Patent Application
20190001277
Not applicable
Not applicable
The present invention relates generally to a laundry wastewater or waste fluid treatment device. Particular embodiments relate to a commercial and industrial laundry effluent treatment skid mounted device. The processing effluent from such application can be reused as clean water. The removal of contaminants is both organic and inorganic. This invention is uniquely designed to incorporate individual fiber ceramic membranes, bundled together (e.g., by epoxy, ceramic or glass endcaps) to form a membrane module.
Commercial and industrial laundry operations generate quantities of wastewater that must be disposed of. Such laundry operations can employ large washing machines such as tunnel washing machines. U.S. Provisional Patent Application Ser. No. 62/514,834, filed 3 Jun. 2017, is hereby incorporated herein by reference. Several patents have issued for tunnel washing machines.
The following table lists examples of such patents, each patent listed in the table is hereby incorporated herein by reference:
The present invention relates generally an effluent wastewater treatment apparatus including in one embodiment a skid configuration. The method and apparatus of the present invention can preferably use only two fluid pump units and including individual or multiple membrane modules in a stacked longitudinally arranged configuration. The stacked or in series modules can be either vertical or horizontal forming a column.
The present invention includes one or more hollow fiber ceramic membrane modules which each includes multiple hollow fibers bundled together preferably by end bands or caps (e.g., ceramic, epoxy of glass material end caps) to form a complete membrane module. A complete hollow fiber membrane module can comprise multiple symmetric individual hollow fibers, each between about 2.0 to 4.00 millimeters inside diameter and can be made of aluminium oxide (Al2O3) substrate material.
The geometry of the individual ceramic fiber walls can be between about 1.0 to 2.0 millimeters in thickness, known as the membrane wall. Such ceramic hollow fibers can have pores including a range of nominal 1 nanometer to 1400 nanometers. The ceramic hollow fiber membranes can comprise selective membranes pores including a range of nominal 1 nanometer to 1400 nanometers, which may include individual or multiple separating layers attached to the fiber walls of nominal 1 to 100 nanometers. The separating layers can each be a porous polymeric or porous ceramic material.
In one embodiment, a skid mounted treatment device is preferably operable to pass water through an individual hollow fiber ceramic membrane module or multiple membrane modules in series known as a membrane loop. For example, there can be eighteen (18) modules, three stacked columns of three modules each (or nine modules) on a left side and nine more on a right side. Filtration is preferably inside to out flow filtration through each of the hollow fiber membranes. The apparatus is also preferably operable to pass water through the hollow fiber ceramic filter module or multiple membrane modules in an outside to in backflow direction, so as to remove material from the separation layer of the hollow fiber ceramic membrane fibers, a process known as backwashing or back flushing. Contaminant materials (retentate) having been deposited during inside-out filtration of the commercial or industrial laundry effluent is preferably removed with such back flushing or washing.
The apparatus can include a heater or steam injector and diffuser, operable to heat laundry effluent wastewater to between about 50-80° C. to pass through the hollow fiber ceramic membrane module or membrane modules in series after such heating. This aspect provides a controlled and improved flux and yield of recycled water known as permeate and synergistically improved flux longevity and maintenance of the hollow fiber ceramic membrane modules, which provides further improvements in yield and throughput.
The apparatus can include a program logic controller or software or other controller or instrumentation operable to control the flow device to pass effluent through the hollow fiber ceramic membrane modules according to any selected or desired operating schedule. The controller may be operable to collect and read data defining a maintenance schedule for the skid mounted effluent treatment device.
The apparatus can include a forward-flow function, operable to provide the inside to out filtration process through the hollow fiber ceramic membrane wall.
The apparatus can include a reverse-flow function operable to provide outside to in flow through the hollow fiber ceramic membrane wall, for backwashing or back flushing.
The apparatus may include a membrane cleaning step operable to provide periodical chemical cleaning.
The apparatus may include an ancillary permeate or back wash tank that receives permeate water. This permeate water can provide water to the reverse-flow process or backwash part of the system.
The apparatus may include an inlet conduit operable to receive commercial or industrial laundry effluent wastewater to be filtered by passing through each hollow fiber ceramic membrane of the hollow fiber ceramic membrane modules in a forward direction.
The apparatus may include an inlet conduit operable to receive commercial or industrial laundry recycled fluid known as permeate (in addition to a clean water supply derived from local city sources) to be passed through the hollow fiber ceramic membrane module in a reverse direction, during back washing or back flushing.
The apparatus may include multiple hollow fiber membrane modules to operate individually or in series, stacked as multiple modules creating one or more vertical columns (for example, six stacks of three modules each or a total of eighteen modules).
The apparatus may include hollow fiber membrane modules to operate individually or in series, stacked in multiple preferably creating one horizontal column. The stacking of the membrane modules consisting of multiple hollow fiber membrane preferably provides a compact configuration and high filtration surface area which can reduce overall footprint of the apparatus. In one embodiment, a compact skid arrangement is preferably provided.
The apparatus may include conduits connected to the membrane module or multiple modules in series to channel effluent wastewater into the membrane module or multiple modules in series alternatively, as conduits right and left.
The apparatus may include a conduit connected to the membrane module or multiple modules in series to evenly channel effluent or fluid known as retentate to a selected retentate tank or flow line.
The apparatus may include a hollow fiber ceramic membrane module which preferably holds multiple hollow fibers bundled together by end bands or caps (e.g., ceramic material or epoxy material end bands or caps) to form a complete membrane module. A complete hollow fiber membrane module can comprise as an example multiple (e.g., 200-1500) nominal 2.0 to 4.0 millimeters inside diameter symmetric individual hollow fibers, made of ceramic (e.g., aluminium oxide (Al2O3)) substrate material. The geometry of the individual ceramic hollow fiber walls can be for example about 1 to 2 millimeters in thickness, known as the membrane wall. Such ceramic hollow fibers can comprise of selective membranes pores including a range of between about 1 nanometer to 1400 nanometers.
The apparatus may include a hollow fiber membrane module, which includes between about 200 and 1500 individual ceramic hollow fibers preferably made of a ceramic (e.g., aluminium oxide (Al2O3)) substrate material. The fiber geometry can be between about 2 to 4 millimeters inside diameter, between about 4.00 to 6.00 millimeters outside diameter, length between about 360 to 1000 millimeters, bundled together with either epoxy, ceramics or glass end caps to provide excellent thermal stability and a wide range of pH stability and the ability to operate at high operating temperature of between about 50 to 80 degrees centigrade.
The apparatus may include individual or multiple hollow fiber membrane modules which can include for example between about 200 to 1500 individual ceramic hollow fibers made of ceramic (for example of aluminium oxide (Al2O3)) substrate material. Pore sizes of the aluminium oxide substrate material (Al2O3) can be between about 50 to 1400 nanometers, also but not limited to selective pore sizes of the aluminium oxide substrate material (Al2O3) being nominal 50 to 1400 nanometers, including nominal 1 to 100 nanometers porous ceramic or polymeric coating or multiple separate ceramic porous polymeric coatings, acting as a separating layer attached to the membrane fiber wall. The polymeric coating can be of any porous polymeric material. In one embodiment, each hollow ceramic fiber can have a polymeric or metal oxide or graphene oxide coating on the tube wall. The metal oxide can preferably be, for example, aluminium oxide, zirconia oxide or titanium oxide.
The compact hollow fiber membrane module preferably with selective membrane pores including a range of about 1 to 1400 nanometers separates undesirable matters in the industrial commercial laundry effluent such as and not limited to fine suspended particulates, microbes, bacteria and viruses, coloring matter, colloidal matter and dissolved solids and producing clean permeate for reuse in the laundering process.
One embodiment of the present invention relates to a water treatment apparatus that provides a hollow fiber ceramic membrane module preferably operable to filter effluent passed through one or more of the hollow fiber ceramic membrane modules. A heater or steam injector and diffuser preferably heats the fluid to be filtered by the hollow fiber ceramic membrane module. The apparatus may include a heater or steam injector and diffuser to heat effluent to be passed through the hollow fiber ceramic membrane module in a forward direction. The heater may be used to heat the effluent to about 40 degrees centigrade or more. The heater may be used to heat the water to about 50 degrees centigrade or more. The heater may be used to heat the effluent to within a temperature range of between about 50 to 80 degrees centigrade.
The apparatus may include a feed pump and a circulation pump. The apparatus may include a preliminary filter to filter effluent prior to it being passed through the hollow fiber ceramic membrane module, such as a vibrating mesh screen, to remove larger organic or inorganic material such as lint or fibers.
The apparatus may include multiple valves such as controlled actuated valves (e.g., solenoid actuated valves).
The apparatus may include a pH adjustment device operable to adjust the pH level of permeate water that is preferably discharged from the apparatus.
The apparatus may include a conductivity measuring and adjustment device, preferably operable to adjust the analyse and control the level of conductivity in the permeate monitor to the effluent quality.
The apparatus may include turbidity measuring, preferably operable to analyse the level of turbidity in the permeate water.
The method can include pumping commercial or industrial waste, firstly in a forward direction into a conduit such as “conduit right”, being a stainless steel pipe or header with a diameter of between about 100 to 250 millimeters. The “conduit right” pipe or header preferably transmits flow to the hollow fiber ceramic membrane module or modules in series, so as to enable the hollow fiber ceramic membrane to remove contaminants from the effluent using in to out cross flow, whilst forcing water know as permeate through the fiber wall.
The method may include pumping wastewater in a second forward direction, alternately, into conduit such as “conduit left”, also being a pipe or header with a diameter of between about 100 to 250 millimeters. Flow in the “conduit left” is preferably to the hollow fiber ceramic membrane module or modules in series, so as to preferably enable the hollow fiber ceramic membrane surface using “crossflow” to remove contaminants from the effluent, whilst forcing water know as permeate through each tube wall of the module.
The method of pumping through the inlets right conduit and left conduit may be carried out on an alternating cycles with a backwash in between such “left conduit” and “right conduit” filtration. The “left conduit” can include three (3) vertical columns of three modules each or nine modules total. The “right conduit” could also have nine modules. In one embodiment, filtration is preferably for a longer period of time than backwashing.
The disclosed method of pumping and distributing the contaminated fluid to the inlet conduits “right” or “left” may substantially improve the separation efficiency through every membrane loops with optimised cross-flow rate and lower operating pressure possible.
The method of the present invention may include pumping permeate water from a permeate storage tank into the inlet conduit, to conduits “right” and conduits “left”, preferably flushing the effluent treatment in a third direction with permeate water.
The method of the present invention may comprise pumping fluid such as permeate water from a permeate storage tank, into the inlet conduit in a reverse direction, to conduits connected to the hollow fiber ceramic membrane module or modules in series, dislodging contaminants by way of back washing or back flushing of the hollow fiber ceramic membrane fibers or module or modules in series, lodged on the hollow fiber ceramic membrane surface, during pumping effluent either in first or second directions.
The method of the present invention may include a short backwash timing of for example between about 10 to 60 seconds using permeate water with a tangential flow suited for the plurality of the membrane fibers and modules and thin membrane separating layer structure.
The method of the present invention advantageously helps preserve the efficiency of the membrane separating layers of the hollow fiber ceramic membrane modules and increase its resistance to fouling, preserving the service life of the membrane significantly and reducing the need for membrane chemical cleaning.
The membrane filtration water treatment process may operate on continuous basis, therefore preferably improving permeate recovery rate and preferably minimizing the loss of thermal energy in the commercial laundry effluent, thus preferably providing potential water and energy savings for the industrial commercial laundry application.
The method of the present invention may comprise multiple valves which can be operated preferably by controller, by computer, or program logic control or using control software as examples.
The method of the present invention may include heating wastewater effluent to be forced in the first and second forward directions (e.g., left conduit and right conduit). Some embodiments relate to a process to treat water including filtering water through a pre-filter such as a vibrating screen device and subsequently pumping the effluent through one or more hollow fiber ceramic membrane modules.
Some embodiments of the present invention optionally relate to a computer readable carrier medium, carrying computer executable code, the code operable when executed to configure a configurable device to control a water or effluent treatment device.
Some embodiments of the present invention relate to a computer system including a code memory preferably operable to store processor executable code; a processor preferably operable to execute code stored in the code memory; and a data memory preferably operable to store data; a cloud-based system preferably operable to collect and store data points from the programmable logic control or controls software from the effluent treatment device, wherein the code memory stores code, which when executed, preferably causes the computer to control an effluent treatment device to perform the method of one of the paragraphs above or causes the computer to configure a configurable device to control an effluent treatment device to perform the method of one of the paragraphs above. Some embodiments can use the computer system as part of a computer-controlled effluent treatment system configured to perform the functions various of the system.
The water treatment process of the present invention may not require carbon filtration downstream of the water treatment device.
The present invention includes a method of removing waste from a laundry wastewater stream, comprising the steps of:
a) heating the wastewater stream to a temperature of at least 40° Celsius;
b) transmitting the waste stream with piping to one or more modules, each module having multiple hollow ceramic fibers, each hollow ceramic fiber having a wall with an exterior and a bore;
c) filtering the waste stream to remove waste material from the waste stream by flowing the waste stream from the bore laterally through the wall to the exterior of the wall;
d) collecting a permeate fluid stream in step “c” of cleaned water that has passed through the walls of the hollow ceramic fibers;
e) after a time interval, backwashing each hollow ceramic fiber by flowing a backwash fluid from the exterior of the wall, through the wall and into the bore of each hollow ceramic fiber;
f) wherein in step “e” the backwash fluid is cleaner than the wastewater stream;
g) wherein in step “e”, a fluid stream flows longitudinally through the bore of each hollow ceramic fiber and simultaneously with backwashing to generate a retentate stream; and
h) transmitting the retentate stream to a collection vessel.
In one embodiment, the temperature can be between about 40-90 degrees Celsius.
In one embodiment, the backwash fluid can be permeate fluid that was collected in step “d”.
In one embodiment, the backwash fluid includes clean water.
In one embodiment, the wall of each hollow ceramic fiber can be between about 1 and 4 mm thick.
In one embodiment, the wall of each hollow ceramic fiber can be between about 2 and 4 mm thick.
In one embodiment, there can be multiple of the modules of hollow ceramic fibers.
In one embodiment, each hollow ceramic fiber has a separating layer with a pore size of between 1 and1400 nanometers.
In one embodiment, there can be between about 200 and 1500 of the hollow ceramic fibers in each module.
In one embodiment, the removed material in step “c” includes suspended and dissolved solids.
In one embodiment, the removed material in step “c” includes dye.
In one embodiment, the removed material in step “c” includes dissolved organics.
In one embodiment, the removed material in step “c” includes bacteria and viruses.
In one embodiment, the removed material in step “c” includes colloids.
In one embodiment, the multiple modules are stacked and aligned in series.
In one embodiment, the waste stream flows at a rate of between 10 and 500 gallons (38-1,893 liters) per minute.
In one embodiment, the permeate fluid stream can be transmitted to a washing machine after step “d” at a temperature of at least 35 degrees Celsius.
In one embodiment, each hollow ceramic fiber in step “b” can have an outside diameter of between about 4 and 6 mm.
In one embodiment, each hollow ceramic fiber in step “b” has a length of between about 300 and 1000 mm.
In one embodiment, in step “b” each hollow ceramic fiber includes a ceramic substrate with a pore size of between about 50 and 1400 nanometers.
In one embodiment, each hollow ceramic fiber has a polymeric or metal oxide or graphene oxide coating on the tube wall.
In one embodiment, the filtration of step “c” has a duration of between about 5 and 120 minutes.
In one embodiment, the backwashing of step “e” has a duration of between about 10 and 60 seconds.
In one embodiment, the invention further comprises venting the piping and module or modules to reduce the risk of trapped air before the filtration of step “c”.
In one embodiment, there are multiple loops of stacks of modules.
In one embodiment, the filtration of step “c” includes transmitting the waste stream through the modules in a first flow direction and after the backwashing of step “e” transmitting the waste stream through the modules in a second flow direction that is preferably opposite the first flow direction.
The present invention includes a laundry wastewater treatment apparatus comprising:
a) a piping system having an inflow for receiving the wastewater stream to be treated;
b) a heater for enabling heating of the wastewater stream to a temperature of at least 40° Celsius;
c) the piping including one or more modules, each module having multiple hollow ceramic fibers, each hollow ceramic fiber having a wall with an exterior and a bore;
d) one or more pumps that pump the wastewater stream to the module or modules and laterally through the wall to the exterior of the wall of each hollow ceramic fiber;
e) the piping system including a permeate fluid stream of cleaned water that has passed through the walls of the hollow ceramic fibers;
f) the piping system having valving that enables a backwashing each hollow ceramic fiber by flowing a backwash fluid with the pump or pumps from the exterior of the wall, through the wall and into the bore of each hollow ceramic fiber;
g) wherein the backwash fluid is cleaner than the wastewater stream;
h) wherein the pump or pumps transmit a fluid stream that flows longitudinally through the bore of each hollow ceramic fiber and simultaneously with backwashing to generate a retentate stream; and
i) a retentate stream collection vessel that receives retentate from the modules.
In one embodiment, the temperature of the wastewater stream is between about 40-90 degrees Celsius.
In one embodiment, backwash fluid is from the permeate fluid that was collected in step “d”.
In one embodiment, the backwash fluid includes clean water.
In one embodiment, the wall of each hollow ceramic fiber can be between about 2 and 4 mm thick.
In one embodiment, there are multiple of said modules of hollow ceramic fibers.
In one embodiment, each hollow ceramic fiber has a porous polymeric separating layer with a pore size of between 1 and1400 nanometers.
In one embodiment, there are between about 200 and 1500 of said hollow ceramic fibers in each said module.
In one embodiment, the retentate includes suspended and dissolved solids.
In one embodiment, the retentate includes dye.
In one embodiment, the retentate includes dissolved organics.
In one embodiment, the retentate includes bacteria and viruses.
In one embodiment, the retentate includes colloids.
In one embodiment, the multiple modules are stacked and aligned in series.
In one embodiment, the wastewater stream flows at a rate of between 10 and 500 gallons (38-1,893 liters) per minute.
In one embodiment, the invention further comprises a washing machine and wherein the permeate fluid stream flows to the washing machine with a flow line at a temperature of at least 35 degrees Celsius.
In one embodiment, each hollow ceramic fiber has an outside diameter of between about 4 and 6 mm.
In one embodiment, each hollow ceramic fiber has a length of between about 300 and 1000 mm.
In one embodiment, each hollow ceramic fiber includes a ceramic substrate with a pore size of between about 50 and 1400 nanometers.
In one embodiment, each hollow ceramic fiber has a porous polymeric coating on the hollow ceramic fiber wall.
In one embodiment, there are multiple loops of stacks of modules.
In one embodiment, the invention further comprises a skid or base and wherein all or part of the piping system is mounted on the skid or base.
In one embodiment, the invention further comprises a skid or base and wherein all or part of the pumps is mounted on the skid or base.
In one embodiment, the invention further comprises a skid or base and wherein all or part of the modules is mounted on the skid or base.
In one embodiment, the piping system includes permeate and retentate flow lines supported upon the skid or base.
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
Feed tank or vessel 14 receives flow from sump 15 and screen 13 via flow lines 16, 17. Feed tank 14 transmits the wastewater stream 12 to the various pump, valve and treatment module components that can be skid mounted on skid or base or frame 62 (see
The method of the present invention intermittently alternates fluid to a left hand side membrane loop conduit 39 then to the right hand side membrane loop conduit 40 via a 180 degree elbow 94. In between the left hand conduit filtration (see
In one embodiment, the method includes heating the wastewater stream or effluent held in a feed tank 14 by way of a valve 21 (e.g., actuated control valve) and heater or steam injector line 20. Feed tank 14 can have a level control and overflow line 19. Steam or heater 20 may be operable to heat the wastewater or effluent in tank 14 to about 40 degrees centigrade or more. The heater 20 may be operable to heat the effluent to about 50 degrees centigrade or more. The heater 20 may be operable to heat the effluent to within a temperature range of about 50 to 80 degrees centigrade. The heater 20 may be operable to heat the effluent to about 60 degrees centigrade or more.
Once effluent 12 is at a temperature of between about 50 and 80 degrees centigrade, the feed pump 22 is enabled to a set point of between about 1-10 bar. Pump 22 receives flow from feed tank 14 via line 23 with valve 24. Pump 22 pumps to line 26 which is an inlet conduit. From pump 22, flow goes to pump 25 (circulation pump) and through valve 35 or 36 to the filtration modules 44 or 45. There are two (left and right) conduits 39, 40 each with multiple modules 44 or 45. Each module 44 or 45 is preferably contained in a stainless steel conduit or pipe 39 or 40 that enables filtered water to be collected after filtration through each hollow fiber ceramic membrane 46. The stainless steel conduit or pipe 39, 40 also preferably contains fluid used for backwash in an out to in flow path (seen in
In
Pump 22 supplies the wastewater 12 to circulation pump 25 via line 26 and valve 27. Tee fitting 32 connects line 26 and 33. Pump 25 discharges into line 31 and tee fitting 34 which provides selective transmission of fluid to either line 37 or 38 depending upon the open or closed state of valves 35, 36.
A circulation is enabled during filtration by transmitting the wastewater 12 in a first direction through lines 39, 40 and modules 44, 45 and back to circulation pump 25 via flow line 33.
Retentate line 41 enables transmission of retentate to feed tank 14 via valves 42, 43. Part of the retentate stream of line 41 can be discarded to drain or sewer 49 via drain line 47 and valve 48. Permeate flow lines 50, 51, 52 transmit cleaned fluid from modules 44, 45 to permeate tank 57. Line 52 has valve 88. Permeate lines 50, 51 connect to line 52 at tee fittings 54, 55. Permeate tank 57 can be used for backwashing (
The filtration of
Channels 79 of membranes 46 are open ended so that wastewater 12 enters channel 79 at a first end 81 then exits channel 79 at a second end 82. Membrane 46 can have a generally cylindrically shaped wall 84 surrounding channel 79. Wall 84 has inner surface 83 with a separating layer of porous polymeric material or porous ceramic material.
In
The present invention can optionally use cleaning in place. Cleaning in place can include the external injection from clean in place dosing tank 28 and pump 29 and via line 30 into the commercial or industrial laundry effluent treatment device of an alkali or acidic solution into the feed tank 14, mixed with clean water being city or permeate water. Clean in place is operable to preserve, maintain or restore the clean fluid permeation flow through the ceramic hollow fiber wall 84, being either individual or multiple hollow fiber membranes 46, which preferably includes nominal 220 to 1500 individual ceramic hollow fibers 46 preferably made of a substrate such as an aluminium oxide (Al2O3) substrate material. Selective pore sizes of the aluminium oxide substrate material (Al2O3) can be about 50 to 1400 nanometers, also but not limited to selective pore sizes of the aluminium oxide substrate material (Al2O3) being nominal 50 to 1400 nanometers, including nominal 1 to 100 nanometers ceramic or porous polymeric coating or multiple separate porous ceramic or polymeric coatings, acting as a separation layer attached to the membrane fiber wall at 83. In one embodiment, each hollow ceramic fiber 46 can have a polymeric or metal oxide or graphene oxide coating on the tube wall 84. In one embodiment, each hollow ceramic fiber can have a polymeric or metal oxide or graphene oxide coating on the tube wall. The metal oxide can preferably be, for example, aluminium oxide, zirconia oxide or titanium oxide. In
The treatment equipment 10 shown in the drawings should be completely vented of air before filtration of
The following is a list of parts and materials suitable for use in the present invention:
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
This application claims benefit of U.S. Provisional Patent Application Ser. No. 62/514,828, filed 3 Jun. 2017; and U.S. Provisional Patent Application Ser. No. 62/514,834, filed 3 Jun. 2017, each of which is hereby incorporated herein by reference. Priority of U.S. Provisional Patent Application Ser. No. 62/514,828, filed 3 Jun. 2017; and U.S. Provisional Patent Application Ser. No. 62/514,834, filed 3 Jun. 2017, each of which is hereby incorporated herein by reference, is hereby claimed.
| Number | Date | Country | |
|---|---|---|---|
| 62514828 | Jun 2017 | US | |
| 62514834 | Jun 2017 | US |
