes from the nozzle to downstream parts of the backwashing mechanism. Alternatively, it would be possible for the pitch to decrease with decreasing radius so that a large diameter end of the rotor forms the inlet for backwashing fluid.
Preferably the blade is mounted to both of the outer rim and inner surface. This means that the outer rim is joined directly to and rotates with the blade and the remainder of the rotor. As a result, when the rotor moves linearly as well as rotating, there is no need for any complicated arrangement for connection of the outer rim or inner surface to allow movement of these parts relative to the conduit as the rotor nozzle moves toward or away from the filter element wall.
In the present context, a conic helix is a three dimensional curve formed on a surface of a generally conical body. The surface of the generally conical body may be conical, frustoconical or any other shape formed as a surface of revolution that has a generally increasing or decreasing radius. Thus the surface is not specifically limited to a straight sided cone but could instead be a convex sided cone or frustocone such as a zone or ogive nose cone shape, or alternatively the cone could be a concave sided cone or frustocone. What is important is that each conic helix is formed with a radius that increases along an axis of the rotor and a pitch that decreases as the radius increases. The inner and outer conic helixes preferably have the same decrease in pitch, although applications are possible where a different decrease in pitch for the inner and outer conic helix may be used.
The terms “inner” and “outer” are used herein to refer to portions of the rotor that are at a smaller or greater radius from the axis of rotation of the rotor.
Internally, the rotor has one or more flow passages formed between front and back blade surfaces, the outer rim and the inner surface. The flow passages effectively contain the flowing fluid and prevent energy being lost due to tip losses. When the blade extends between and is mounted to both of the outer rim and inner surface then the flow of fluid is fully contained and tip losses are minimised.
In a preferred embodiment the rotor has an inlet opening at the small diameter end of the rotor that is arranged for axial flow of fluid, preferably for solely axial flow. Thus, the opening is perpendicular to the axis of rotation of the rotor and the blades are preferably formed to receive fluid flowing in a generally axial direction and preferably without any (significant) radial flow. Preferably the rotor has an outlet opening at the large diameter end that is also perpendicular to the axis of rotation of the rotor. However, in the preferred embodiment the blades at the large diameter end are not arranged for solely axial flow, but instead may be adapted to expel fluid flowing with a radial component to its movement.
The inner and outer conic helixes preferably start at the same longitudinal position along the axis of rotation of the rotor before extending along the direction of the axis of rotation of the rotor. Preferably the inner and outer conic helixes also extend for about the same axial length along the direction of the axis of rotation of the rotor. With this arrangement when an outer rim of the rotor is present it naturally encloses an opening that requires an axial component of the flow for fluid to flow through the opening.
The conic helix can be any suitable shape that allows for a three dimensional curve with a decreasing pitch and optionally an increasing radius as described above. One preferred option is the use of an Archimedean spiral with a linear increase in radius, can be used to produce a rotor with a simple shape based on a straight sided frustocone. However, the conic helix could alternatively be based on Euler, Fibonacci, Hyperbolic, Lituus, Logarithmic, Theodorus or any other known spiral having varying radius r as a function of the polar coordinate θ but also having a third variable, the length l, varying also as function of the polar coordinate θ. Some curves and/or the use of non-linear radius increases will result in conic helixes based on conical shapes with convex or concave sides, as discussed above.
The inner and outer conic helix may be based on the same form of spiral or curve, with different initial and final radii. Alternatively, different forms of curve or spiral could be used for the inner and outer conic helix to produce a more complex shape for the blade.
Whilst a single blade could be used it is advantageous to use multiple blades. This creates multiple flow passages and also allows the rotor to be easily balanced. The choice of two, three or more rotor blades may depend on a balance of rotor strength, ease of manufacture and energy lost to friction. In the present embodiment, three rotor blades is the preferred choice since it offers a strong and balanced three point construction with minimal friction loss.
The blade or blades are preferably formed as surfaces generated by straight lines between points on the inner and outer conic helixes at the same longitudinal distance along the direction of the axis of rotation of the rotor. Thus, the blade surface may connect the pair of conic helixes in the radial direction. Alternatively, the blades may be formed as surfaces generated by curves between points on the inner and outer conic helixes at the same longitudinal distance along the direction of the axis of rotation of the rotor. With this arrangement the blades surfaces may, for example, be concave when viewed from the large diameter end of the rotor.
The inner and outer conic helixes may both increase in radius at the same rate, such that the conic surfaces are generally parallel. However, it can be advantageous to adjust the performance of the rotor by having a different rate of increase in diameter for the inner and outer conic helixes. The inner conic helix may increase in radius at a slower rate than the increase in radius of the outer conic helix in order to reduce or restrict the hydrodynamic reaction forces and torsional forces produced by the rotor. Alternatively, the inner conic helix radius may increase at a faster rate than the outer conic helix radius in order to increase hydrodynamic reaction forces and torsional forces.
The parameters discussed above, including the radius of the conic helix, pitch of the conic helixes and the relative increase in radius of the inner and outer conic helixes are preferably varied linearly along the length of the rotor. However, non-linear variations of radius, pitch and relative radius would also be possible.
The fluid flow kinetic energy converted by the nozzle is fully adjustable. A desired torsional force for a predetermined flow condition can be achieved by adjusting one or more of (A) the rate of change of radius of one conic helix or both conic helix; (B) the relative change of radius of inner and outer conic helix (C) the change in pitch of one or both conic helix.
Seals or flexible stretchable covers to prevent lost process fluid may be provided between the rotor and the hollow conduit that the rotor is supported by. These seals may be passive O-ring or lip type of seals or may be spring or otherwise activated depending on the application and the level of sealing required or they may be a flexible stretchable cover that distorts easily when the rotor rotates.
The sealing force applied by the nozzle to the filter element wall must be selected carefully so as to provide an effective seal between the contact part of the nozzle and the inner wall of the filter element but should not be selected to produce such a high force that the nozzle creates a force that may deform the filter element wall, create excessive wear or is not able to be reversed by an opposing force that might be experienced in normal operation of the backwashing mechanism. Such an opposing force may occur if the manufacturing tolerance of the filter element requires the nozzle to ‘back off’ or a short distance so as to accommodate the small differences in dimensions of the filter element. Providing the sealing force is selected carefully, an opposing force is able to cause a reverse rotation of the nozzle thus minimising the chance of seizure or damage to the filter element. Once the variation in manufacturing tolerance has passed the contact part of the nozzle may advance in its normal way towards the filter element wall.
When there is no backwash flow, the sealing force is zero, then the nozzle is deactivated, and the contact part only very lightly touches the inner wall of the filter element. Normally, at this time the backwashing mechanism is motionless as there is no need for the backwashing mechanism to operate. As a zero sealing force occurs between the nozzle and the filtration wall, dismantling of the backwashing mechanism should be easy to perform. However, in some application is may be advantageous to include a tension or torsion spring within the filter cleaning head that causes a ‘retractable’ force to act on the contact part and/or on the rotor causing the contact part to withdraw from the filter element wall and/or causing the rotor to rotate in reverse when the normal working load is removed i.e. backwashing ceases. Moving the contact part of the nozzle in a linear motion away from the filtration wall in this way allows a clearance between the contact part and the inner wall of the filter element. Alternatively, a device may be provided to create a flow of fluid through the rotor in the reverse direction to the backwash flow, hence reversing the rotation of the rotor thereby also moving the contact part of the nozzle in a linear motion away from the filtration wall allowing a clearance between the contact part and the inner wall of the filter element. Or a simpler mechanism could be to include blank holes in the nozzle so that a suitable tool can be inserted and the contact part can be backed off manually by hand.
Preferably the filter cleaning head forms part of a backwashing mechanism for installation in a filter with one or more filter element(s), the filter element(s) comprising a semi-permeable filtration wall and a filter cleaning head forming part of the backwashing mechanism.
The filter elements may be elements constructed by a metal weave-wire sintered screen method where multiple metal screen layers are sintered together with supporting structures to create a strong filter element that is able to support its own weight. Alternatively, other types of filter element design may be used that under the operating conditions of the filter are permeable to one or more selected components of the liquid mixture, solution or suspension under treatment and is impermeable to the remaining components. Such filter elements may be constructed from natural or processed fibre, man-made organic or synthetic materials, ferrous and non-ferrous metals, glass, activated or natural carbon, ceramics, papers and plastics, sheet or woven materials, non-woven materials, pleated meltspun materials, inorganic bonded porous media, mineral wools, glass fibre, carbon fibre, woven wire and screens, sintered wire mesh, perforated plate, wedge wire and membrane type of designs or any combination thereof.
As an additional benefit, the filter element may advantageously be coated with a suitable compound to provide increased corrosion resistance and/or improved surface qualities. For example, coatings prepared from e.g. TiO2 or Polyaniline-nano-TiO2 particles synthesized by in-situ polymerization have excellent corrosion resistance in aggressive environments. The individual filter elements may therefore be coated to improve corrosion resistance. In addition the nano-surface achieved can provide improved surface qualities making the surface very slippery and difficult for matter to ‘stick’ to the surface thereby requiring less frequent cleaning. The slippery surface also reduces wear of the contact part of the nozzle.
The filtration size specification is determined according to the liquid and particle properties to be filtered. Thus, the filtration size (that is the size of the holes or flow paths through the filter element) may be any suitable size depending on the desired application. For example the filtration size specification of the filter elements may be selected to be <1, 1, 10, 20, 40 or 50 microns or greater depending on the application.
The backwash flow is generated by a pressure differential across the filter element wall and this may be achieved in any suitable way. Advantageously however the pressure differential may be achieved by reducing the pressure at the backwashing flow outlet that communicates with the filter cleaning head via the hollow conduit. This consequently reduces the pressure at the inlet to the filter cleaning head and causes debris to move into the filter cleaning head, along the hollow conduit communicating with the filter cleaning head and finally to the backwash outlet.
The difference between atmospheric pressure at the backwash outlet and the pressure on the outside of the filter element may be sufficient to achieve the required back flow and in such an arrangement a control valve may be provided to selectively open and close the backwash outlet thereby creating the required reverse back flow.
Additionally, or alternatively, a vacuum or suction apparatus may be provided to increase the pressure differential to enhance the back-wash or cleaning operation. In such an arrangement a vacuum or suction apparatus may be coupled to the backwash outlet or to the hollow conduit communicating with the filter cleaning head, either in combination with the control valve or alone.
Advantageously, in filter arrangements that incorporate a plurality of filter elements then each filter element is provided with a backwashing mechanism within the filter element but the multiple filter elements may have a common backwashing outlet. With a plurality of cylindrical filter elements the backwashing mechanisms can be mounted with alignment to the centre line of each filter element and can be driven independently of each other or simultaneously or as a sub-group, for example in pairs. Thus, the filter arrangement can be backwashed in the most effective manner with minimal detrimental influence on process fluid flow within the filter arrangement. Indeed, the multiple backwashing mechanisms could also be programmed to automatically adjust depending on the filtration load so that two, three or all of the backwashing mechanisms operate together with the maximum efficiency possible depending on the pressure loss detected over the filter elements.
In order to move the backwashing mechanism the assembly may be provided with a drive mechanism arranged to rotate the backwashing mechanism whilst simultaneously moving the backwashing mechanism in a linear motion along the axis of the filter element. Movement may be by means of an electric motor and screw or other electro-mechanical, pneumatic or hydraulic arrangement.
As the backwashing mechanism is simultaneously rotated and moved linearly, each filter cleaning head forming part of the backwashing mechanism follows a helical trajectory as it traverses the filter surface. Thus, the filter cleaning head is able to be conveyed over 100% of the entire inner surface of the filter element such that debris can be collected from all parts of the filter element wall. The entire surface of the filter element wall can be cleaned of debris. The filter element can be backwashed whilst allowing the normal operation of the filter arrangement to continue i.e. the backwashing can take place during normal filtration.
The backwashing mechanism preferably supports a plurality of filter cleaning heads which may be spaced along the axial length of the filter element and separated by a predetermined distance. In this way, the amount of linear movement required may be divided by the number of filter cleaning heads so that each filter cleaning head need only be conveyed over part of the inner surface of the semi-permeable wall of the filter element whilst still reaching and cleaning 100% of the semi-permeable filtration wall.
Advantageously, the filter cleaning head forming part of the backwashing mechanism is scalable up to very high filtration capacities from less than 100 m3/hr to above 10,000 m3/hr by simply duplicating the filter cleaning heads, in line with the area of the filter element to be cleaned.
The filter cleaning head ultimately provides an improved overall backwashing mechanism which efficiently and effectively removes debris from the filtration wall of each filter element. The rotor arrangement advantageously converts fluid flow kinetic energy in the backwash flow into a sealing force that results in the close alignment of the filter cleaning head with the inner wall of each filter element. This enables an improved sealing effect resulting in a highly efficient cleaning of the filtration wall with minimal process fluid loss.
The geometry of the nozzle, rotor and the hollow conduit that it rotates within and is supported by lends itself well to efficient manufacture and assembly. These parts may be made from machined, cast or welded material but preferably they may be injection moulded or made by rapid prototyping methods to reduce the costs of mass production.
The inclusion of the filter cleaning head herein forming part of the backwashing mechanism improves the overall efficiency of the backwashing mechanism. The process fluid loss through the improved backwashing mechanism compared with prior art is reduced. Additionally, the cleaning of the filter is also improved. These improvements allow for a reduction of filter mesh sizes without reducing the flow-rate or capacity of a given filter arrangement. Thus, the improved cleaning allows for improvements to the filtration process. Liquid can be subsequently delivered to a (high capacity) treatment process which is considerably “cleaner” because of finer filtration, and this will reduce the burden on the treatment process allowing it to be scaled down (e.g. reducing the concentration of “conditioning” chemicals or opening up for introducing alternative treatment processes).
It will be recognised that the cleaning head may be utilised not only for liquid filtering but also in gas filtration arrangements. For example the cleaning head may be used in a filter that filters solid particles from a gas stream.
Viewed from a second aspect, the invention provides a method comprising use of a cleaning head for cleaning a filter element wall, wherein the cleaning head is as described in relation to the first aspect above, and optionally as described in relation to preferred features of the first aspect. The method may comprise use of a backwashing mechanism as discussed above.
The method may comprise the steps of: (A) creating a pressure differential between outside of the filtration screen and the filter cleaning head such that fluid is caused to flow in a reverse direction through the filter element wall; and (B) activation of the filter cleaning head by conversion of the fluid flow kinetic energy into sealing forces resulting in self-adjusting sealing of the filter cleaning head with the inner wall of the filter element thereby preventing the loss of process fluid and increasing cleaning effectiveness; and (C) moving the filter cleaning head(s) relative to the filtration wall so as to remove debris from 100% of the filtration wall.
Thus, according to such an aspect there is provided for a method of efficiently and effectively backwashing a filter arrangement.
Viewed from a third aspect, the invention provides a method of manufacturing a filter cleaning head comprising providing a nozzle as described in relation to the first aspect above, and optionally as described in relation to preferred features of the first aspect. The method may be a method of manufacturing a backwashing mechanism and may advantageously include retro-fitting the cleaning head to a pre-existing backwashing mechanism, or alternatively providing part or all of the entire cleaning heads in a backwashing mechanism.
Certain preferred embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings in which:
a and 1b illustrate a filter cleaning head and its various components in cross-section;
c and 1d illustrate an alternative filter cleaning head in cross-section;
a is a cross-section of a modular conduit segment for holding the filter cleaning head;
b shows two conduit sections joined together forming a part of a backwashing mechanism for a cylindrical filter element;
a and 6b show an embodiment of a rotor in side view and end view,
a and 7a show the rotor of
a and 8b are perspective views of the rotor of
a and 9b show an alternative embodiment of a rotor where the inner conic helix radius increases at a lesser rate than the outer conic helix radius,
a and 10b show a further alternative where the inner conic helix radius increases at a greater rate than the outer conic helix radius.
a and 11b show an alternative embodiment where the helical pitch is decreased at a lesser rate than the rotor of
a and 12b show an alternative embodiment where the helical pitch is decreased at a greater rate than the rotor of
a and 1b illustrate a first embodiment of the filter cleaning head and its various components. The filter cleaning head element in
c and 1d illustrate an alternative embodiment of the filter cleaning head and its various components. As with the embodiment described above, the filter cleaning head element in
The rotating rotor/nozzle 3 in the embodiment of
The rotor/nozzle 3 in this preferred embodiment is supported for rotating movement on a screw thread 6, the male part of which is an integrated feature of the rotor/nozzle 3 and the female part of which is an integrated feature of nut 7. The screw thread 6 maintains the rotor/nozzle 3 on its axis of rotation.
As with the first embodiment, the filter element 1 receives incoming fluid 8 and provides filtered fluid 9. During filtration, filtered material will build up on the inner surface of the filter element 1. The cleaning head is used in a backwashing process as described below in order to clean the filter element 1 and take filtered material and backwashed fluid 10 away from the filter element 1. In use the filter cleaning heads discussed above each functions in a generally similar way as follows. The rotor/nozzle 3 is initially at a fully retracted position as shown in
Once the backwash flow begins to move, the fluid flow kinetic energy contained in the backwash flow is converted into a torque that rotates the rotor/nozzle 3. The design of the rotor/nozzle 3 in the preferred embodiment includes rotor blades formed as conic helixes which are particularly effective in generating this torque. The conic helix shape of the rotor blades is discussed in more detail below with reference to
The torque from the rotor/nozzle 3 and the consequent rotation thereof is converted into a linear motion of the rotor/nozzle 3 relative to the conduit 2 by the screw thread 6 and nut 7. The rotating rotor/nozzle 3 moves from the retracted position shown in
The accumulated debris on the filter element wall 1 is thus removed from the filter element wall by means of the backwash or reverse flow of process fluid. In normal operation the pressure on the inside of the filter element is greater than that on the outside thereby creating a forward flow of fluid. By enabling a second pressure differential between the outside of the filter element and the inlet to the filter cleaning head forming part of the backwash mechanism a high speed localised (isolated) reverse or back-flow of process fluid is created, causing accreted filter residue to be stripped from the filtration wall 1 and collected by the filter cleaning head. The stripping of debris from the filtration wall 1 is facilitated by the substantial shearing forces created by the high speed backwash flow which in turn are generated by the pressure differential across the filter element wall 1.
The sealing force generated by the rotor/nozzle 3 is selected carefully so as to provide an effective seal between the rotor/nozzle 3 and the inner wall of the filter element 1 whilst avoiding such a high force that deformation of the filter element wall may occur, or that the rotor/nozzle 3 may become stuck against the filter element 1 and is not able to be reversed by an opposing force that might be experienced in normal operation of the backwashing mechanism. Such an opposing force can be usefully applied if the manufacturing tolerance of the filter element 1 requires the rotor/nozzle 3 to ‘back off’ or a short distance so as to accommodate small differences in dimensions of the filter element 1. Providing the sealing force is selected carefully, an opposing force is able to cause a reverse rotation of the rotor/nozzle 3 thus minimising the chance of seizure or damage to the filter element 1. Once the variation in manufacturing tolerance has passed the rotor/nozzle 3 may advance in its normal way towards the filter element wall 1.
When the rotor/nozzle 3 is located at the deployed position shown in
The high speed localised backwash flow generated at the rotor/nozzle 3 causes cleaning of the filter as debris is stripped from the filtration wall 1 and is collected by the filter cleaning head. The stripping of debris from the filtration wall 1 is facilitated by the substantial shearing forces created by the high speed backwash flow.
With this design the filter cleaning head can be used to replace conventional filter cleaning heads employing nozzles such as the spring loaded nozzles of WO 2006/008729 or the bellows type nozzles of WO 2011/058556. As the nozzles of the cleaning heads suffer from wear they are a consumable part and can be replaced during maintenance. Replacing a conventional cleaning head with a cleaning head using a rotor/nozzle 3 as described herein can result in improved performance and can increase the time before the nozzles need replacing again, for the reasons set out above.
a and 3b show a design for the hollow conduit 2 that provides a modular arrangement for a multi-head filter cleaning device for a cylindrical filter element 1. With this design the conduit 2 takes the form of a T-piece with a main flow passage intended to align with the axis of the cylindrical filter element 1 and a branch passage that joins the rotor/nozzle 3, which is as in
It will be appreciated that whilst
b shows two conduits 2 fitted within a cylindrical filter element 1. The filter element 1 is shown in cross-section. The joint between the conduits is designed for a ‘snap fit’ and a further ring seal 13 is included to seal adjacent segments together. With this arrangement it is possible to build up multiple-heads in a cleaning device for various lengths of filter element 1 as required.
In order to effectively clean the internal surface of the cylindrical filter element 1 the rotor/nozzle 3 of each cleaning head should be placed close to the inner surface of the filter element 1 when they are in the retracted position, so that a small rotational movement will place the rotor/nozzle 3 of each cleaning head in contact with the filter surface for effective cleaning. Thus, the lengths of the side branches of the conduits 2 should be set based on the radius of the filter element 1.
The driving mechanism provided by the shaft and motor/gearbox 22 can rotate the backwashing mechanism whilst simultaneously moving the backwashing mechanism in a linear motion along the axis of the filter element 1. Movement may be by means of an electric motor and screw or other electro-mechanical, pneumatic or hydraulic arrangement. As the backwashing mechanism is simultaneously rotated and moved linearly, the filter cleaning heads forming part of the backwashing mechanism follow a helical trajectory. Thus, the filter cleaning heads are able to be conveyed over 100% of the entire inner surface of the filter element 1 such that debris can be collected from all parts of the semi-permeable filtration wall. Thus, the entire surface of the semi-permeable filtration wall can be cleaned of debris.
In use, the filter receives fluid via inlet 15 and passes this fluid 8 to the inside of the cylindrical filter element 1. Filtered fluid 9 is expelled via the outlet 16. When it is necessary to clean the filter, for example when a pressure loss across the filter element 1 has increased beyond a threshold level, the backwashing mechanism is activated. This can be done by a valve 24 or similar control mechanism. This results in a pressure differential between the fluid 8, 9 undergoing filtration and the backwash fluid 10. Fluid therefore flows along the rotor/nozzles 3 resulting in torque that seals the rotor/nozzles 3 against the filter wall as discussed above. Fluid 9 from the outer region of the filter then flows back through the semi permeable filtration wall 1 causing a high speed localised (isolated) reverse or back-flow of process fluid at open end of the rotor/nozzles 3. This results in process fluid and debris moving into the rotor/nozzles 3 of the filter cleaning head, along the hollow conduits 2 to the main flow path of the backwashing mechanism and finally to the backwash outlet region 10. The filter body 14 includes a backwash outlet 23 on which may be installed a suitable control valve 24 and/or a vacuum or suction apparatus 25 that enables the pressure differential causing the backwash process to be initiated.
The drive mechanisms provided by the shafts and motor/gearboxes 22 are arranged to rotate the individual backwashing mechanisms whilst simultaneously moving the individual backwashing mechanisms in a linear motion along the axis of the individual filter elements 1. As for the arrangement of
In use, the backwash fluid passes through the filter wall 1 into the rotor/nozzles 3 and cleans the filter residue in the manner described above. The filter of
In an alternative embodiment, which is not shown, each of the filter elements is provided with a separate outlet or a valve system to permit the separate filter elements to be cleaned independently. This may be useful in systems where the build-up of residue occurs at different rates for the different parallel filter elements.
a and 6b depict an embodiment of a rotor for the combination rotor/nozzle 3 including an outer peripheral rim 30, blades 31 and inner peripheral surface 32. As explained above, the rotor is used to turn the flow of a liquid and the pressure differential during backwashing into rotational movement and torque on the rotor/nozzle 3 to hold the cleaning head against the filter wall 1. The rotor can be mounted to the cleaning device with a screw thread arrangement using a nut held at the axis of rotation of the rotor within body of the rotor inside of the inner peripheral surface 32, hence being mounted as shown in
a and 7b depict the rotor of
a and 8b show perspective views of the rotor of
a and 9b show a variation of the rotor design. In this embodiment the pair of conic helixes 34 and 35 are generated in a clockwise direction and form the shape of the blades 31 in the manner discussed above. However, the radius ri of the inner conic helix 35 increases at a lesser rate than the radius ro of the outer conic helix 34 to thereby form a pair of non-parallel conic helixes that are spaced further apart at the large diameter end of the rotor than at the small diameter end of the rotor.
a and 10b show a further variation in which the radius ri of the inner conic helix 35 increases at a greater rate than the radius ro of the outer conic helix 34 to thereby form a pair of non-parallel conic helixes that are spaced closer together at the large diameter end of the rotor than at the small diameter end of the rotor.
a and 11b show a further variation which has parallel inner and outer cones as in
For the rotating rotor/nozzle 3 the design of the blades and rotor can be optimised for expected operating conditions of the filter, as discussed below with reference to
The geometry of the rotor facilitates the conversion of the kinetic energy in the liquid fluid flow to rotational force or torque. The geometry of the rotor is based on pair of conic helixes 34, 35 that have an increase in radius r with a polar coordinate θ along the longitudinal axis 33, each helix 34, 35 possessing a different initial radius. The pair of conic helixes 34, 35 also have a pitch that decreases with the polar coordinate θ as the radius increases. The decreasing helical pitch provides an increasing helical frequency. This type of conic helix may be defined as a three dimensional spiral having varying radius r as a function of the polar coordinate θ but also having a third variable, the length l, varying also as function of the polar coordinate θ.
The pair of conic helixes may be generated in a clockwise or anticlockwise direction and as shown in
The rotor blade surfaces of the rotor are formed when the pair of conic helixes are connected together in the radial direction. In the rotor shown in the Figures three identical rotor blades 31 are present. There could alternatively be less or more identical rotor blades 31 spaced equally around the rotor. The rotor blades 31 extend between the inner peripheral surface 32 and the outer rim 30 and are fixed to both of the inner peripheral surface 32 and the outer rim 30 for rotation therewith.
A hydrodynamic reaction force is created on a solid surface when a body of fluid flowing over the solid surface experiences a change of momentum. The net hydrodynamic force acting on the body of fluid in a particular direction is equal to the rate of change of momentum of the body of fluid in that direction as dictated by Newton's Second law. In accordance with Newton's Third Law, an equal and opposite hydrodynamic reaction force acts on the solid surface bounding the body of fluid. Examples of such hydrodynamic reaction forces are those found when a jet of water strikes a wall, or the force felt in a pipe system when the fluid is forced to turn a bend or the force felt on a solid body when placed in a flowing fluid forcing the fluid to flow around it.
In the rotor described herein a solid surface bounding the body of flowing fluid is formed by the front and rear of a pair of rotor blades and the inner and outer rims of the rotor. As the body of fluid flows through the specially shaped rotor and its complicated flow passages it is constantly forced to change direction due to the shape of the blades and the decreasing helical pitch from inlet to outlet which results in an increasing helical frequency, thereby resulting in a continuous rate of change of momentum. This rate of change of momentum necessarily results in a hydrodynamic reaction force that acts on the solid surfaces of the rotor. As the conic helix has a given geometrical direction, this being clockwise or anticlockwise, the hydrodynamic reaction force acts in the opposite direction and since the centre of the hydrodynamic reaction force is displaced at a radial distance from the longitudinal axis, a torsional force is generated that acts around the longitudinal axis of the rotor.
The underlying mathematical spiral of the conic helix can be based on Archimedean, Euler, Fibonacci, Hyperbolic, Lituus, Logarithmic, Theodorus or any other known spiral having varying radius r as a function of the polar coordinate θ but also having a third variable, the length l, varying also as function of the polar coordinate θ. For the reasons discussed above, it is apparent that an underlying spiral possessing a more rapid change in inner and outer radius r with the polar coordinate θ would induce a more rapid rate of change of momentum necessarily resulting in an increased hydrodynamic reaction force. This is akin to comparing a shallow bend with a sharp bend. It is well known that the force felt in a pipe system is increased when the fluid is forced to turn the sharper of the two bends.
In the embodiments described above, for reasons of simplicity, the underlying spiral is based upon an Archimedean spiral when there is a linear increase in radius r with the polar coordinate θ. However, it is equally feasible to construct the rotor by way of a non-linear increase in inner and outer radii r with the polar coordinate θ through the use of a different underlying mathematical spiral such as Archimedean, Euler, Fibonacci, Hyperbolic, Lituus, Logarithmic, Theodorus or any other known spiral having varying radius r as a function of the polar coordinate θ but also having a third variable, the length l, varying also as function of the polar coordinate θ. The use of an Archimedean spiral with linear increase in the radii r with the polar coordinate θ provides a conic helix formed about a straight sided frustocone as shown in the Figures. Conversely, a non-linear increase in the inner and outer radii r with the polar coordinate θ would provide a different shape, for example the external and internal conic surfaces may be curved.
In the preferred embodiments illustrated herein, the pair of conic helixes are chosen to have a linear increase in radii r with the polar coordinate θ along the longitudinal axis, each possessing a different initial radius. In some embodiments, as in
The helix shape, radius increase and pitch decrease combine to provide the overall hydrodynamic reaction force on the rotor and thus the torque required to rotate the nozzle and press it against the filter wall. These parameters may be optimised to maximise the power extraction from a given fluid flow or to limit the power extraction from a given fluid flow if required. The following set of equations considers the hydrodynamic reaction forces and torques generated.
{dot over (m)}
in
={dot over (m)}
out
={dot over (m)} 1
F
x
={dot over (m)}(u2−u1) [2.1]
F
y
={dot over (m)}(v2−v1) [2.2]
F
g
={dot over (m)}(w2−w1) [2.3]
T
x
=F
g
×y−F
y
×z [3.1]
T
y
=F
x
×z−F
g
×x [3.2]
T
g
=F
y
×x−F
x
×y [3.3]
As stated in Equation 1, the mass flow {dot over (m)} into the rotor is constant. The hydrodynamic reaction forces Fx, Fy and Fg are necessarily produced due to the continuously decreasing helical pitch or in other words, due to a continuous change in the direction of the fluid flow and thus a change in the velocity components u, v and w of the fluid between the velocity components at first and second arbitrary cross sections in the rotor, the first and second arbitrary cross sections being at different distances along the rotor length. This results in a rate of change of momentum and the hydrodynamic reaction forces as expressed by Equation [2.1] to [2.3]. Observing the right hand rule, the torques Tx, Ty and Tg around the x, y and z axis of the rotor are produced by the out of balance cross product of the hydrodynamic force components and the relevant distances x, y and z from the longitudinal axis about which they act as shown by Equations [3.1] to [3.3].
According to this set of equations it can be understood that a change in the rate of decrease of the helical pitch will result in an increase or decrease in the torsional forces and power output. A decrease in torsional force is achieved by a slower rate of decrease of helical pitch and an increase in torsional force is achieved by a faster rate of decrease of helical pitch.
The distance from the longitudinal axis at which the hydrodynamic reaction forces act is continuously increased or decreased by the change in radius of the pair of conic helixes. For each complicated flow passage a separate set of torsional forces result, the total torsional force around the longitudinal axis of the rotor being the sum of all torsional forces acting around the longitudinal axis of the rotor.
In the case where the increasing radii of the pair of conic helixes increase at the same rate to form a pair of parallel conic helixes this results in an equal increase in the distance from the longitudinal axis at which the hydrodynamic reaction forces act and thus a magnification of the torsional force and power output as determined by Equation [3.1] to [3.3]. In this case, the cross sectional areas at first and second arbitrary cross sections in the rotor increase at a constant rate and since the mass flow is constant, the velocity differences and thus hydrodynamic reaction forces produced are constant. The magnification of the torsional force and power output is only dependent on the rate at which the radius of the pair of conic helixes increases.
Where the radius of the pair of conic helixes increase at greater or lesser rates to form a pair of non-parallel conic helixes, this has the effect of changing the rate at which the cross sectional areas at first and second arbitrary cross sections in the rotor increase. When the inner conic helix increases in radius at a slower rate than the increase in radius of the outer conic helix, the arbitrary cross sectional areas increase at a faster rate. This has the effect of reducing the changes in the velocity components and since the mass flow is constant, the hydrodynamic reaction forces produced are lower. When the inner conic helix radius increases at a faster rate than the outer conic helix radius, the arbitrary cross sectional areas increase at a slower rate. This has the effect of increasing the changes in the velocity components and since the mass flow is constant, the hydrodynamic reaction forces produced are larger. Thus, through manipulation of the parameters of the rotor, it is possible to manipulate the extracted power output and optimise or restrict it as required.
In addition, the connection between the pair of conic helixes is not limited to being straight. The connection may be curved, for example, a concave surface may be used to increase the surface area along the surface of the specially shaped rotor blade in order to spread the resulting hydrodynamic forces over a larger area and reduce internal stresses. Similarly, the pair of conic helixes are generally axially aligned for simplicity but may be slightly misaligned in order to change the surface characteristics of the conic helixes in a beneficial way.
As discussed above, various parameters of the rotor and blade shape can be varied depending on the purpose of the rotor and the operating conditions that it will be exposed to, such as flow rate and so on.
As a baseline.
In some of the variants discussed above, the inner and outer conic helixes are formed on non-parallel conic surfaces.
Other variants discussed above involve the use of different changes in pitch for the decreasing pitch of the conic helixes.
The relationships set out in
It will be appreciated that the cleaning head described above can be used for any filter arrangement and is not limited to the cylindrical filter element and rotating backwash arrangement described above. In the preferred embodiments above the fluid is moving from the inside to the outside of the cylindrical filter element 1 but the reverse direction may also be accommodated. Alternative systems may be used to traverse the cleaning head across the filter wall, as appropriate for the geometry of the filter wall. The cleaning head may be adapted for retro-fitting to any suitable known backwashing mechanism, for example by design of the conduit 2 to join with flow passages of the known backwashing mechanism in an appropriate fashion.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1206003.4 | Apr 2012 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2013/057136 | 4/4/2013 | WO | 00 |
