CHEMICAL FEEDER INCLUDING DILUTION CONTROL SYSTEM

Abstract

A chemical feeder for producing a solution of dissolved chemical material that includes a hopper, a pump, a water supply line that extends from the pump, a chemical solution preparation unit that has a reservoir and a dissolution device and a dilution control device that are each connected to the water supply line. The dissolution device has a spray manifold to spray water towards the hopper that contains solid chemicals to contact and dissolve the chemical material. The dilution control device sprays water in a direction opposite the spray manifold and into the reservoir to aid in adjusting the concentration of a chemical solution and to arrive at a desired chemical concentration range. Thus, the dilution control device allows the chemical feeder to be used in a wide range of applications.

Claims

1. A chemical feeder, comprising: a pump; a water supply line extending from the pump; a chemical solution preparation unit with a housing having a reservoir disposed therein, a discharge line connected to the reservoir to discharge a chemical solution to a water system to be treated, and a dissolution device connected to the water supply line and disposed above the reservoir, the dissolution device includes a spray manifold directed to spray water away from a base of the reservoir and a dilution control device having a water line which is configured to spray water in a direction opposite the manifold and toward the base of the reservoir to dilute the chemical solution prior to exiting the chemical solution preparation unit via the discharge line; a first inlet line adapted with a first valve extending from the water supply line and being connected to the spray manifold and a second inlet line adapted with a second valve extending from the water supply line and being connected to the dilution control device, the first and the second valves being adjustable independent of each other thereby allowing the flow of water to the spray manifold and to the dilution control device to be adjusted during use of the chemical feeder, the first and second valves being adapted to the first and second inlet lines at a position exterior to the housing; and a hopper, which includes a container and a grid positioned within the container, arranged on the chemical solution preparation unit such that the spray manifold is directed to spray water toward the grid of the hopper to contact and dissolve solid chemicals that are arranged in the hopper; wherein the chemical solution preparation unit includes a water overflow switch at a position intermediate the dilution control device and the reservoir.

2. The chemical feeder according to claim 1, wherein the spray manifold has a main body that extends parallel to the water line of the dilution control device, wherein the spray manifold and the dilution control device are spaced equally from the hopper.

3. The chemical feeder according to claim 2, wherein the spray manifold has a first arm that extends in a first direction from the main body of the manifold and a second arm that extends in a second direction from the main body of the manifold.

4. The chemical feeder according to claim 3, wherein the spray manifold has a first nozzle disposed at a distal end of the main body, a second nozzle disposed at a distal end of the first arm a third nozzle disposed at a distal end of the second arm.

5. The chemical feeder according to claim 4, wherein the first nozzle, the second nozzle and the third nozzle of the spray manifold are each directed away from the base of the reservoir.

6. The chemical feeder according to claim 1, wherein the dilution control device has a nozzle at an end thereof that sprays water toward the base of the reservoir.

7. The chemical feeder according to claim 1, wherein the first inlet line and the second inlet line are configured to receive equal pressure from the water supply line.

8. The chemical feeder according to claim 1, wherein the first and second valves are manually operable.

9. A method for treating water, which comprises: providing a chemical feeder including a pump, a water supply line extending from the pump, a chemical solution preparation unit with a housing having a reservoir disposed therein, a discharge line connected to reservoir to discharge the chemical solution to a water system to be treated, a dissolution device connected to the water supply line, the dissolution device includes a spray manifold directed to spray water away from a base of the reservoir and a dilution control device having a water line configured to spray water in a direction opposite the manifold and toward the base of the reservoir to dilute the chemical solution prior to exiting the chemical solution preparation unit via the discharge line, a first inlet line adapted with a first valve extending from the water supply line and being connected to the spray manifold and a second inlet line adapted with a second valve extending from the water supply line and being connected to the dilution control device, the first and the second valves being adjustable independent of each other thereby allowing the flow of water to the spray manifold and to the dilution control device to be adjusted during use of the chemical feeder, the first and second valves being adapted to the first and second inlet lines at a position exterior to the housing, and a hopper arranged on the chemical solution preparation unit, wherein the chemical solution preparation unit includes a water overflow switch at a position intermediate the dilution control device and the reservoir; inserting solid chemical products in the hopper of the chemical feeder; pumping water from the pump through a water supply line that is connected to the first inlet line and the second inlet line that extend into the chemical solution preparation unit; adjusting a pressure of the water via the first valve of the first inlet line and the second valve of the second line; spraying water toward the hopper from the manifold that extends from the first inlet line into the reservoir to dissolve the solid chemical products to form a chemical solution; spraying water toward the base of the reservoir from the dilution control device to dilute the chemical solution; forming a diluted chemical solution with a solution strength that directly correlates to the pressure of the water being sprayed from the manifold and the dilution control device; and discharging the diluted chemical solution from chemical solution preparation unit via the discharge line to water system to be treated.

10. The method according to claim 9, wherein the spray manifold of the chemical feeder has a main body that extends parallel to the water line of the dilution control device, wherein the spray manifold and the dilution control device are spaced equally from the hopper.

11. The method according to claim 10, wherein the spray manifold has a first arm that extends in a first direction from the main body of the manifold and a second arm that extends in a second direction from the main body of the manifold.

12. The method according to claim 11, wherein the spray manifold has a first nozzle disposed at a distal end of the main body, a second nozzle disposed at a distal end of the first arm a third nozzle disposed at a distal end of the second arm.

13. The method according to claim 12, wherein the first nozzle, the second nozzle and the third nozzle of the spray manifold are each directed away from the base of the reservoir.

14. The method according to claim 9, wherein the dilution control device has a nozzle at an end thereof that sprays water toward the base of the reservoir.

15. The method according to claim 9, wherein the first inlet line and the second inlet line are provided with equal pressure from the water supply line.

16. The method according to claim 15, which further comprises adjusting the first and second valves to adjust the flow of water the spray manifold and to the dilution control device.

17. The method according to claim 9, wherein the first and second valves are manually operable.

18. The chemical feeder according to claim 8, wherein the first and second valves are ball valves.

19. The method according to claim 17, wherein the first and second valves are manually operable.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present invention will be further understood and appreciated by reading the following description in conjunction with the accompanying drawing, in which:

[0015] FIG. 1 is a perspective view of a chemical feeder in accordance with an embodiment of the invention showing some of the internal components thereof;

[0016] FIG. 2 is another perspective view of the chemical feeder;

[0017] FIG. 3 is a partially exploded view of the chemical feeder of FIG. 2, showing a pump unit, a hopper unit and a chemical solution preparation unit of the chemical feeder;

[0018] FIG. 4 is a perspective view of the chemical solution preparation unit of the chemical feeder showing internal components thereof, including a spray manifold and a dilution control device;

[0019] FIG. 5 is another perspective view of the chemical solution preparation unit of the chemical feeder of FIG. 4;

[0020] FIG. 6 is a partially exploded view of the chemical solution preparation unit of FIG. 5 showing components thereof, including the feeder reservoir, the spray manifold and the dilution control device;

[0021] FIG. 7 is a perspective view of a hopper unit of the chemical feeder;

[0022] FIG. 8 is an exploded view of the hopper unit of FIG. 7;

[0023] FIG. 9 is a perspective view of the hopper unit of FIG. 7 showing and underside of the hopper unit; and

[0024] FIG. 10 is a perspective view of the hopper unit of FIG. 7 showing the underside of the hopper unit and internal structure thereof.

DETAILED DESCRIPTION OF THE INVENTION

[0025] Referring now to the figures, FIG. 1 illustrates a chemical feeder 10 that includes a pump unit 12, a chemical solution preparation unit 14, and a hopper unit 16, which are connected to (i.e., in fluid communication with) each other. The exterior walls 18, 20 of the chemical solution preparation unit 14 and the hopper unit 16 are shown, respectively, as transparent in FIG. 1. As a result of the transparency, a grid 22 for disposing solid chemical material (e.g., tablets, briquettes, pellets, or the like) thereon can be seen along with a spray manifold 24 for spraying water onto the solid chemical material, and a dilution control device 26. Although the chemical feeder 10 herein is shown as containing individual components, the feeder 10 can also be manufactured using a molding process to eliminate the number of components required for the feeder 10.

[0026] FIG. 2 is a perspective view of the chemical feeder 10. As can be seen in FIG. 2, a pump 28 of the pump unit 12 and the chemical solution preparation unit 14 are installed on a skid 30 and the hopper unit 16 is disposed on top of the chemical solution preparation unit 14.

[0027] An inlet line 31 is affixed at one end to an inlet 32 of the pump 28 and at another end, the inlet line 31 is connected to a coupler 34, which may be a quick-connect coupler, via a coupler 36. Water enters the chemical feeder 10 via a feed line (not shown) that is connected to the coupler 34 and water is discharged from the pump 28 via a discharge line (not shown) to a connector 38.

[0028] The water hat is discharged from the pump 28 may be conducted through a strainer 40 to a feed line 42. The feed line 42 may have a pressure gauge 44 and an inline solenoid valve 46, which may be bypassed using a manual valve 48. The feed line 42 connects to a first line 50, which extends to an interior 52 (FIG. 3) of a housing 54 (FIG. 3) of the chemical solution preparation unit 14, through a first bulkhead connector 56 and the feed line 42 also connects to a second line 58, which branches from the feed line 42, to into the interior 52 (FIG. 3) of the housing 54 (FIG. 3) of the chemical solution preparation unit 14 through a second bulkhead connector 60. The first line 50 and the second line 58 each have manual valves 62, 64, respectively. The valves 62, 64, which may be ball valves, aid in controlling the water pressure that flows through the first line 50 and the second line 58, respectively.

[0029] FIG. 3 is a partially exploded view of the chemical feeder 10 of FIG. 2. In FIG. 3, aspects of the interior 52 of the chemical solution preparation unit 14 can be seen, such as the spray manifold 24 and a feeder reservoir 66.

[0030] FIGS. 4 and 5 are perspective views of the chemical solution preparation unit 14. In FIG. 4, the housing 54 is shown as transparent, so that spray manifold 24, the dilution control device 26 and the feeder reservoir 66 are visible. The spray manifold 24 extends from the first bulkhead connector 56, which is affixed to the first line 50, into the housing 54 of the chemical solution preparation unit 14 and the dilution control device 26 extends from the second bulkhead connector 60, which is affixed to the second line 58, into the housing 54 of the chemical solution preparation unit 14.

[0031] FIG. 6 is a partially exploded view of the chemical solution preparation unit 14, showing additional details of the spray manifold 24 and the dilution control device 26. In this embodiment, the spray manifold 24 is cross-shaped. The spray manifold 24 has an elongated main body 68 that extends from the first bulkhead connector 56 and two arms 70, 72, which protrude at right angles from the main body 68. The first arm 70 extends in a first direction from the main body 68 and the second arm 72 extends in a second direction, which is opposite the first direction from the main body 68. A spray nozzle 74, which is directed upward toward the hopper unit 16, is arranged at the end of the main body 68. Also, spray nozzles 76, 78 are arranged at the ends of each of the arms 70, 72, respectively, for spraying water toward the grid 22 of the hopper unit 16. When in use, the solid chemicals dissolve and fall through the grid 22 and into the feeder reservoir 66 that is disposed in the lower part of the housing 54.

[0032] The dilution control device 26 is a manually operated, water line 80 that extends from the feed line into the interior 52 of the housing 54, parallel to the main body 68 of spray manifold 24. The water line 80 has a spray nozzle 82 that is arranged at the end thereof. The nozzle 82 of the dilution control device 26 is designed to spray at a rate that ensures a desired water pressure is maintained between the spray manifold 24 and the dilution control device 26 so that there is not a pressure loss over the system. The nozzle 82 is directed downwards towards the feeder reservoir 66. Hence, the direction of the nozzles 74, 76, 78 of the spray manifold 24 and the direction of the nozzle 82 of the dilution control device 26 are directed away from each other with the dilution control device 26 spraying water toward the base of the feeder reservoir 66 at the same time that the spray manifold 24 sprays water toward the hopper unit 16 to contact and dissolve the solid chemical material. Accordingly, two streams of water collect and mix in the reservoir 66, a solution of the dissolved chemical material (e.g., calcium hypochlorite), and a water stream from the dilution control device 26.

[0033] It should be noted that the chemical solution preparation unit 14 also includes an overflow switch 84, and that the chemical solution is conducted out of the reservoir 66 via a discharge valve 94 that connects to a discharge line 86, which has a check valve 88 and a coupler 90, which may be a quick connect coupler, that is used to connect the discharge line 86 to the water system that is being treated. Also, if necessary, the interior 52 of the housing 54 may be drained via a valve 92.

[0034] By adjusting the water pressure via the first valve 62 and the second valve 64, the dilution control device 26 permits the strength of the water treatment solution to be controlled in a consistent and predictable manner to meet the needs of various customers. As can be seen in the figures, the first line 50 and the second line 58 have the same construction. Moreover, the same inlet supply pressure is present at both the spray manifold 24 and dilution control device 26. At a given supply pressure (e.g., 45 psi), the flow from spray nozzles 74, 76, 78 of the spray manifold 24 will cause dissolution of the chemical material. Flow from spray nozzle 82 of the dilution control device 26, is adjustable by opening or closing the second valve 64 to aid in diluting the solution, such that the solution will have a concentration that falls within a desired range. By partially closing the valve 64, water flow into the water line 80 and through the nozzle 82 is reduced, thereby increasing the solution strength in a controlled fashion. Alternatively, the opening of the second valve 64 results in an increased flow of water into water line 80 and through the nozzle 82, which in turn dilutes the strength of the solution.

[0035] Details of the hopper unit 16 of the chemical feeder 10 are shown in FIGS. 7-10. FIG. 7 is a perspective view of the exterior of the hopper unit 16. In this embodiment, a cylindrical sidewall 20 of the hopper unit 16 is attached to a plate 96, which covers the top of the housing 54 of the unit 14. The hopper unit 16 also has a lid 98 and a lid switch 100, which secured the lid 98 on the hopper unit 16. As shown in FIG. 8, the plate 96 has a central hole 102 with a circumference that is approximately the same as the circumference of the cylindrical sidewall 20. The grid 22 of the hopper unit 16 covers the central hole 102 of the plate 96. FIGS. 9 and 10 illustrate other perspective views of the hopper unit 16. As shown in FIGS. 9 and 10, a circular flange 104 extends from the circular hole 102 formed in the plate 96, and the circular flange 104 has a crossbar 106 that traverses the circular hole 102. The circular flange 104 and the crossbar 106 aid in ensuring the grid 22 is secured in the hopper unit 16. Additionally, a protrusion 108 extends from the crossbar 106.

[0036] The chemical feeder 10 embodying the disclosure herein can deliver chemical solutions in a range of concentrations, which allows the chemical feeder 10 to be used in a wide variety of applications. While the disclosure has been described in terms of specific embodiments, it is evident in view of the foregoing description that numerous alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the disclosure is intended to encompass all such alternatives, modifications and variations which fall within the scope and spirit of the disclosure and the following claims.