UNDERDRAIN AND SEPTA FOR MEDIA VESSEL AND METHOD OF CLEANING

Abstract

An underdrain system for a media pressure vessel has a set of removable pipe sections located between an external header and the bottom of a vessel. Septa extend upwards from the removable pipe sections into the vessel by up to 16 inches. The septa may have diameters of 6 inches or more. The header is attached to the bottoms of the removable pipe sections. Each pipe section, and its associated septum, may be removed individually. To clean the vessel. after media is removed from the vessel the pipe sections are removed sequentially while the header remains otherwise attached to the vessel. While a pipe section is removed. its associated septum is removed so that solids can be removed from the annulus between the septum and the vessel. In this way. media can be cleaned from the annuli without moving the external header or entering the vessel.

Claims

1-17. (canceled)

18. A water treatment system comprising, a vessel having a bottom; and, a plurality of septa extending upwards into the vessel from the bottom, wherein the septa have one or more of a) a diameter of at least 4 inches, and b) a penetration depth measured from the bottom of the vessel of about 13 inches or less.

19. The water treatment system of claim 18 wherein the vessel has a diameter in the range of 7-12 feet.

20. The water treatment system of claim 18 wherein the septa have a diameter or at least 6 inches, optionally up to 10 inches.

21. The water treatment system of claim 18 wherein the penetration depth is 10 inches or less.

22. The water treatment system of claim 18 wherein the penetration depth is at least 5 inches.

23. The water treatment system of claim 18 having an underdrain system disposed below the vessel comprising a plurality of removable pipe sections each having a lower end and an upper end, each pipe section corresponding to one of the septa.

24. The water treatment system of claim 23 wherein the upper end of each of the removable pipe sections is attached to the bottom of the vessel.

25. The water treatment system of claim 23 further comprising an external header attached to the lower end of each of the removable pipe sections.

26. The water treatment system of claim 25 wherein attachments between the removable pipe sections and the vessel and the external header are made by way of horizontal flanges.

27. The water treatment system of claim 23 wherein each septum extends upwards from its corresponding removable pipe section.

28. The filtration system of claim 18 where the vessel is a pressure vessel.

29. A water treatment method comprising, inserting a plurality of septa into a bottom of a vessel such that the plurality of septa extend no more than than 13 inches, or no more than 10 inches, optionally at least 5 inches, upwards from the bottom into the pressure vessel; filling the vessel with a water treatment media; flowing water through the vessel such that the water contacts the water treatment media before flowing through the plurality of septa.

30. The water treatment method of claim 29 wherein the water treatment media comprises any one or more of, a filtration material, an absorptive material or an ion exchange material.

31. The water treatment method of claim 29 comprising inserting the plurality of septa into the bottom of the pressure vessel such that the plurality of septa extend at least 6 inches, or at least 7 inches, into the pressure vessel.

32. The water treatment method of claim 29 wherein each of the plurality of septa have a diameter of at least about 4 inches or at least about 6 inches, optionally up to about 10 inches.

33. The water treatment method of claim 29 comprising removing a septum from the vessel while cleaning the vessel.

34. The water treatment method of claim 33 comprising removing a removable pipe section from below a septum before removing the septum.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0019] FIG. 1 is an isometric view of a pressure vessel for water treatment using a media bed with an external header underdrain system.

[0020] FIG. 2 is a side view of the pressure vessel of FIG. 1.

[0021] FIG. 3 is a front view of the pressure vessel of FIG. 1.

[0022] FIG. 4 is an isometric view of a header and spools (i.e. removable pipe sections) of the underdrain system of FIG. 1.

[0023] FIG. 5 is a top view of the header and spools of FIG. 4.

[0024] FIG. 6 is a side view of the header and spools of FIG. 5.

[0025] FIG. 7 is a side view of a septum of the underdrain system of FIG. 1.

[0026] FIG. 8 is an isometric view of the septum of FIG. 7.

[0027] FIG. 9 is an enlarged view of part of the vessel of FIG. 1 showing a flange pad and spool removed from the flange pad.

[0028] FIG. 10 shows steps in cleaning a vessel of FIG. 1.

[0029] FIG. 11 shows and an alternative removable pipe section.

[0030] FIG. 12 shows another alternative removable pipe section.

DETAILED DESCRIPTION

[0031] A detailed description of one or more examples or embodiments will be described below to assist in describing the invention and to further enable the reader to make and use the invention. In this detailed description, the invention will be described as used with an otherwise conventional pressure vessel of the type used to hold a water treatment media, for example granular activated carbon or ion exchange resin beads. However, the invention may be applied to other water treatment equipment having a drain system near the bottom of the vessel. A particular example or embodiment might not be within every claimed invention.

[0032] A conventional pressure vessel with an underdrain system including an external header has a number, for example 8, of ports attached (i.e. welded) to the bottom of the tank. The ports may be located in a circle around a central media outlet, which is used to remove media from the vessel. The ports are typically made of a section of pipe about 6-12 (15-30 cm) long. A flange is welded on one end of the port and the other end of the port is welded to the tank. Septa in fluid communication with the ports extend upwards into the tank. An external ring header is then attached (i.e. bolted) to flanges of the ports.

[0033] In a vessel described herein, removable pipe sections are added between the vessel and the ring header. These pipe sections (optionally called spools in some examples) facilitate removal of the septa for cleaning or inspection, or for cleaning of the annuli around them, without the need to remove the ring header. The pipe sections may be, for example, 6-18 (15-45 cm) long. This may improve one or more of the speed, ease, and safety of cleaning the septa or annuli during maintenance or when replacing the media in the vessel.

[0034] In some examples the removable pipe sections are rigid assemblies. For example a removable pipe section may be made up of a length of steel pipe with flanges welded onto each end of it. In other examples, a removable pipe section may be made in the form of a flexible connector or include a rigid section and one or more flexible connectors. A flexible connector, alternatively called an expansion joint, includes a flexible section that allows for an axial misalignment between an upper end and a lower end of the flexible connector, or an axial expansion of the flexible connector, or both. When the removable pipe sections include a flexible section, independent attachments may be added between the header and the vessel.

[0035] Optionally, the ports of a conventional vessel are also replaced with tangential

[0036] flange pads (alternatively called flange pads or studding outlets). Alternatively, short ports may be used but the flange pads are typically the shortest form of fitting to a curved vessel bottom having a flange available. A flange pad may have a length, measured on its longest side, of 4 (10 cm) or less. The bottom of the flange pad, or a short port or other fitting attached to the vessel, may be less than 5 cm below the lowest point, excluding any attached fittings, of the bottom of the vessel (typically found at the center of the bottom of the vessel), and optionally may be above the lowest point, excluding any attached fittings, of the bottom of the vessel. The top of the flange pad may be welded over a hole in the vessel. The bottom of the flange pad has a set of threaded holes. A septum with a flange on its lower end is inserted into the vessel through the flange pad. A removable pipe section is then bolted to the flange pad by way of a flange on the top of the pipe section. The flange of the septum is secured between the flange of the pipe section and the flange pad. The use of flange pads, or other short flanges, reduces the height of the vessel directly, and also by way of reducing the length of the septa which in turn allows the removable pipe sections to be short. However, conventional ports could alternatively be used, for example because they are readily available to the manufacture or already fitted to an existing vessel that is being adapted for use with the removable pipe sections. When using conventional ports, the vessel legs may need to be lengthened. Optionally, if conventional ports are used, they may be modified or originally fabricated to be not more than 20 cm long.

[0037] Optionally, the flange pad may have one or more ports through its sidewall. A port may be drilled through the flange pad and tapped to receive a pipe fitting. The port may be used to flush or drain an annulus between the septa and the flange before or without removing the septum. In this way, removal of the septum to clean the annulus may be delayed or avoided.

[0038] The ring header is attached to the bottom of the removable pipe sections, for example by way of horizontal flanges. Unbolting a pipe section from the flange pad and a flange on the ring header allows the pipe section to be removed by sliding it sideways. The septum can then be pulled downwards into the space previously occupied by the pipe sections. This allows an annulus between the septum and the flange pad to be cleaned from outside of the vessel. Optionally, the septum may be shorter than the pipe section. The septum can then be moved sideways to completely remove it from the tank to allow for better access to the annulus or to clean, inspect or replace the septum.

[0039] While one or more pipe sections are removed, the ring header remains attached to the vessel by other pipe sections that have not been removed, by optional independent attachment members, such as struts or U-bolts, between the ring header and the vessel, or both. One, or more than one, pipe section can be removed at a time. Optionally, flexible connectors, for example of the type having a flexible section between two flanges, may be inserted between the removable pipe sections and the header or the vessel or both the header and the vessel. In some examples, the flexible connectors may be METRASPHERE flexible connectors sold by Metraflex Quality Products. One or more flexible connectors may be removed with a rigid removable pipe section (and be considered part of the removable pipe section) or remain attached to the header or the vessel. In another option, the entire removable pipe section might be made of a flexible section, made for example of reinforced rubber, with flanges, made for example of plate steel, attached to each end of the flexible section. When removable pipe sections with one or more flexible sections that are part of or attached to the removable pipe section are used it is preferable, though optional, to have independent attachments between the header and the vessel.

[0040] However, if independent attachments are not provided it is preferable, though optional, to use rigid removable pipe sections and leave a second set of at least three pipe sections connected to the vessel while a first set of pipe sections are removed. After the first set of pipe sections are reconnected to the ring header and the vessel, the second set of pipe sections can be removed to clean their associated annuli.

[0041] A filtration system described herein comprises an underdrain system, for example as further described in this specification or any conventional underdrain system, with a plurality of removable septa extending upwards from the bottom of the pressure vessel. Each septum may be sized and shaped to generally maintain or increase the screening surface area as compared to an industry standard sized septum (diameter of 4 inches and penetration depths greater than 16 inches, typically about 16 inches), while reducing the volume of dead space at the bottom of the vessel. Each septum may have a diameter of at least 4 inches or at least 6 inches, or at least 7 inches, or at least 8 inches, or at least 9 inches, optionally up to 10 inches. The septa may be further or alternatively configured to have a length, only penetrate into the vessel by 13 inches or less or 10 inches or less, optionally by 5 inches or more. For example, the septa may extend into the vessel by a distance, or have a length, between about 5 inches and 13 inches or between about 7 and 10 inches. Optionally, the surface area of a set of 8 septa is at least 7.7 square feet. For example, there may be 4 inch or more diameter septa having a penetration of at least 11 inches; 5 inch or more diameter septa having a penetration of at least 10 inches, 6 inch or more diameter septa having a penetration of at least 9 inches; 7 inch or more diameter septa having a penetration of at least 8 inches; 8 inch or more diameter septa having a penetration of at least 7 inches; 9 inch or more diameter septa having a penetration of at least 6 inches; or, 10 inch or more diameter septa having a penetration of at least 5 inches. In an example, a septum may be fabricated to have the desired length such that the whole length of the septum is inserted into the vessel or a flange pad attached to the vessel. In another example, the penetration depth of the septum into the vessel may be configured or changed, for example by adding a spacer between the septa and the vessel and/or flange pad.

[0042] Septa configured according to this description may help maintain or increase a screening surface area, increase water flow, and/or limit pressure loss, while at the same time reduce the typical volume of wasted media in the dead space. The media found in the dead space is not fully utilized or not utilized at all, but it is typically disposed of along with the rest of the exhausted media during regular media exchanges. With the growing use of high value, single use media for PFAS remediation increases the need for minimizing the wasted resin in the dead space. However, the invention may be used with any media. The system and methods as described herein may reduce the dead space and wasted media to less than the current dead space volume, optionally while avoiding the disadvantage of an increase of pressure loss.

[0043] A treatment system that reduces dead space as described in this specification may save between USD $200,000 and USD $400,000 over a ten-year life cycle of a 7-12 diameter vessel when using resin and about half those savings when using specialty carbon. The treatment system with reduced dead space may further allow for fewer shutdowns for media exchange, less media to dispose of, and therefore less labor, transportation and shut down costs.

[0044] In an example of a water treatment method, a plurality of septa are inserted into the bottom of a pressure vessel, or other water treatment tank, having a drain at or near the bottom of the vessel, such that the septa extend a maximum of 13 inches, or a maximum of 10 inches, optionally at least 5 inches, into the vessel. The vessel is filled with a water treatment media such as resin, specialty carbon, or another suitable filtration material, absorptive material or ion exchange material. Water to be treated is flowed through the vessel such that it contacts the media and produces an effluent, which flows through the plurality of septa. Preferably the septa used in the method have a diameter of at least 4 inches or at least 6 inches, optionally up to 10 inches. This method may provide for water treatment that utilizes an increased amount of the media in the vessel (as compared to industry standard), without compromising performance in the area of pressure loss. When combined with an underdrain system having removable pipes, the reduced length of the septa also reduces the required length of the removable pipes.

[0045] FIGS. 1-3 shows an example of a vessel 10 with an underdrain system 12. The vessel 10 in this example is a pressure vessel for holding a water treatment media such as granular activated carbon or ion exchange resin beads. The underdrain system includes a header 14 that is external to the vessel 10. In the example shown, the vessel 10 has a diameter of about 12 (3.7 m).

[0046] The vessel 10 has a set of legs 16 to support the vessel 10 on a floor. The vessel 10 also has a wash nozzle 18 and a flanged media outlet port 22. During media changes, media is removed through the outlet port 22 while water is added through the wash nozzle 18. A media inlet port 24 is used to add new media to the vessel 10. A hatch 28 allows a person to enter the vessel 10 when necessary. A sight glass 30 is provided to allow a person to see into the vessel 10. A set of anticipatory probes 32 are provided at different elevations to allow for monitoring the condition of the media.

[0047] During use, water to be treated enters the vessel through an inlet distributor nozzle 26. The water flows through the media in the vessel, septa 34, and spools 36 to the header 14. The header 14 is in the shape of a ring with a flanged outlet port 20.

[0048] Referring still to FIG. 3, the volume of dead space at the bottom of a vessel 10 may be defined by the volume below an upper boundary 21 defined by a plane passing through the tops or crowns of the septa 34 and running orthogonally into and through the tank walls. Where the septa 34 penetrate into the vessel 10 at varying depths, the upper boundary of the dead space may be defined by a plane passing through the tops of the septa 10 that are closest to the bottom of the vessel 10, or in other words which penetrate into the vessel at the smallest distance from the bottom compared to the other septa 34. The side boundary of this dead volume is the tank wall. The bottom boundary 23 of this dead volume is the bottom of the vessel 10. The penetration distance 25 of the septa 34, which is the between the upper boundary 21 and the lower boundary 23, is 13 inches or less, or 10 inches or less, and optionally down to about 5 inches or more or 6 inches or more or 7 inches or more. Reducing the penetration distance reduces the volume of dead space at the bottom of the vessel 10. The septa 34 as shown in FIG. 3 have diameters of 4 inches or more or 6 inches or more. Optionally, an increased diameter of the septa 34, relative to industry standard septa, may maintain or increase the surface area of the septa 34 with a reduced length, relative to industry standard septa. For example, 10 inch or more diameter septa may have a penetration of at least 6 inches; 9 inch or more diameter septa may have a penetration of at least 8 inches; 8 inch or more diameter septa may have a penetration of at least 8 inches; 7 inch or more diameter septa may have a penetration of at least 10 inches; 6inch or more diameter septa may have a penetration of at least 11 inches; or, 5 inch or more diameter septa may have a penetration of at least 13 inches. By maintaining the surface area of the septa 34, the treatment system may have little to no degradation of performance in the area of pressure loss. Optionally, an increased screening surface area may facilitate faster and easier flow of water through the septa 34 at any given pressure.

[0049] FIGS. 4-6 show the header 14 and spools 36 in greater detail. In the example shown, the header 14 is made up of sections of 8 (20 cm) diameter pipe bolted together. The header 14 has a set of inlet flanges 38. The inlet flanges 38 are located at the top of the header 14 and oriented horizontally. Each spool 36 is a section of pipe with an upper flange 40 at the top of the spool 36 and a lower flange 42 at the bottom of the spool 36. The upper flange 40 and lower flange 42 are perpendicular to the length of the spool 36. In the example shown, the section of pipe of the spool is about 6 (15 cm) in diameter and 12 (30 cm) long. Bolts and nuts, not shown, attached the spools 36 to the header 14.

[0050] FIGS. 7-8 show a septum 34. The septum 34 has a plate flange 44 attached to a solid pipe segment 46. A screen 48, for example a wellscreen, is attached (i.e. welded) to the top of the solid pipe segment 46. The screen 48 may be made, for example, of stainless steel v-wire or other well screen material. The screen 48 or the pipe segment 46 may be fabricated to account for the desired penetration depth of the septum into the vessel. For example, the combined length of the screen 48 and the pipe segment 46 may be 12 inches or less, or 10 inches or less, or such that the septum 34 penetration distance into the vessel 10 does not exceed 12 inches or 10 inches, or is in a range of 7 to 10 inches. In another example, the combined length of the screen 48 and the pipe segment 46 may be greater than 10 inches, but only a portion of the septum 34 is inserted into a vessel to a maximum penetration depth into the vessel of less than 12 inches, for example to a penetration depth of about 7 inches to about 10 inches.

[0051] FIG. 9 shows one of a set of tangential flange pads 50 attached to the bottom of the vessel. The flange pad 50 presents a horizontal flange surface. The flange pad 50 has threaded holes 55 to accept bolts (not shown) passing through the upper flange 40 of the spool and the plate flange 44 of the septum 34. The septum 34, when inserted into the flange pad 50, extends upwards from its flange 44 into the vessel 10. Optionally, one or more ports 52 are provided through the side wall of the flange pad 50. The ports 52 may be connected to pipes and used to spray water into an annulus 54 between the flange pad 50 and the septum 34, or to withdraw a slurry from the annulus 54.

[0052] FIG. 10 shows steps in cleaning the vessel 10. A spool 36 is unbolted from the flange pad 50 and the header 14 and moved sideways away from the header 14. The septum 34, which is shorter than the spool 36, is then lowered into the space previously occupied by the spool 36. In this way, the septum 34 is removed from the vessel 10. Optionally, the septum 34 can be moved sideways to better expose the annulus 54 inside the pad flange 50. The annulus 54, or the inside of the pad flange 50 generally, can then be cleaned out. For example, media or other solids are removed from the inside of the pad flange 50. After the annulus 54 is cleaned, the septum 34 is reinstalled in the vessel 10 and the spool 36 is bolted back into place. Another spool 36 and septum 34 can then be removed. The process can be repeated until every spool 36 and septum 34 have been removed and replaced, and all of the annuli 54 are clean.

[0053] In the method described above, the header 14 remains attached to the vessel 10 even when a spool 36 is removed. Optionally, additional struts 56 may be added between the header 14 and the vessel to allow more spools 36 to be removed simultaneously. However, keeping 3 or 4 spools 36 attached may be adequate to support the header 14 while other spools 36 are removed. Accordingly, eight annuli 52 can be cleaned in two to four sets if desired. Alternatively, one annulus 52 at a time may be cleaned.

[0054] FIG. 11 shows a first alternative removable pipe section 68, which may be used in place of the spool 36 described above. The first alternative removable pipe section 68 has a flexible section 60 connected to an upper flange 40 and a lower flange 42. FIG. 12 shows a second alternative removable pipe section 70. The second alternative removable pipe section 70 has a flexible section 60 connected to an upper flange 40 and a first intermediate flange 62. The second alternative removable pipe section 70 also has a rigid pipe section 66 connected to a second intermediate flange 62 and a lower flange 42. Alternatively, variations on the second alternative removable pipe section 70 may be made with the flexible section 60 at the bottom of the second alternative removable pipe section 70 or on both the top and bottom of the second alternative removable pipe section 70.

[0055] The invention may be practiced in various alternative forms and/or with modifications to the description of examples above. Ordinary methods and devices used to build pipe networks, such as gaskets, sealants, fasteners, fittings etc. have not been described above but may be used as required.