US20190100450A1 - Systems and methods for treatment processes - Google Patents

Abstract

Systems and methods for aeration and mixing processes are disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• This application claims priority to U.S. Provisional Patent Application No. 62/565,833, filed Sep. 29, 2017, wherein the contents of the foregoing is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
• The present invention relates to control systems and methods, particularly systems and methods for implementing and controlling mixing and aeration processes, such as in wastewater treatment.
BACKGROUND
• Methods and systems for treating wastewater are known in the art. Such methods may include aerobic, anoxic, and anaerobic processes.
SUMMARY OF THE INVENTION
• The present invention includes systems and methods as described herein.
• The present invention may be better understood by reference to the description and figures that follow. It is to be understood that the invention is not limited in its application to the specific details as set forth in the following description and figures. The invention is capable of other embodiments and of being practiced or carried out in various ways.
BRIEF DESCRIPTION OF THE DRAWINGS
• These and other features, aspects, and advantages of the present invention are better understood when the following detailed description is read with reference to the accompanying drawings, wherein:
• FIG. 1 is a side cut-away view of a basin with mixing and aeration components for use in conjunction with an embodiment of the present invention;
• FIG. 2A is a front cutaway view of a controller box for an exemplary embodiment of the present invention;
• FIG. 2B is a front cutaway view of a controller box for an alternative exemplary embodiment of the present invention;
• FIG. 3A is a schematic diagram showing components of a control system an embodiment of a system of the present invention;
• FIG. 3B is schematic diagram showing components of an alternative control system an embodiment of a system of the present invention;
• FIG. 4 is a detailed view of certain components of the embodiment shown inFIG. 1;
• FIG. 5A is a detailed view of certain components of the embodiment shown inFIGS. 1 and 4;
• FIG. 5B is a detailed view of certain components of an alternative embodiment of the configuration shown inFIG. 5A;
• FIGS. 6A-6C are detailed views of an embodiment and its components of an exemplary nozzle in conjunction with an embodiment of the present invention;
• FIG. 7 is a schematic view showing the flow of gas through the nozzle ofFIGS. 6A-6C pursuant to an embodiment of the present invention;
• FIG. 8A is a view of an alternative embodiment of a nozzle of the present invention;
• FIG. 8B is a top view of the nozzle ofFIG. 8A;
• FIG. 9A is a view of a header in communication with a first line in accordance with an embodiment of the invention;
• FIG. 9B is a view along line A-A ofFIG. 9A;
• FIG. 10 is a view of an embodiment of an adjustable nozzle orifice of the present invention;
• FIGS. 10A-10D are cross-sectional views of various settings of the adjustable nozzle orifice ofFIG. 10 from the perspective of B-B (at various adjustments of the nozzle shown inFIG. 10);
• FIG. 11A is a view of an alternative embodiment of a basin with mixing components for use in conjunction with an embodiment of the present invention;
• FIG. 11B is a view of an additional alternative embodiment of a basin with mixing components for use in conjunction with an embodiment of the present invention;
• FIG. 11C is a view of an additional alternative embodiment of a basin with mixing components for use in conjunction with an embodiment of the present invention
• FIG. 12 is a schematic view of an embodiment of the present invention including reservoir tanks; and
• FIG. 13 is a detailed view of certain mixing and aeration components in an alternative embodiment of the present invention.
• Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
• Reference will now be made in detail to various embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation, not limitation, of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope and spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
• Systems and methods of the present invention may be used in connection with various treatments or storage of substances. By way of example, the embodiments of the present invention may be utilized in the treatment of wastewater, such as in aerobic, anaerobic, and anoxic wastewater treatment phases. In other applications, may be used in storing substances. One of ordinary skill in the art will appreciate that such uses are for illustrative purposes only and are not intended to limit the full scope of the invention disclosed herein.
• Referring toFIG. 1, a cut-away perspective view of an exemplary wastewater treatment mixing system1 is shown. The system1 includes a containment unit for wastewater, which is shown inFIG. 1 asbasin2 having foursidewalls4 and abottom6. One of ordinary skill in the art will appreciate that alternative types of containment units, such as tanks, vessels, channels, lagoons and ditches, are also within the scope of the present invention. The containment unit may additionally have an inlet through which wastewater enters and an outlet through which the treated wastewater exits. In some embodiments, the containment unit may allow for continuous flow of the wastewater whereas other embodiments may restrict the flow of the wastewater. In some embodiments, multiple containment units, of the same type or of differing types, may be present and connected such that the wastewater passes through them sequentially or not connected such that wastewater passes thru them in parallel. The remaining components of the wastewater treatment mixing system1 of the present invention are shown in more detail in additional figures and described therewith.
• With further reference toFIG. 1, a source of compressed air is shown outside ofbasin2 as acompressor8, although the placement ofcompressor8 can be in any suitable location for a particular application.Compressor8 is connected to supplyline10, which feeds into acontroller box12. Aconventional regulator9 or a throttling valve (not shown) may be placed along the supply line to regulate the pressure or flow rate of pressurized gas from thecompressor8. In other embodiments, any suitable pressure or flow rate control device may be utilized. In the depicted embodiment,controller box12 is located outside ofbasin2, but it is understood that the precise placement ofcontroller box12 may vary.
• Controller box12 is shown in further detail inFIG. 2A, in which, in the particular embodiment depicted,controller box12 includes eightvalves14 with each having asolenoid valve16. In some embodiments, alternative types of valves or flow control devices may be used as an alternative to solenoidvalves16.Valves14 are connected withsupply line10. Eachvalve14 has anexhaust pressure sensor15 that is in communication with a programmable logic controller (PLC)20. Eachpressure sensor15 provides a signal to thePLC20 each time thevalve14 to which it is attached opens and closes. If the signals do not fall within a predetermined range, thePLC20 generates a fault signal to the plant process control system (not shown) or to the operator. In this manner, mixing system1 includes an alert for certain malfunctions, such as when avalve14 is stuck open or stuck closed.PLC20, which can include a memory (not shown) and a processor (not shown), is also capable of selectively opening and closing eachvalve14 located incontroller box12. In other embodiments, systems may also be utilized in the context of this invention that use manual manipulation of valves instead of the computerized control system described above.
• In an alternative embodiment, as shown inFIG. 2B,controller box12 is again shown with eightvalves14 with each having asolenoid valve16.Valves14 are connected withsupply line10.Electronic throttle valve99 andpressure sensor95 are located in connection withsupply10 insidecontroller box12. In addition,pressure sensor15 is located insidecontroller box12 on asingle header18. In alternative embodiments, a plurality of headers or all headers may have apressure sensor15. In addition, any components shown insidecontroller box12 could alternatively be located on its exterior.
• As shown inFIG. 3A, each of programmable logic controller (PLC)20 and programmable logic controller (PLC)200 is in communication withcontrol panel17. As used herein, reference to “in communication with” indicates that data and/or signals are transferable between the referenced components, and such reference includes both physical connections and wireless connections. In addition, “in communication with,” whether used in connection with data or otherwise, also includes embodiments in which the referenced components are in direct connection (i.e., directly connected to each other with a cable) as well as indirect connections, such as when data is transmitted through an intermediate component and either relayed in the same format or converted and then relayed to the referenced component.
• In some embodiments, an alternative configuration may be present other than shown inFIG. 3A. For example, in some embodiments, a PLC may not be present or may be present in an alternative configuration. In addition, in someembodiments PLC20 andcontrol panel17 may be combined within a single device. For example, inFIG. 3B, asingle control panel17′ is shown that may optionally include all of the functions discussed herein forcontrol panel17,PLC20, andPLC200. In addition, in some embodiments,control panel17 may not include a PLC. In other embodiments, more than onecontrol panel17 and/or more than onePLC20 may be present. Although not shown,control panel17 orcontrol panel17′ may also be in communication withsolenoid valve16,pressure sensor15,pressure sensor95, and/orelectronic throttle valve99.
• In some embodiments, control panels used for the present invention may include any machine having processing capacity, such as, by example, a machine having a processor, a memory, and an operating system. In some embodiments,control panel17 may include an interface for inputting such manual instruction. By way of example, and without limitation, control panels may include one or more of a personal computer, handheld computer, microcontroller, PLC, smartphone, and/or tablet. In still other embodiments,control panel17 may be any device capable of controlling the operation of a mixing system, such as a timer.
• In some embodiments,control panel17 may be located withincontroller box12, in its proximity, or at a remote location, such as within a treatment facility or another site. In addition, an existing facility may have existing PLCs or control panels or hardware such as mixers and aerators, and the present invention could be interfaced with those existing systems, such as by loading software to perform the processes described herein and communicate with the previously-existing structures. Furthermore, as noted,control panel17 may be remotely accessible, and it may be configured to a network or internet connection. In addition, in some embodiments,control panel17 and/orPLC20 may be connected to a wireless and/or wired network. In addition,control panel17 may permit an operator to manually control the processes and system components, such as manually overriding the automatic control and activating or deactivating aeration to the wastewater.
• Referring again toFIG. 3A,PLC20 is also in communication with and receives input fromORP probe processor109,nitrate probe processor111,ammonia probe processor113,DO probe processor115, andpH probe processor125. In other embodiments, some or all ofORP probe108,nitrate probe110,ammonia probe112,DO probe114, andpH probe124 may be in communication with a single probe processor. Other probes may alternatively or additionally be utilized, such as, without limitation, level sensors, flow meters, total suspended solids probes, or any device providing information about the system and/or content of the containment unit. In other alternative embodiments, a probe processor may be omitted for some or all probes and some or all probes may be in direct communication withPLC20 without a probe processor. However, as noted above, alternative configurations may be present in other embodiments.
• Referring again toFIG. 1, system1 further includes foursupply headers18 made of polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), chlorinated polyvinyl chloride (CPVC), fire retardant polypropylene (FRPP), or stainless steel piping, wherein eachsupply header18 is connected to avalve14 incontroller box12.Supply headers18 extend fromcontroller box12 towardbottom6 ofbasin2.Supply headers18 also extend in a pattern parallel with bottom6 in an arrangement in which they are at substantially equally-spaced intervals. As apparent to an ordinary artisan,supply headers18 can be made of a single, continuous component or, in an alternative embodiment,supply headers18 can be constructed from multiple components joined by conventional measures, such as welding, adhesive, threading, bending, use of a connector, or other known measures or combinations thereof. In addition, the headers, as well as all of the piping in this system, can be of any construction and material that meets the particular needs of the mixing system. For example, the piping can be made from plastic, galvanized steel, stainless steel, carbon steel, copper, ABS, PVC, FRPP, CPVC, or any other material from which piping is typically formed and which meets the requirements of the particular system. It should also be appreciated that in other embodiments, the location ofsupply headers18 can be varied. By way of example,headers18 can run abovebasin2. In addition, one or more headers may be placed in distinct locations, such as enteringbasin2 at different points.
• In the embodiment depicted inFIG. 1, and as also shown in more detail inFIGS. 4-5A, each of thesupply headers18 has afirst line22 that extends substantially perpendicular from eachsupply header18 and that are substantially parallel tobottom6. It is understood thatfirst lines22 can extend at different angles in other embodiments. As seen inFIGS. 4 and 5A,first lines22 are connected to supplyheader18 using a T-type connector19 withcap21 sealing the unconnected branch, although any conventional means for connecting can be employed and such means are readily known to a person having ordinary skill in the art. Alternatively, for example,supply header18 can be integral tofirst line22 or welded, bonded, or otherwise connected thereto either with or without a connector of any suitable type. In still another embodiment,header18 andfirst line22 may be joined by a coupling, such as a threaded coupling, wherein such a coupling may optionally include an orifice as discussed below. In still other embodiments, as shown inFIG. 5B, a singlefirst line22 may be present, optionally having an L-shape in order to provide the same design as that shown inFIG. 5A but using a single, integralfirst line22 that is bent or curved to provide an L-shape or elbow instead of connectingfirst line22 andsecond line24 to obtain that shape shown inFIG. 5A. Althoughfirst lines22 are depicted in a staggered layout, i.e., eachfirst line22 extends in the opposite direction from the previous and subsequentfirst lines22, other layouts are within the scope of the present invention. Although, certain advantages may be achieved with the particular layout depicted in the figures hereof.
• In some embodiments of the present system,first lines22 andsecond lines24 each have an inner diameter that is smaller than the inner diameter ofsupply header18 to which they are in communication. In some embodiments,first lines22 have an inner diameter equal to the inner diameter of thesupply header18 to which it is connected, and the correspondingsecond lines24 has a smaller inner diameter. In addition, some embodiments may not include afirst line22, andsecond line24 may connect to supplyheader18. As indicated,second line24 may be a vertical pipe or line extending fromfirst line22. However, in some embodiments, eitherfirst line22 orsecond line24 may be omitted or alternative configurations may be employed without departing from the scope of the present invention.
• In still other embodiments,headers18 may extend across a containment unit, such asbasin2, above the basin, at the surface level of the basin, immediately under the surface level of the basin, or near the top area of the basin. In some embodiments,headers18 may be submerged within a solution, such as wastewater inbasin2, and inother embodiments headers18 may be above such solution. In similar fashionfirst lines22 and/orsecond lines24 may be configured accordingly to positionnozzles30 withinbasin2, such as at or nearbottom6 ofbasin2. In some instances, such embodiments may offer benefits such as ease of interchangeability of components (such as nozzles), ease of access to headers for maintenance or replacement, and other potential benefits.
• By way of example,FIG. 11A illustrates an embodiment in whichheaders18 extend at, near, or above the surface level ofbasin2. Such headers may optionally be secured using any suitable type of bracings or brackets. In some embodiments, headers located at, near, or above the surface level of a containment unit may be located near an edge of such unit, thereby rendering it more easily accessibleFirst lines22 extend vertically downward to connectheader18 to respective nozzles.Valves28, which may be any suitable type to control or stop flow, are located onfirst line22. In other embodiments, additional lines may be present betweenheader18 and anozzle30. In some embodiments,first lines22 may be removably connected toheader18, andnozzle30 may be removably coupled tofirst line22. In this manner, by way of example,first line22 may be disconnected fromheader18 and removed, along with attachednozzle30, thereby makingfirst line22 andnozzle30 accessible for maintenance, servicing, or any other purpose. Components for aeration, such as shown inFIG. 1 may also be present but are not illustrated.
• In alternative embodiments, such as shown inFIG. 11B,headers18 may connect, directly or indirectly, to asingle nozzle30. As shown,header18 is secured to a wall ofbasin2 usingbrackets27.Nozzle30 is connected toheader18 via second line24 (extending vertically in basin2) and first line22 (extending horizontally in basin2). In some other embodiments, such as shown inFIG. 11C,first line22 may extend vertically downward from a header to connect to a nozzle without any second line. In such embodiments such as inFIG. 11C, a vertically downward connector (not shown) may be present to connectheader18 tofirst line22, and such a connector may have a valve such that flow may be restricted or stopped tofirst line22, such as if were desired to removefirst line22 for maintenance or service.
• With respect to the embodiments ofFIGS. 11B-11C, the embodiment ofFIG. 11B, the connection of a header to a single nozzle allows in a different manner for localized varying mixing intensity within a basin, wherein flow to a specific nozzle or group of nozzles may be controlled in the same manner as described above. In addition, single nozzles may be isolated and flushed with liquid, or alternatively pressurized or mechanically rodded, such as to clear blockages. In addition, in any embodiment relating toFIG. 11A-11C, a removable cap, such as described above, may be located near a first line or second line to allow for maintenance or inspection.
• In some embodiments,headers18,first lines22, and/or any other gas or aeration lines, or any connector associated therewith, may have aremovable cap25. Such a removable cap, which may be threaded or otherwise securely attachable and detachable, permits the removal to access the interior of a pipe or line, such as for easy cleaning or debris removal from the system. In some embodiments, suchremovable caps25 may be present at one or more distal ends of aheader18 and/orfirst line22. In addition, in some embodiments aparticular header18 and/orfirst line22 may have more than oneremovable cap25. In addition, in some embodiments, a connector between any ofheader18,first lines22, orsecond line24—such as T-Type connector19 or T-type connector23—may have an additional opening (not shown) that has a removable cap. Exemplary illustrations for positioningremovable caps25 are shown inFIG. 4.
• Attached to eachfirst line22 is asecond line24, which extends in the same general direction assidewalls4. As shown inFIGS. 1 and 3, eachsecond line24 is connected to anozzle30 at the distal end ofsecond line24 opposite thesupply header18. The connection betweensecond line24 andnozzle30 can be made by any conventional measures, such as those discussed above. It is understood that in other embodiments, thesecond line24 can extend at different angles. In the depicted embodiment, as shown inFIG. 4,first line22 andsecond line24 are connected using a T-type connector23 and are generally at a 90° angle with respect to one another.
• Any suitable types of nozzles may be used in connection with the present invention. By way of example, nozzles disclosed in U.S. Pat. No. 8,508,881, which is incorporated herein in its entirety by reference, may be utilized. An illustrative nozzle is shown inFIGS. 6A-6C asnozzle30. As shown in this illustrative embodiment,nozzle30 includesnipple32, which is hollow to permit gas flow, anupper plate34, alower plate36, andspacer37.Upper plate34 andlower plate36 are parallel to each other and are spaced apart byspacer37 such thatchannel38 is formed between them, whereinchannel38 hasoutlets40 at each distal end.
• In other embodiments, multiple channels are present, wherein each channel may have an outlet at each distal end. By way of example, one embodiment of a nozzle of the present invention has a nipple that connects with three channels, wherein each channel has an outlet at each distal end. In yet another exemplary embodiment, as shown inFIGS. 8A and 8B, anozzle30 may have twochannels38 forming a cross configuration with each channel having anoutlet40 at each distal, thus providing fouroutlets40.Nozzle30 may be constructed in any suitable manner, including optionally in a similar manner tonozzle30 by using anipple32, anupper plate34, and alower plate36.
• One of ordinary skill in the art will appreciate that alternative constructions may be used to provide nozzles having channels and outlets as described herein. By way of example, an upper plate or lower plate may be an otherwise solid structure having a channel etched or formed therein, which is covered by an upper plate or lower plate to form a closed channel without the use of any spacers. In still other embodiments, a nozzle may be entirely integrally formed as a single structure having a channel formed therein as opposed to being constructed from assembled plates.
• In addition, as shown in the exemplary embodiment shown inFIGS. 1-2,nozzles30 are displaced throughoutbasin2 in a grid pattern, with five nozzles in communication with each supply header by way of asecond line24 and afirst line22, and the nozzles are shown in a staggered pattern. In other embodiments, more or fewer nozzles can be in communication with a header. In yet other embodiments, the arrangement of the nozzles can vary, including being on the same side of a supply header (as opposed to staggered) or below the supply header. In addition, in even further embodiments, the supply header may be of a circular shape or serpentine shape as opposed to the linear grid depicted inFIG. 1. The particular arrangement of a mixing system of the present invention can depend upon the size of a containment unit and the particular process being performed, and additional and alternative arrangements are appreciated by a person having ordinary skill in the art. In some embodiments, the nozzles may be placed approximately five to ten feet longitudinally along a supply header and offset approximately one to four feet from the header. In addition, as shown in the embodiment inFIGS. 1, 3, and 4,nozzles30 are located on the bottom of the basin. In some embodiments,nozzles30 can be attached to thebottom6 ofbasin2. In yet other embodiments,nozzles30 are placed above thebottom6 ofbasin2.
• In some embodiments, systems and methods of the present invention may include a flow control feature. In particular, in supplying gas to eachfirst line22 from aheader18, the gas may distribute unequally to each first line22 (and the nozzle associated therewith). By way of example, gas may be supplied more freely to thefirst line22 that is closest to thecompressor8 supplying the gas, and gas may flow less freely to the remainingfirst lines22 and their respective nozzles.
• In some embodiments, to obtain uniform or nearly uniform flow to all nozzles connected to a particular header, the present invention may include orifices, which may be located at any location between aheader18 and anozzle30. For example, in some embodiments an orifice may be configured for each connection point ofheader18 with afirst line22. In some embodiments, an orifice may be located, alternatively or additionally, in eachsecond line24. Alternatively or additionally, an orifice could be located in the nozzle, such as, by way of example, in the portion of the nozzle connected to or adjacent to a second line. Orifices may be a relatively smaller passageway that limits flow from the header to the nozzle. In some embodiments, a check valve (not shown) may be used in addition to or instead of an orifice. Such check valves permit flow of gas from the header to the nozzle but do not permit backflow from the tank to the header. By using an orifice or check valve as described herein, the gas in the header may be provided in a generally equalized manner to each nozzle associated with that header. In addition, check valves offer an additional advantage of preventing backflow into the system, which could result in clogs and other problems in the system. The cracking pressure (at which flow is permitted in the output direction) can be selected for any particular system. Similar flow control measures may also be installed, if desirable, within the aeration components.
• By way of example,header18 may have a diameter, such as two inches, that is greater in diameter than eachfirst line22, such as one inch. In some embodiments, an orifice may be configured near a connection point whereheader18 joins eachfirst line22, such that the opening at that junction is at a desired diameter. For example, if aheader18 has a diameter of two inches and afirst line22 has a diameter of one inch, an orifice at the junction ofheader18 andfirst line22 may have a diameter of one-half inch. An example of such a configuration is shown fororifice33 in the section view ofFIG. 9B along the line A-A ofFIG. 9A. The shaded area betweenfirst pipe22 andorifice33 may be formed in any suitable manner, such as by an insert or a modification tofirst line22, an insert or modification toheader18 at the junction withfirst line22, or the configuration of any type of connector used to joinheader18 tofirst line22.
• As noted, such an orifice of any size could additionally or alternatively be located at other locations. In some embodiments, such orifices may be configured to provide a particular pressure to a nozzle and the orifice size may be configured to provide such a desired pressure based upon the particular specifications of a system, either through calculation or trial and error. In some embodiments, orifice configurations of the present invention may be replaceable or interchangeable, such that the orifice size may be changed. In still other embodiments, orifices of the present invention may be adjustable, such as during installation.
• In some embodiments of the present invention, an orifice size may be altered as a function of the distance from the air source. In this regard, the orifice size may be increased or decreased for supply air to nozzles farther away from the source of air relative to nozzles that are located closer to the air source. Such deviations may promote, in some embodiments, a more uniform distribution of gas for mixing to the nozzles.
• An illustrative embodiment of an adjustable orifice positioned at a nozzle is shown inFIG. 10. As shown,nozzle30 is partially obstructed and partially open, andorifice33 is disposed onnipple32. As shown,orifice33 is shown as a half-moon shape, although other shapes and orifice sizes may be utilized in a particular embodiment.Connector35 is connected to nipple32 andconnector35 is capable of rotation aboutnipple32. Such rotation results in increasing or decreasing the exposed portion oforifice33, thereby controlling the amount of pressurized gas that may pass throughorifice33 during operation.FIGS. 10A-10D illustrate various exemplary adjustments that alter the size oforifice33, thereby regulating gas flow to the associated nozzle. Such adjustments may be made during installation of a system or subsequent to installation of the system. In addition, although shown inFIG. 10 in the context of a nipple, an adjustable orifice of this configuration or similar configurations may also be positioned at any location between a header pipe and a nozzle. For example, an orifice may be positioned in afirst line22 and aconnector35 may be disposed between aheader18 and suchfirst line22, thereby providing an adjustable orifice.
• In some embodiments, systems of the present invention may also utilize receiver tanks. In operation, gas velocity insupply line10 andreceiver tank5 may be low, but air velocity betweenreceiver tank5 and the containment unit, such asbasin2, may be high. A receiver tank, as described herein, may minimize piping headloss and the need to oversize piping. In this regard, such receiver tanks may be employed to negate any hydraulic differential between containment units and may facilitate the use of a common compressor for two or more containment units with different tank levels, volumes, or amount of substance therein.
• With reference to inFIG. 12, an exemplary embodiment utilizing receiver tanks is shown. As shown,compressor8 is connected to and providing air to one ormore aeration basins2 and one or moresludge holding tanks2′ by way ofsupply lines10. In the depicted embodiment,supply line10 connectscompressor8 toreceiver tanks5. Receiver tanks may be located at any point between a compressor and a control panel for valves as described above. In some embodiments, a receiver tank may be positioned in close proximity to the valves controlling entry of air intoheaders18. As one of ordinary skill in the art would appreciate, alternative mixing systems, such as mechanical mixers, submersible mixers, surface mixers, agitators, static mixers, and hyperbolic mixers, may be used withbasin2 or any containment unit for wastewater and are within the scope of certain embodiments of the present invention. Similarly, the number of mixing components and layout of the mixing components may vary within the scope of the present invention. In addition, the number and arrangement of mixing components may vary in other embodiments of the present invention. Furthermore, as used herein, the terms “connected” and “attached,” and variations of those terms, includes, unless indicated otherwise by the context, components that are in direct connection and components that are indirectly connected by way of other components.
• In some embodiments of the present invention,basin2 may also be equipped for aeration. For example, as shown inFIG. 1, embodiments of the present invention may include diffuser heads100 as the aerators, and eachdiffuser head100 is serially connected to adiffuser pipe102. Each depicteddiffuser pipe102 is then connected withheader pipe104, andheader pipe104 is connected withsupply pipe106.Supply pipe106 is connected toblower108, which delivers air or oxygen under pressure to eachdiffuser head100 by way ofsupply pipe106,header104, anddiffuser pipe102.Valve109 is connected withblower108 to control the flow of air to supplypipe106. In addition,valve109 is in communication withPLC20′, which may control its opening and closing.
• Various modifications to the illustrative embodiment are included within the scope of the present invention. In some embodiments, diffuser heads100 may be located in proximity to bottom6 but are not flush withbottom6. In addition,diffuser pipe102 may be secured tobottom6 or located abovebottom6 andsupply pipe106 may be secured to aside4 ofbasin2. In some alternate embodiments, a system may includemultiple supply pipes106, wherein eachsupply pipe106 may be connected to avalve109.
• Whether a single or multiple supply pipes, in the same manner as described above in the context of mixing, a control panel and/or PLC may optionally be used in connection with the valves to selectively control the supply of air or oxygen to each diffuser pipe. In such circumstances, thesame PLC20 andcontrol panel17 used for controlling mixing may also be used to control aeration, or a separate PLC or control panel may be used.
• In an alternative embodiment of the invention, as shown inFIG. 13,diffuser pipe102 may abut or be adjacent to or attached to supplyheader18. In such embodiments,diffuser pipe102 may be secured toheader18 by any suitable means, such as cable ties, clamps, or other mechanisms. Such diffuser pipes may be configured to release air above or below any adjacent or attached supply header.
• The depicted aeration components herein are illustrative only, and it will be readily apparent to one of ordinary skill in the art that alternative types of aeration systems, aerators, and aeration components are within the scope of the present invention. By way of example, alternative aerators for use in embodiments of the present invention may include fine bubble (or fine pore) diffusers or course bubble diffusers, mechanical aerators, centrifugal blowers, turbo blowers, screw compressors, jet aerators, and positive displacement blowers. In addition, the layout and number of aeration devices may vary in alternative embodiments of the present invention. For instance, in some embodiments, the number or arrangement of diffuser heads100 may vary.
• In operation, wastewater treatment mixing system1 functions to mix the contents ofbasin2 and/or to aerate the contents ofbasin2. For mixing, system1 operates bycompressor8 providing pressurized gas intosupply line10. A conventional regulator or a throttle valve may be utilized to control the pressure or flow of the pressurized gas. The pressurized gas is generally a gas or fluid that has a lower density than the wastewater mixture (including any added compounds) that is present inbasin2. The pressurized gas flows throughsupply line10 to thevalves14 incontroller box12. Eachvalve14 is capable of opening and closing to selectively and controllably allow the pressurized gas to flow into thesupply header18 corresponding to thatparticular valve14. When avalve14 is opened, the pressurized gas flows into therespective header18 for that valve. In one embodiment, the opening and closing of the valve can be controlled by theprogrammable logic controller20. In others, the opening and closing of the valve(s) can be controlled manually or by other components described herein.
• In one embodiment, no more than onevalve14 withincontrol box12 is open at any given time. In alternative embodiments, a plurality ofvalves14 may be simultaneously open. When avalve14 is open, the pressurized gas flows into and through aheader18 corresponding with thatparticular valve14. As sufficient pressurized gas flows intoheader18, it will also fillfirst line22 andsecond line24. The gas flow continues intonozzle30. The flow of gas innozzle30 ofFIG. 6 is shown by arrows inFIG. 7. As shown, the gas flows intonozzle30 by enteringnipple32 and then continues to channel38 and towardoutlets40. In general operation,valves14 are opened in short, cyclic intervals.
• In this regard, with reference toFIGS. 1 and 2A orFIGS. 1 and 2B,control panel17 can send a signal toPLC20 indicating to activate or deactivate the mixing system, such as the flow of air tonozzle30 viaheader18,first line22, andsecond line24. In that instance,PLC20 may transmit a signal tocontroller box12, andcontroller box12 would actuate one ormore control valves14, optionally by way ofPLC20, based upon the signal to begin or end the mixing by controlling the supply of air tonozzle30. Such operation may be carried out for the embodiment shown inFIG. 3B bycontrol panel17′. As a result of the bursts ofgas exiting nozzle30 throughoutlets40 and enteringbasin2,nozzle30 generates a displacement of the substance inbasin2, which is generally larger in size than the displacement introduced into the system by conventional aerators used in an aeration process for treating wastewater. Due to the displacement of the substance withinbasin2, mixing occurs. In addition, because the pressurized gas is less dense than the surrounding liquid composition inbasin2, the gas may rise inbasin2 and currents may be formed in the substance.
• The burst of gas from the nozzle and the resulting displacement of the substance inbasin2 may vary in size, and various parameters may influence the burst and displacement, such as the size ofchannel38 andoutlets40, the flow rate of the pressurized gas, and the density of the pressurized gas. In some embodiments,nozzles30 do not create any bubbles that exceed a diameter of six inches. In addition, in other embodiments, other types of mixers, such as mechanical mixers, a signal may be supplied, such as from a control panel or PLC, to either supply or terminate power to the mixer.
• In alternative embodiments,control panel17 can also transmit a signal to the mixing system to control the rate or intensity of mixing. For instance, with reference to the embodiment shown inFIG. 1 and with reference toFIG. 2A,control panel17 may send a signal toPLC20, andPLC20 may transmit a signal tocontroller box12 to adjust the number of valves open or their degree of opening, thereby controlling the mixing rate. The actuator may control the flow rate by permitting or obstructing the flow of air, or the rate of air flow, to one or more ofheaders18. In other embodiments in which other types of mixers are used, such as mechanical mixers,control panel17 andPLC20 may transmit signals to control the speed of the mixer. In still other embodiments,control panel17 andPLC20 may send signals to deactivate some of a plurality of mixers, thereby decreasing the overall mixing rate.
• For instance, in some treatment processes, it is unnecessary to continuously mix the wastewater, and mixing may only be conducted during certain treatment processes or when certain conditions are met. Therefore, in some embodiments of the present invention,control panel17 may indicate to activate or deactivate a mixing system or an aeration system, or to control the rate, duration, or intensity of mixing or aeration, such as based on the dynamic condition or parameters of the wastewater or the system. By way of example, probes for a single parameter (such as multiple ORP probes108, nitrate probes110, ammonia probes112, DO probes114, andpH probes124 or for any other parameters, including, without limitation, devices indicating level, pressure, or flow) may be displaced within a containment unit, such asbasin2, andcontrol panel17 may monitor the measurements for a parameter withinbasin2 and activate or deactivate mixing based upon those parameters. Furthermore, multiple probes for a single parameter may be located throughout the basin, and mixing or aeration may be activated in a particular area based upon the measurements from such probes in that area. Embodiments concerning mixing and aerating using such probes for dynamic measurements and operation are further disclosed in U.S. Pat. No. 9,567,245, which is incorporated by reference herein in its entirety. In addition, as used herein, the term “measured” and “measurements” include detected parameters, directly-measured values of parameters, and parameter values calculated or otherwise determined from the direct measurement or detection of one or more other parameters, either alone or in combination with additional data or measurements.
• In some embodiments, system1 may operate to provide sequence variability in mixing. By way of example, as described above, one or more headers (and their associated nozzles) may be selectively activated and deactivated. In some embodiments, the particular header(s) activated may be randomly, pseudo-randomly, or quasi-randomly selected, and such random cycles of mixing may advantageously avoid stagnation in the substance in the basin and disrupt steady state flow patterns in the substance. In addition, such random cycles may avoid accumulation of surface materials by dispersing such materials, thereby providing both potential aesthetic and utility benefits. In other embodiments, individual nozzles may be selected for activation and deactivation. In such embodiments, each nozzle may have a valve in communication with the control panel, which can transmit signals for opening or closing the nozzle valve or the degree it is opened or closed. In yet another embodiment, the activation and deactivation of the headers, or alternatively nozzles, may be conducted in a pre-selected pattern or based upon dynamic measurements of parameters in or relating to the basin.
• In either the random or cyclic mixing processes, valves may control both the amount of gas permitted to enter a header, thereby controlling the intensity of gas introduced from that header to the substance, as well as the duration of gas permitted to the header. Alternatively, if a valve controlled by the control panel is included in the nozzle, the degree a valve is opened may be controlled to determine the intensity of the mixing from that nozzle. Similarly, the duration of time that gas is released to a header or a nozzle may also be controlled.
• Pressure sensor95 may be utilized in some embodiments as a system check for proper operation. In operation, with reference toFIG. 2B,pressure sensor95 monitors the pressure of aheader18. As a result, the pressure required to open valve can indicate if the system is functioning properly or if there is an actual or potential malfunction, such as if the valves are not properly opening or if there is a clog. If a pressure measurement detected by a pressure sensor is an anomaly from normal operating conditions, the system may indicate that a valve or multiple valves or nozzles are not functioning or are clogged or that inspection is required. In such instances, the control panel may generate an alert, such as a sound, light, message, text message, email, or any other suitable indication. Alternatively, an automatic corrective action, such as a maintenance purge described below, could be initiated. In some embodiments, a paddle switch may be used instead of, or in addition to,pressure sensor95, wherein the paddle switch measures air flow (as opposed to the pressure measured by pressure sensor95).
• In some embodiments, the present invention may also include tank level monitoring and control equipment, which may be utilized in the operation of the system. For example, again with reference toFIG. 2B,pressure sensor15 may be utilized to control mixing and/or aeration of the substance of the basin based upon the amount, or level, of substance in the tank (also referenced herein as the tank level). In particular, upon installation,pressure sensor15 may be calibrated such that the pressure inheaders18 serves as a proxy for the substance level in the basin, whereby the approximate tank level may be calculated from the measured pressure when nozzles in connection with the header associated withpressure sensor15 are not in operation. In some instances, tank level may be used in determining the activation, deactivation, duration, or intensity of mixing or aeration in the system. By way of example, given that a decreased tank level may indicate more dense wastewater (or other substance depending on the application) in the basin and an increased tank level, such as after storms or heavy rain, may increase less dense and more diluted wastewater (or other substance depending on the application), the system may control the mixing frequency and/or intensity based upon such measured tank level. In some embodiments, the water level may also be used to control the frequency and intensity of aerating the substance inbasin2. Similarly, the tank level may be used to determine which and how many mixers should be activated in the tank at a given time. In addition, the use ofpressure sensor15 permits placement of the sensor outside of the basin such that it is more accessible and easily installed as opposed to other means of measuring substance level that require the installation and maintenance of hardware components within the basin itself. In some embodiments, the water level may also be used to control the frequency and intensity of aerating the substance inbasin2 in this same manner.
• In addition, some embodiments of the present invention may allow for proportional mixing and aeration controls. For example, desired mixing parameters for a system, such as the amount and duration of gas supplied to a nozzle under certain conditions, may be calibrated, such as by adjusting valve operations, during the installation process for a particular tank level. As the tank level varies, it may be desirable in some applications to maintain a consistent impact on the system. Thus, the mixing parameters, including the duration and intensity of mixing from a nozzle (or for all nozzles connected to a particular header) may be adjusted proportionately (as dictated by the control panel) based upon the measured tank level so that the impact on the system remains proportionately consistent during dynamically-changing operating conditions. Thus, as the tank level increases or decreases, the system may modify the mixing duration, frequency, and/or intensity in a manner that it proportionally remains at that the desired level as applied to a particular tank level. Appropriate data for such operations can be stored in a memory in or connected to the control panel or may be determined by using the processor in the control panel. As explained above, such adjustments may be completed by adjusting which valves are opened, the duration of their opening, and/or the sequencing of their opening to allow air to flow to particular headers. In similar fashion, the aeration of the system may be similarly controlled based upon tank level. In some embodiments, tank level may be one of multiple factors considered in mixing or aerating a substance.
• With respect to aeration, the disclosed embodiments of control panels and/or PLCs may also control the flow of air to diffuser heads100, including based upon parameters dynamically measured from the wastewater. In some embodiments, the same control panel and/or PLC may be used for aeration and mixing, and in other embodiments a different control panel and/or PLC may be used. In either scenario, a control panel and/or a PLC may activate and deactivate the flow of air to diffuser heads100, thereby controlling the aeration of the contents ofbasin2. In other embodiments, the control panel and PLC may also control the rate of air flow to diffuser heads100. As explained further herein, this system and process allow for automated control between wastewater treatment processes, such as aerobic, anaerobic, and anoxic treatment processes, and that control may optionally be based upon dynamically-measured parameters of the wastewater.
• In some embodiments, other types of aeration devices may be utilized, such as mechanical aerators or blowers without variable speed drives that can only be turned on or off and the oxygen flow not regulated. In such embodiments, a control panel may signal to deactivate less than all of a plurality of devices used to compress atmospheric air for purposes of oxygenation, such as, without limitation, positive displacement blowers, centrifugal blowers, turbo blowers, screw compressors, or rotary disc surface aerators, in order to decrease the overall oxygen flow to the wastewater without regulating the specific output of each blower. In this manner, by selective activation and deactivation, the overall aeration and rate of aeration to the entire system may also be controlled.
• In some embodiments of the present invention, the mixing systems and/or aeration systems described herein may also include a maintenance cycle. By way of example, a maintenance cycle may be manually initiated by a user or automatically initiated by the control panel, such as after a period without operation or upon detection of parameters indicated that cleaning is needed (such as an indication in a pressure sensor indicated that a system may be clogged). In operation, a maintenance cycle can discharge gas through the mixing system or aeration system to purge it, which may remove any undesired entry of substance from the tank into the mixing or aeration components. Such purging may be completed selectively for headers of the system or simultaneously for all mixers. In addition, such maintenance cycles may limit periods of inactivity of the system.
• Although the foregoing description has been provided in the context of wastewater treatment, other types of wastewater treatment and also applications unrelated to wastewater treatment are within the scope the present invention. By way of example, embodiments of the present invention could include treatments in oxidation ditches, sludge treatment, other wastewater treatment processes, water storage, chemical storage, sequencing batch reactors, pumping stations, and food and beverage processing tanks.
• As such, the foregoing description of illustrative embodiments of the invention has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Numerous modifications and adaptations thereof will be apparent to those of ordinary skill in the art without departing from the scope of the present invention.
• It will be understood that each of the elements described above, or two or more together, may also find utility in applications differing from the types described. While the invention has been illustrated and described in the general context of wastewater treatment, it is not intended to be limited to the details shown, since various modifications and substitutions can be made without departing in any way from the spirit and scope of the present invention. As such, further modifications and equivalents of the invention herein disclosed may occur to persons skilled in the art using no more than routine experimentation, and all such modifications and equivalents are believed to be within the spirit and scope of the invention as described herein.

Claims (6)

We claim:

1. A wastewater treatment system for dynamically monitoring and treating wastewater, the system comprising:

a source of pressurized gas,

one or more supply headers in connection with the source of pressurized gas,

one or more nozzles on each of the supply headers, wherein each nozzle is connected to a supply header and each nozzle has at least one release opening, and

a pressure sensor that measures pressure in one or more of the one or more supply headers.

2. The system ofclaim 1 further comprising a controller configured to adjust one or more of mixing and aeration of wastewater as a function of a dynamic pressure measurement by the pressure sensor.

3. The system ofclaim 1 wherein the system includes a processor that determines a tank level based upon the measured pressured by the pressure sensor.

4. The system ofclaim 3 wherein the system is configured to start, terminate, or adjust the intensity of one or more of mixing or aeration of the wastewater based upon the determined tank level.

5. The system ofclaim 4 wherein the system is configured to adjust the supply of pressurized gas to one or more supply headers based upon the determined tank level.

6. The system ofclaim 4 wherein the system is configured to adjust the supply of pressurized gas to one or more supply headers to maintain substantially consistent mixing of the wastewater despite fluctuations in the determined tank level.

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