SEWAGE DEWATERING PROCESSES AND APPARATUSES

Abstract

A process of dewatering any liquid/solid materials, primary-treated or non-treated sewage which includes mixing the sludge with a coagulant or flocculant aid, usually activated polymer. The sludge is then mixed and flocculated at conditions which involve extensive mixing turbulence of the sludge and whereby part of the sludge is recycled so as to be again subjected to such mixing and flocculating. Flocks form the solid particles in the sludge. The pH of the sludge is chemically adjusted into the basic pH range or to a higher basic pH. The flocked material is applied to any mechanical or non-mechanical device or a sand bed whereby the flocculated solids in the sludge are separated from the liquid in the sludge, by collecting on the top of the sand bed. The flocculated solids located on the top of the sand bed are air dried. The dried flocculated solids are removed from the top of the sand bed.

Claims

1. A mixing-flocculating unit comprising: an inlet section; an outlet section fluidly connected to the inlet section; and a bottom section and a recycling section fluidly coupled to the inlet and outlet sections; the inlet section includes a first baffle positioned upstream of the recycling section; the inlet section further includes a second baffle, the outlet section includes a baffle, the recycling section includes a plurality of baffles, and the bottom section includes a plurality of baffles.

2. The mixing-flocculating unit of claim 1, wherein the first baffle is non-flexible and fixed to the inlet section increases the velocity of liquid flow through the inlet section.

3. The mixing-flocculating unit of claim 2, wherein the first baffle restricts a liquid flow through the inlet section by between 50% and 80%.

4. The mixing-flocculating unit of claim 3, wherein the first baffle of the inlet section restricts a liquid flow through the inlet section by about 50%.

5. The mixing-flocculating unit of claim 1, wherein the baffles for the inlet section, the outlet section, the recycling section, and the bottom section are non-flexible and fixed.

6. The mixing-flocculating unit of claim 1, wherein the recycling section has a diameter that is smaller than diameters of the inlet section, the outlet section, and the bottom section such that a venturi effect is created to draw liquid flow into the recycling section.

7. A mixing-flocculating unit comprising: an inlet section; an outlet section fluidly connected to the inlet section; a bottom section and a recycling section fluidly coupled to the inlet and outlet sections, the recycling section having a diameter smaller than diameters of the inlet section, the outlet section, and the bottom section; and a first baffle positioned in the inlet section upstream of the recycling section, the first baffle is non-flexible and fixed to the inlet section increases the velocity of liquid flow through the inlet section; wherein the inlet section includes a second baffle, the outlet section includes a baffle, the recycling section includes a plurality of baffles, and the bottom section includes a plurality of baffles.

8. The mixing-flocculating unit of claim 7, wherein the first baffle of the inlet section is configured to increase liquid flow velocity.

9. The mixing-flocculating unit of claim 8, wherein the baffle of the outlet section is configured to reduce liquid flow velocity.

10. The mixing-flocculating unit of claim 9, wherein the plurality of baffles for the bottom section are arranged in a serpentine pattern such that liquid flow velocity is reduced.

11. The mixing-flocculating unit of claim 7, wherein the smaller diameter of the recycling portion creates a venturi effect to draw liquid flow from the outlet section into the recycling section.

12. A mixing-flocculating unit comprising: an inlet section coupled to a spool apparatus, the spool apparatus configured to provide for injection of gas, liquid, or combination of materials into liquid flow entering the inlet section; an outlet section fluidly connected to the inlet section; a bottom section and a recycling section fluidly coupled to the inlet and outlet sections, the recycling section having a diameter smaller than diameters of the inlet section, the outlet section, and the bottom section; and a first baffle positioned in the inlet section upstream of the recycling section; wherein the inlet section includes a second baffle, the outlet section includes a baffle, the recycling section includes a plurality of baffles, and the bottom section includes a plurality of baffles.

13. The mixing-flocculating unit of claim 12, wherein the spool includes a plurality of tangential openings in fluid communication with a liquid gas injection line such that gas can be injected into liquid flow when entering the inlet section.

14. The mixing-flocculating unit of claim 12, wherein the smaller diameter of the recycling portion creates a venturi effect to draw liquid flow from the outlet section into the recycling section.

15. The mixing-flocculating unit of claim 12, wherein the first baffle and the second baffle of the inlet section are configured to increase liquid flow velocity.

16. The mixing-flocculating unit of claim 15, wherein the baffle of the outlet section is configured to reduce liquid flow velocity.

17. The mixing-flocculating unit of claim 16, wherein the plurality of baffles for the bottom section are arranged in a serpentine pattern such that liquid flow velocity is reduced.

18. The mixing-flocculating unit of claim 12, wherein the first baffle is non-flexible and fixed to the inlet section increases the velocity of liquid flow through the inlet section.

19. The mixing-flocculating unit of claim 18, wherein the first baffle restricts a liquid flow through the inlet section by between 50% and 80%.

20. The mixing-flocculating unit of claim 19, wherein the first baffle of the inlet section restricts a liquid flow through the inlet section by about 50%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0098] In the drawings:

[0099] FIG. 1 is a schematic diagraph of the steps or stages in the process/method of the present disclosure;

[0100] FIG. 2 is a side, elevational view, partially cut-away, of the polymer mixing-feeding device of the present disclosure;

[0101] FIG. 3 is a perspective view, partially cut-away, of the apparatus for flocculating fluids containing solids, along with polymer injectors, of U.S. Pat. No. 5,248,416;

[0102] FIG. 4 is a side elevational view of the mixing-flocculating system on a trailer;

[0103] FIG. 5 is a side, cross-sectional view of the mixing-flocculating unit;

[0104] FIG. 5A is another side, cross-sectional view of a mixing-flocculating unit according to various embodiments;

[0105] FIG. 6 is a side, elevational view of the mixing-flocculating system on a trailer including a barrel, a dip tube, a motor and a control valve;

[0106] FIG. 7 is a perspective view of a vertical cross-section of the sand filter set-up of the various embodiments including a layer of sand, a sand-cell media in the sand layer, a porous (stones or pebbles) layer, non-porous pipes having holes therein and a non-porous bottom layer;

[0107] FIG. 8 is a perspective view of a vertical cross-section of the sand filter set-up of various embodiments shown in FIG. 7; having holes and a non-porous layer;

[0108] FIG. 9 is an elevational view of the sand-cell media having a honeycomb formation;

[0109] FIG. 10 is an elevational view of the sand-cell media (in honeycomb formation) and surrounding sand layer showing the forces impacting the sides of a single sand-cell when the wheel of a loader or other loading equipment is on the sand surface above it;

[0110] FIG. 11 is a side, elevational view of the sludge retriever operating on top of a sludge drying sand bed which includes sand-cell media;

[0111] FIG. 12 is a longitudinal, partial cross-sectional view of one embodiment of the pneumatic dewatering device according to various embodiments; and

[0112] FIG. 13 is a longitudinal, partial cross-sectional view of another embodiment of the pneumatic dewatering device according to various embodiments.

DETAILED DESCRIPTION

[0113] FIG. 1 describes the five step/stage process of the present disclosure described in FIG. 1. Sewage 40 is obtained from a primary sewage treatment system which is or includes a filtering step to remove large objects, grit and the like and a sedimentation tank step to remove suspended settleable solids. Activated polymer solution from inline polymer mixer 41 is injected into sewage 40 to aid in flocculation. The sewage 40 then moves into inline mixing-and-flocculating unit 42 wherein the sewage is mixed and flocculated to enhance chemically induced liquid-solids separation. The treated sewage exiting from mixing-and-flocculating unit 42 is subjected to chemical pH adjustment 43 by the addition thereto by a base such as lime or caustic (potassium hydroxide or sodium hydroxide). The pH of the sewage is adjusted into the basic pH range or to a higher basic pH. The sewage is then poured onto sand bed 44 which contains a support grid therein. The larger insoluble solids and flocks in the sewage collect on the top of sand bed 44 and the water in the sewage passes/filters through sand bed 44. Once the solids and flocks located on top of sand bed 44 dry, a layer of dried sludge pieces is obtained on top of sand bed 44. The dried sludge pieces are then removed in sludge retrieval step 45 to provide dried sludge 46.

[0114] With regard to the first step of the process of the present disclosure, that is, polymer mixing and injecting device (see FIG. 1) is more fully shown in FIG. 2. The polymer mixing-feeding (injecting) (165) system is an integrated equipment package which automatically meters, activates, dilutes and feeds liquid polymer and water. (See FIGS. 2 and 6.) Concentrated polymer and water are blended in a complete high energy chamber.

[0115] The prepared solution via tube (166) exits the original chamber (167) through the top of the vessel (168). It then re-enters an outer retention chamber (169) and exits the chamber (169) via tube (170) at the bottom of the vessel to the polymer injectors. A round access plate (171) is fabricated in the bottom of the primary chamber (167) for repair and service. The chamber (167) can be constructed of polyvinyl chlorides, stainless steel or any other suitable material. Polymer from a source not shown is transported in tube (172) by means of metering pump (173). Unit (173) mixes water with the polymer. The polymer is injected into the chamber (167) through a tube (172) passed through the top of the chamber (167). The tube (172) is designed to be adjustable in length giving variations in depth or placing the polymer closer to the aspirator or mixing energy. At the end of the tube (172), a spring loaded check valve (174) allows polymer to spray into the mixing area in a thin filming process (182). Energy for polymer activation is created by a inch or any size stainless steel hollow shaft (175) which at the end of the shaft is a polyvinyl chloride or stainless steel 4-way aspirator (176). With the aspirator turning at 3,450 rpm, a tremendous vacuum occurs drawing free air down the hollow shaft (175) into the chamber (167). This process causes high energy mixing. The stainless steel shaft (175) is driven by a hollow core motor (177). The motor (177) and shaft (175) are attached by a coupler (176). The inch or any size shaft (177) with aspirator (176) is placed inside the chamber (176) and that chamber (176) is made water tight with exterior mechanical seals (178). Inline check (179) and ball valves (180) are installed on the top or inlet side of the motor (177). These valves (180) can regulate the amount of air passed through the hollow shaft (175) to the mixing chamber (176). The one way directional flow check valve (179) is used to prevent liquid from exiting through the aspirator (176) and shaft (175) when the motor (177) is in the off position. The mixer has a brass solenoid valve for on/off control of dilution water supply (not shown), and a rotameter-type flow indicator (181) equipped with integral rate-adjusting valve. Water is supplied to primary chamber (167) via tube (183). The flow indicator is machined acrylic and has valve stop and guided float. Water flow rate is adjustable 0 to 500 USGPH. Water supply input and stock solution output fittings are 0 to 500 FNPT. The drive motor (177) of the unit is powered by a 2500 watt generator producing 120 V-15 amps. The generator (not shown) is mounted to the trailer and becomes a permanent fixture of the transportable system.

[0116] With regard to the second step of the process of the present disclosure, that is, inline mixing and flocculating (see FIG. 1), the following mixer-flocculating system is constructed: Onto the bed of a trailer (110), the mixer-flocculating system (101) is secured. (See FIG. 4.) Part of the mixer-flocculating system is a mixer-flocculator unit (80). Sewage enters pipe (102) the mixing-flocculator unit (80) through an elbow (103). The elbow (103) is attached to a vertical inlet pipe segment (104) which is, in turn, attached to another elbow (103). This latter elbow (103) has a flange (82) which is attached to a flange on the end of a downflow segment (105). The downflow segment (105) continues into a horizontal bottomflow segment (106). A recycle segment (111) contacts the downflow segment (105). An electrical control-drive unit (88) turns a threadedly adjustable rod (88a) extending through the wall of the device to contact the top of adjustable baffleplate (87). Baffleplate (87) is pivotally attached (87a) to the side of to the downflow segment (105) near the top where the downflow segment (105) and recycle segment (111) intersect. The adjustable, nonflexible baffleplate (87) is located at an angle (which can be readily changed) within the downflow segment (105). (See FIG. 5.) The electrical control-drive unit (88) can, instead, be a manual control (of the angle of the adjustable baffleplate), such as, manually turning the rod (88a). The other end of the recycle segment (111) and the other end of the bottomflow segment (106) are joined to openings in an upflow segment (107). At one end of the upflow segment (107) is a flange (82) which is attached to a flange (82a) at one end of an elbow (103). The other end of this elbow (103) is attached to a vertical, exit pipe segment (108). Attached to the other end of the vertical, exit pipe segment (108) is another elbow (103) through which the sewage exits (109).

[0117] Running into the elbow (103) which is attached both to the vertical inlet pipe segment (104) and the downflow segment (105) are polymer or flocculant injection lines (84). Attached to the other end of these polymer or flocculant injection lines (84) are a manifold (85), a quick connect (86), a motor (115) and a control valve (114). (See FIG. 6.) A dip tube (113) runs from the control valve (114) into a barrel (112) resting on the trailer (110). Preferably the polymer mixing and injecting apparatus of FIG. 13 is used to provide the activated polymer solution to barrel 112.

[0118] Sewage enters an elbow (103) and runs through the vertical inlet pipe segment (104). It then passes through another elbow (103) into the downflow segment (105). As the sewage/flow passes into the downflow segment (105), it passes through a 45 degree angle. This area is called mixing zone 1 (83). As the sewage/flow runs through the downflow segment (105), it encounters an adjustable baffleplate (87), which is positioned at an angle. The adjustable baffleplate (87) restricts the vessel's flow by about 50 to about 80 percent, thus increasing the original flow velocity by as much as 600 percent. Then, the sewage/flow is fanned in one directiontowards the bottomflow segment (106). A fixed baffle (90), which restricts typically 40 percent of the vessel's size, is positioned in the downflow segment and serves to oppositely direct and fan the passing sewage/flow. The area between the adjustable baffleplate and the fixed baffle is called mixing zone 2 (89). Then, the sewage/flow is directed into a 45 degree round angle into the bottomflow segment (106). Positioned within the bottomflow segment are at least two (preferably, a number of) fixed, horizontal baffles (92), the positioning of which cause the sewage/flow to pass under and over and under these fixed, horizontal baffles (92) in a serpentine flow pattern, thereby reducing the flow velocity. This area is called mixing zone 3 (93). The sewage/flow, then, enters the upflow segment (107) in a 45 degree round angle which causes the sewage/flow to move in a spiraling pattern. Positioned in the upflow segment (107) is (at least one) fixed vertical baffle (96). Mixing zone 5 is in the exit end of upflow pipe 107 where it bends to the horizontal. Before the sewage/flow exits the mixer-flocculator unit (80), before it enters an elbow (102) and the vertical exit pipe segment (108), it passes a horizontal pipe/recycle segment (111) which causes a portion of the sewage/flow to divert through this line, because of the pressure drop caused by the adjustable inlet baffle (87) placed at an angle. The bypass velocity may be increased, if the size of the pipe is increased and with baffle adjustments. Also before the sewage/flow exits the mixer-flocculator unit (80), before it enters an elbow (102) and the vertical exit pipe segment (108), but after it passes the horizontal pipe/recycle segment (111), it passes through a 45 degree angle. This area is called mixing zone 4 (99). Recycle segment (111) has a smaller diameter than the rest of the pipes of the unit.

[0119] A drainage plug (91) is present in the downflow segment (105), close to where the sewage/flow enters the bottomflow segment (106). A flush plug (95) is present in the upflow segment (107) close to where it joins together with the bottomflow segment (106).

[0120] Model RF6 of the mixing and flocculating unit 80 is basically shown in FIG. 5. Note the two non-flexible baffles 92 located in the bottom of bottomflow segment 106. The results of tests using Model RF6 in dewatering test are given below in Table 1 and 2.

TABLE-US-00001 TABLE 1 MIXING ZONES (Velocity versus feet per second) G.P.M. ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 A) 100 1.28 5.04 2.89 8.68 1.28 B) 150 1.92 7.56 3.83 13.10 1.92 C) 200 2.57 10.10 4.44 17.4 2.57

TABLE-US-00002 TABLE 2 Emulsion Polymer Baffle Plate Sludge Polymer Solution Position Filtrate Dried Sludge Velocity Con. Conc. Conc. (% of Floc Size Conc. (% and (G.P.M.) (% T.S.) (Neat) (%) Vessel Dia) (SML) (% T.S.) Time) A) 100 2% 55% .25 .70 L 0 6 hrs.-14% 24 hrs.-24% 48 hrs.-30% 72 hrs.-47% 168 hrs.-60% B) 150 2% 55% .25 .65 L 0 same C) 200 2% 55% .25 .60 M 0 same

[0121] Model RF8 is similar to Model RF6 except it has a larger flow capacity and only has one nonflexible baffle 92 in the bottom of flow segment 106 (located between the two baffles 92 in the top thereof). The results of tests using Model RF8 in dewatering tests are given below in Tables 3 and 4.

TABLE-US-00003 TABLE 3 MIXING ZONES (Velocity versus feet per second) G.P.M. ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 A) 200 1.28 5.04 2.89 8.68 1.28 B) 300 1.92 7.56 3.83 13.10 1.92 C) 400 2.57 10.10 4.44 17.4 2.57 D) 500 3.31 12.60 5.55 21.7 3.21 E) 600 3.85 15.10 6.66 28.0 3.85 F) 700 4.49 17.60 7.77 30.4 4.49

TABLE-US-00004 TABLE 4 Emulsion Polymer Baffle Plate Sludge Polymer Solution Position Filtrate Dried Sludge Velocity Con. Conc. Conc. (% of Floc Size Conc. (% and (G.P.M.) (% T.S.) (Neat) (%) Vessel Dia) (SML) (% T.S.) Time) A) 200 2% 55% .25 .70 L 0 6 hrs.-12% 24 hrs.-22% 48 hrs.-35% 72 hrs.-45% 168 hrs.-65% B) 300 2% 55% .25 .65 L 0 same C) 400 2% 55% .25 .60 M 0 same D) 500 2% 55% .30 .55 S 0 same E) 600 2% 55% .50 .50 S 0 same F) 700 2% 55% .55 .50 S 0 same

[0122] The sewage apparatus of U.S. Pat. No. 5,248,416 (Howard) is shown in FIG. 3. In the apparatus of Howard, incoming liquid containing solids and recirculated liquid containing solids and flock fills the entire apparatus, including pipe 229. The velocity going into the system is the same as that exiting the system. The path of the flow of material is down conduit 217, through bottom conduit 222, up conduit 224, and then split so as to be partly recycled through the top pie 229 and partly passed on out conduit 224, without any meaningful restrictions. Item 220 is a moveable flutter or ledge and items 229a are fabricated rubber tumblers which bend with the flow and, thus, offer little or no restrictions in the flow paths. Moveable flutter or ledge 220 is located in down flow conduit 217 at the lower intersection point of recycle conduit 229 and down flow conduit 217. Through testing of the Howard system, applicant has found that the Howard system is not very effective in achieving its stated purpose and in solving its stated prior art problem.

[0123] In contrast, the improvements of the present disclosure include a mixer-flocculator unit having an adjustable baffleplate placed at an angle to the direction of flow of the incoming sewage (containing, for example, to 8 percent of solids). The baffle plate restricts the flow area in downflow pipe segment 106 just before the intersection with recycle pipe segment 111 by about 50 to about 80 percent. This cross-sectional area adjustment process can increase the original flow velocity by as much as 600 percent or more. The pattern of flow of the combination of the incoming material and the recycle material, then, is moved in one direction. Thereafter, flowing liquid is oppositely directed and fanned by a fixed, nonflexible baffle 390 which restricts 40 percent or so of the internal size (cross sectional area) of the pipe. Then, the liquid flow is directed into a 45 degree round angle which causes the liquid flow to turn and pass under and over and under fixed, nonflexible baffles 392 in a serpentine flow pattern, thereby further reducing the velocity of flow in the pipe. Thereafter, the liquid flow enters a 45 degree round angle which causes the flow to move upward in a spiraling pattern. The liquid flow, then, comes in contact with a fixed, nonflexible baffle 390. Baffle 390 is located across from the entrance to a side or recycle pipe. As the upward liquid flow reaches such baffle and side horizontal recycle pipe, a portion of it to divert through this line by the action of baffle 390 and by the pressure drop caused by the adjustable inlet baffle plate in the down flow pipe segment 106. The internal diameter of recycle pipe 111 is less than the internal diameter of down flow pipe 105 or upward flow pipe 107. The bypass velocity in the recycle pipe can be increased by decreasing the size of the pipe and/or by adjusting the baffle. This recycle system allows the continued size growth of the floc.

[0124] Preferably the mixer-flocculator unit will have multiple injector ports at the influent end of the mixer, through which the activated polymer solution can be injected into the liquid-sludge slurry flow stream. The activated polymer and sludge will then be quickly but gently mixed by baffling energy dispersing action. The mixing action promotes large floc growth. A portion of the flocculated sludge, then, is re-circulated into the influent stream by a pressure drop zone to advance and increase the efficiency of the mixing-flocculating process. The device can be fabricated utilizing corrosion free polyvinyl chloride components, stainless steel, concrete, fiberglass, wood or any other suitable metal or other material. The interior baffles can be fabricated from polyvinyl chloride, stainless steel, concrete, fiberglass, wood or any other suitable metal or other material.

[0125] With regard to the third step of the process of the present disclosure, that is, a chemical induced pH adjustment of the sewage exiting the mixer-flocculating system (101), the following is included: As the liquid/solids content exits the inline m ixer-flocculator unit (80), an electronic or gear driven diaphragm pump (not shown) pumps liquid caustic or lime into the discharge line for example, 102, 108, 109, etc.) of the flocculator-mixer unit (80). The pH of the sludge is increased to 12 by the chemical additive (base). The pH of the sludge will remain at 12 for 72 hours, and, during this period of time, the temperature will reach 52.degree. C. and will remain at that temperature for at least 12 hours. At the end of the 72 hour period during which the pH of the sludge is above 12, the sludge can be air dried to achieve a percent solids of greater than 50 percent. The liquid caustic or lime pump is present on the transportable dewatering trailer (110) with the mixer-flocculating system (101) and the polymer feed system and, thus, is easily transported.

[0126] With regard to the fourth step of the process of the present disclosure (see FIG. 1), enclosure 49 contains sand bed 44. Onto a layer of non-porous material (50), e.g., concrete, a layer of porous material (53) is positioned. Porous material (53) is used as a filter media and usually stone, crushed rock, ceramic shapes, slag and plastics of 1 to 6 inches, practically 2 to 4 inches, in size are used. Stones or pebbles are preferred. At least oneusually more than oneprojection of porous material (54) extends from the porous layer (53) into the layer of non-porous material (50). Embedded in each projection channels (48) in porous material (54) is at least one non-porous pipe (55) having at least one hole (56) into which liquid can drain. A layer of sand (57) is positioned above the layer of porous material (53). The sand-cell media sections (65) are positioned above this layer of sand (57). Sand is located in passageways 59 in sand cell grid (65). Above each sand-cell media section (65) is placed a layer of sand (61). This layer of sand (61) is usually, though not necessarily, at least six inches in depth.

[0127] Walls (51) surround on all four sides of an area having one or more sand-cell media sections (65)on wall 51 is shorter to allow a front loader or the like into the enclosure. Each surrounding, dividing wall (51) extends upward from one or more footing supports (52) which are positioned, at least partially, in the layer of non-porous material (50). The top of each dividing wall (51) extends above the layer of sand (61) overlaying the sand-cell media section(s). On the top of each dividing wall (51) which runs between two enclosure areas having sand-cell media sections (65) is portable nozzle (62) which is used to pour sewage into the enclosures.

[0128] Each sand-cell media section (65) is made up of one or more sand-cells (58) having the same shape and size. Typically, the sand-cell media section is made up of honeycomb-shaped sand-cells (58) which are joined together in a honeycomb formation (i.e., each sand-cell which is not in an outer layer, where it intersects (59) another sand-cell, it intersects three other sand-cells). A channel (59) runs through the interior of each sand-cell.

[0129] Sewage is poured through the channel (62) into one or more enclosures 49 for sand beds 44. The liquid permeates the outer sand layer, flows through the sand in the channels (59) in the grid 65 in the centers of the sand-cells, permeates the layer of sand beneath the sand-cell media, and permeates the pebble layer beneath that layer, leaving the collected sludge solids to dry from the sun and air.

[0130] With regard to the fifth of the process of the present disclosure (see FIG. 1), a sludge retriever (125) is used to separate the dried sludge layer (134) from the sand (61) in the sand bed (44). (See FIG. 11.) An upper pivoted arm (130) is attached to a front-end loader, as is a lower pivoted arm (129). The other end of each of these pivoted arms is attached to a two cubic yard bucket/hopper (133). The lower side (137) of the bucket/hopper (133) slides along the sandbed slightly above or on the layer of dried sludge (134) being retrieved. The lower, front end (138) of this bucket/hopper (133) is upwardly slanted relative to the rest of the lower end. At the lower back end of the bucket/hopper is attached a rotary drum (135) including a shaft (126) around which a rotary (128), from which multiple raw of three inch tines/teeth (127) project, turns. As the rotary drum (135) turns (clockwise), pieces of dried sludge (134) and minimal amounts of sand (61) are tossed into the bucket/hopper (133). An arm (132) is attached to a ball pivot (131) which has a short arm (139) welded onto the end of ball joint (131). Ball joint (131) is moved up or down in vertical slot (140) in the side of retriever (125) and moved and bolted into one of the three short horizontal slots (141), whereby shaft (126) is moved up or down to the desired position. This arrangement (not shown) is repeated on the other side of the retriever (125). In this manner, the height position of shaft (126) can be adjusted and accordingly the distance that vanes (127) extend below lower side (137) of retriever (125). As typically shown in FIG. 11, vane (127) extension levels of 1 inch, 2 inches and 3 inches are indicated by the marks 1, 2 and 3, respectively. The one inch level is usually used to chop up the dried sludge. The 2 inch level is shown in operation in FIG. 11. The three inch level is used, when the rotation direction of rotary (128) is reversed, to aerate the sand after the dried sludge has been removed. Air flow grill or filter (136) is located in the top surface of bucket (133) near its front.

[0131] With regard to the optional (sixth) step of the present disclosure, that is, dewatering the sewage using an inline vertically-oriented, pneumatic dewatering tube (164) between steps (a) and (b) or (b) and (c) or (c) and (d), or before step (a), see FIG. 12. A cylindrical-shaped screen filter (150) reinforcing ribs (151), usually composed of stainless steel. Rim rings (159) connect the circular-shaped screen filter (150) with a rim block (163). Running through the rim (163) are water exit passageways (158). The flanged ends of cylindrical shell (153) are bolted (161) together with rim block (163). In this shell (153) are peripheral air chambers (154) which traverse the entire circumference of shell (153). One end of the water exit passageways (158) opens into the area in between the shell (153) and filter (151). Positioned in this area are staggered, pressurized air jets (152) communicating with air chambers (154). Manifolds (155) are positioned outside of shell (153) and communicate with every other circular air chamber (154), and hence to every other bank of pressurized air jets (152).

[0132] Use of the pneumatic dewatering device or tube (164) involves conducting (160) the sewage into the central tube-shaped filter where solids in the sewage are caught on the filter (150) and part of the water in the sewage passes through the filter (150). Air under pressure is blown from staggered, high pressure air jets (152) against the outer surface of the filter (150) to dislodge the solids collected on the inner surface of the filter (150). The blowing air jets (152) are alternated in on-off sequences in order to continuously provide regions of the filter for the water to come through unimpeded by blowing pressurized air.

[0133] In an alternate form of the present disclosure (see FIG. 13, as opposed to that which is portrayed in FIG. 12), there is not a liquid exit passageway (158) running through each rim (163) through which liquid sewage is dispelled (157). Rather, there is a channel (162) for sewage to flow through the rim (163) from one section to another and then out the bottom.

LIST OF PARTS NUMBERS

[0134] In connection with the figures, the following list of the names of the parts of the present disclosure are noted:

TABLE-US-00005 Numbers Parts, Etc. 40 sewage; 41 inline polymer mixer; 42 inline mixing and flocculating unit; 43 chemical pH adjustment; 44 sand bed; 45 sludge retrieval; 46 sludge; 48 channels; 49 sand bed enclosures; 50 non-porous layer; 51 dividing wall; 52 support upon which dividing wall is positioned; 53 porous layer positioned directly above non-porous layer (50); 54 projection of porous layer (54); 55 non-porous pipe; 56 hole in non-porous pipe (56); 57 layer of sand underlaying sand-cell media section; 58 single sand-cell; 59 channel running through interior of single sand-cell; 60 point of intersection of 4 individual sand-cells; 61 layer of sand overlaying sand-cell media section; 62 channel into which sludge is poured 63 loader or other loading equipment; 64 wheel of loader or other loading equipment; 65 sand-cell media section; 80 mixer-flocculator unit; 81 input conduit (influent end of mixer); 82 flanges; 82a flange; 83 mixing zone 1; 84 polymer or flocculant injection lines; 85 manifold; 86 quick connect; 87 adjustable baffleplate placed at an angle; 87a pivot attachment; 88 electrical unit; 88a threadedly adjustable rod; 89 mixing zone 2; 90 fixed, vertical baffle; 91 drainage plug; 92 fixed, horizontal baffles; 93 mixing zone 3; 94 walls; 95 flush plug; 96 fixed, vertical baffle; 97 mixing zone 5; 98 recirculation baffles; 99 mixing zone 4; 100 output conduit; 101 mixer-flocculating system; 102 liquid in; 103 elbows; 104 vertical inlet pipe segment; 105 downflow segment; 106 bottomflow segment; 107 upflow segment; 108 vertical exit pipe segment; 109 liquid out; 110 transportable dewatering trailer; 111 recycle segment; 112 barrel; 113 dip tube; 114 motor; 115 control valve; 125 sludge retriever; 126 shaft; 127 multiple 3 inch tines/teeth; 128 rotaty; 129 lower pivoted arm attaching sludge retriever to front-end loader; 130 upper pivoted arm attaching sludge retriever to front-end loader; 131 ball pivot; 132 arm; 133 two cubic yard bucket/hopper; 134 dried sludge; 135 rotary drum; 136 air flow grill or filter; 137 lower side; 138 front end; 139 arm; 140 vertical slot; 141 short horizantal slots; 150 screen filter; 151 rib; 152 high pressure air jet; 153 wall; 154 circular air chamber; 155 manifold; 156 pressurized air in; 157 liquid sewage out; 158 liquid exit ring; 159 rim ring; 160 passageway for sewage; 161 bolt; 162 channel for sewage; 163 rim; 164 inline pneumatic dewatering tube; 165 polymer mixing-feeding system; 166 tube; 167 inner chamber; 168 vessel; 169 retention chamber; 170 exit tube; 171 access plate; 172 tube; 173 water-polymer mixing unit; 174 cheek valve; 175 hollow shaft; 176 aspirator; 177 motor; 178 seal; 179 check valve; 180 ball valve; 181 flow indicator; 182 filming process; and 183 tube.

[0135] In connection with the figures, the following list of the names of the parts of a prior art invention [U.S. Pat. No. 5,248,416 (Howard)] are noted:

TABLE-US-00006 212 Upper right hand conduit/system input; 214 multiple polymer ejectors; 217 conduit; 220 moveable flutter or ledge; 222 conduit; 222a conduit; 224 conduit; 226 output conduit/system output; 229 recirculating conduit; 229a pivotal flaps on recirculating conduit; and 230 support bracing.

[0136] With reference to the embodiment shown in FIG. 5A, an alternate embodiment of the sewage dewatering processes and equipment apparatuses is shown with alterations made on the interior and exterior of the apparatuses. In various embodiments, the alterations in the mixing-flocculating unit of FIG. 5A may improve mixing of the activated or non-activated polymer, coagulant, and/or any other liquid or gas form into the apparatus flow stream and/or any other liquidized material entering into the apparatus. In various embodiments, the improvements help to create a more thorough mixing of the applied compound into the flow or recirculating stream going through the apparatus. Exemplary embodiments of the sewage dewatering equipment apparatus and processes may use or be made from materials that can withstand the psi interior loading of the flow pressure rating passing through the apparatus size, which in some embodiments can be from inch to 48 inches in circumference. Various embodiments may be adjusted based on the volume load and viscosity of loaded material. Exemplary materials include steel, PVC, aluminum, composite materials, vinyl, or combinations thereof. In some embodiments, preferable materials include stainless steel.

[0137] Referring to FIG. 5A, in various embodiments, there may be a plurality of openings 384, such as from about 2 to about 8 (e.g., in some embodiment preferably 4) openings, with a quick disconnect and with fixed nipples and hoses arranged circumferentially around inlet end 354, which is the interface where flanges 382 of conduit pipe 381 and downflow segment are coupled, of the apparatus.

[0138] In some embodiments, an additional spool apparatus 350 having lengths that range between 4 to 12, (e.g., 1 independent inlet being preferably 6 in length), circumference of inch to 48 inches, may be attached to the mixing-flocculating unit of FIG. 5A for sewage dewatering equipment apparatus and processes. In one embodiment, an additional spool apparatus 350 may include from 1 to 6 spool apparatuses 350. Some embodiments may include from about 2 to about 6 inlet spool apparatuses 350 attaching to inlet end 354 of the improved sewage dewatering process and equipment apparatus, for example, via bolts or proper connections with gaskets or other sealing agents, as would be recognized by an ordinary skilled artisan with the benefit of this disclosure. In some embodiments, spool apparatus 350 may tangential openings 352 in fluid communication with quick-connect couplers and hosing allowing for the introduction of additional gas, liquid, or combination of materials into the flow stream of a primary apparatus by liquid or gas injection manifold 302 and liquid or gas injection line 303. In one embodiment, spool apparatus 350 may comprise between about 2 to about 6 tangential openings 352. In another embodiment, spool apparatus 350 may comprise 4 tangential openings 352.

[0139] In various embodiments, the apparatuses and/or processes may be improved through introduction of the activated polymer, non-activated polymer, coagulant, and/or any liquidized material or gaseous material entering into the flow stream (via liquid or gas injection manifold 302 and liquid or gas injection line 303) to be thoroughly mixed by restricting the flow by strategically arranged fixed baffles discussed further herein. In various embodiments, the baffles may leave a decrease pressure of the flow behind it creating turbulent vortex, hydraulic increase throughput, and recirculation inside the apparatus. Moreover, in various embodiments, the baffles may be fixedly mounted horizontally and positioned with the mixing-flocculating unit of FIG. 5A from between to of the distance spanning from the inside entrance of conduit 381 to the outlet apparatus pipe 300. The fixed baffles function to veer the mixing flow materials in certain directions at key locations as discussed further herein.

[0140] Referring to FIG. 5A, fixed items 88a and 87a of the mixing-flocculating unit of FIG. 5, are modified to a fixed baffle 387 located on the vertical inlet side before or upstream of top horizontal transfer line or recirculating pipe 305. In various embodiments, fixed baffle 387 is positioned on the inlet side of the mixing-flocculating unit of FIG. 5A before or upstream of the top horizontal line or recirculating (recycling) pipe 305 and may help to create a first turbulent vortex and may again be utilized when the flow is recycled through the medial plane, producing turbulent vortex. In various embodiments, areas of higher influent pressure may hit stationary baffle 387 leaving a decrease pressure behind the increased hydraulic throughput causing a better backpressure mix and producing a partial backflip or rolling action of the sludge or solution without restricting the flow of the polymerized or solution treated sludge in zone 1. To accelerate the growth of the floc and the separation of the solids from the liquid, a baffle 390 further restricts the flow through the apparatus and thereby accelerates sludge flow past the top horizontal line 305 through zone 2 (reference number 396), which continues to mix/blend the sludge while passing over the strategically placed baffles 392 throughout the apparatus bottom section 394. Bottom section 394 with baffles 392 and ports 391, 395 are configured in a substantially similar manner to the mixing-flocculating unit of FIG. 5 as previously described. Similarly, top horizontal line or recirculating pipe 305 with baffles 398 are configured in a substantially similar manner to the mixing-flocculating unit of FIG. 5 as previously described.

[0141] As also shown in FIG. 5A, baffle 390 is located in zone 5 (reference number 388) on the discharge side of the mixing-flocculating unit along vertical outlet pipe 397. Baffle 390 functions to reduce the rapid flow of sludge caused by inlet baffle 387 in zone 1 and to create a venturi environment causing pressure drop, thereby creating recirculation of the flocced sludge or materials through top horizontal line 305 of the apparatus zone 4 (reference number 399) and extending into the incoming sludge flow in zone 2 (reference number 396). The recirculated flow may carry unused particles or charge sites either positive or negative of the polymer, coagulant or agent causing a reduction of new coagulant or other supplied material needed to properly floc or treated incoming materials or sludge flow. The improved delivery of the prepared solution injected into the flowing stream according to various embodiments may allow for enhanced mixture or floc formation, any sludge, combined compounds, organic or non-organic, gases, water solution or animal waste is thoroughly mixed and recirculated in the improved sewage dewatering processes and equipment apparatuses for the separation of the liquid from solids delivered to a quick dry filter beds, sand beds, lagoons, catch basin, lake, holding tank, filter, micro filters, porous surface, seepage sludge bags or any mechanical dewatering device.

[0142] As also shown in FIG. 5A, cleanout ports 391, 395 are located on the outer side of bottom horizontal portion or apparatus line 394 of the apparatus shown in FIG. 5A. An opening port 356 is located on the inlet vertical side opposite of the mixing zone 1 and 2 (reference numbers 383, 396) is designed to accept a pressure gauge 304 to monitor the apparatus's internal pressure (e.g., psi). In various embodiments, opening port 356 may also be designed to accept a flow monitoring device, viscosity measuring device, a port signal control to measure sludge flow through the apparatus, or any combination thereof. In some embodiments, any of the three aforementioned ports may be designed to receive a pH adjustment solution to alter a condition the sludge characteristics, for example to lower or raise pH of the flow based on the injected material. In various embodiments, all ports may be used to receive a second chemical or dual polymer process or to inject water to thin down the sludge concentration, to drain or force liquid into the apparatus from one port and drain from the other port or drain from both ports, to receive other products such as water, chemicals, or any combination thereof as a side stream flow to remove a portion of the prepared mix for other uses or apparatuses.

[0143] Furthermore, it will be recognized by a person of ordinary skill that the apparatuses, systems, and methods disclosed herein may be used and adapted to a wide variety of uses or industries. For example, the apparatuses and methods disclosed herein may be used in industry to mix various chemicals or liquefied gases.

[0144] Exemplary industries include the biosolids industry, water plant residuals, lagoons, agriculture (e.g., concentrated animal feeding operation (CAFO) operations (e.g., for both solids and liquids)), T-Water industry, the coal industry, the paper industry, storm water surge management systems, and the oil and gas industry (e.g., fracking).

[0145] For example, the systems, apparatuses and methods may be adapted by using materials that would not be corroded by such chemicals or liquefied gases based on the industrial application. Exemplary chemicals or categories of chemicals include buffer solutions, citric acid, muriatic acid, potassium hydroxide, sodium hydroxide, sodium hypochlorite, sodium sulfite, sulfuric acid, aluminum chloride, aluminum chlorohydrate, aluminum sulfate, calcium chloride, ferric chloride, ferrous chloride, sodium aluminate, various polymers (e.g., cationic polymers and/or anionic polymers), metal precipitants, sludge conditioners, or combinations thereof.

[0146] While this disclosure has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.

NUMERAL IDENTIFICATION FOR FIG. 5A

[0147] 300. Apparatus pipe (out) [0148] 302. Liquid or gas injection with manifold [0149] 303. Liquid or gas injection line into manifold [0150] 304. Pressure gage or monitoring apparatus [0151] 305. Top horizontal recirculating pipe [0152] 350. Spool apparatus [0153] 352. Tangential openings [0154] 354. Inlet end [0155] 356. Opening port [0156] 381. Conduit pipe (in) [0157] 382. Flanges [0158] 383. Mixing zone 1 [0159] 384. Polymer flocculants or chemical injection lines [0160] 385. Manifold [0161] 386. Quick connect [0162] 387. Fixed Baffle [0163] 388. Mixing zone 5 [0164] 389. Vertical inlet Pipe [0165] 390. Baffle [0166] 390. Baffle [0167] 391. Opening for Cleanout, Instrumentation gauge, Injection of liquid or gas and side [0168] stream outlet [0169] 392. Baffle [0170] 393. Mixing zone 3 [0171] 394. Bottom of horizontal apparatus line [0172] 395. Discharge ports, injection port or side stream outlet [0173] 396. Mixing zone 2 [0174] 397. Vertical outlet pipe [0175] 398. Recirculation baffles [0176] 399. Mixing zone 4