Continuous Dewatering Recirculation System with Integral Coal Combustion Residual High Flow Plate Separator

Abstract

The system for a continuous dewatering recirculating for removing particulate such as coal combustion residue from a water stream. The system includes multiple dewatering and recirculation containers, each having a submerged flight conveyor and lamella settlings plate located therein, at least one dewatering and recirculation container receives ash water stream overflow.

Claims

1. A system for reducing the particulate in a bottom ash water stream comprising: a) A plurality of continuous dewatering and recirculation containers, each of the plurality of continuous dewatering and recirculation containers containing a submerged flight conveyor therein, with at least one of the plurality of continuous dewatering and recirculation containers receiving coal combustion residue water stream overflow from another of the plurality of continuous dewatering and recirculation containers; b) At least one lamella settling plate located within each of the plurality of continuous dewatering and recirculation containers; and c) A control unit for selecting at least one continuous dewatering and recirculation container from among the plurality of continuous dewatering and recirculation containers for receiving ash water stream overflow.

2. A system for reducing the particulate in a coal combustion residue water stream of at least 2000 gallons per minute comprising: a) At least one continuous dewatering and recirculation container for receiving the coal combustion residue water stream; b) At least one variable water level surge tank operatively connected to the at least one continuous dewatering and recirculation container so as to maintain a substantially constant water level therein for filtering the coal combustion residue water stream; c) A plurality of lamella settling plates located within the continuous dewatering and recirculation containers for filtering the coal combustion residue water stream, wherein the flow of the coal combustion residue water stream, the number and geometry of plates in the plurality of lamella settling plates generates a Reynolds number within the plurality of lamella settling plates of at least 500.

3. The continuous dewatering and recirculation system of claim 2, wherein the plurality of lamella settling plates comprises between 150 and 1000 plates for each continuous dewatering and recirculation container.

4. The continuous dewatering and recirculation system of claim 2, wherein the spacing between at least two neighboring plates in the plurality of lamella settling plates is at least 2 inches.

5. The continuous dewatering and recirculation system of claim 2, wherein the geometry of at least some of the plates in the plurality of lamella settling plates includes a slope of at least 60 degrees.

6. The continuous dewatering and recirculation system of claim 2, wherein the geometry of at least some of the plates in the plurality of lamella plates is 44 feet.

7. The continuous dewatering and recirculation system of claim 2, wherein the plurality of lamella settling plates can generate a non-laminar flow for a coal combustion residue water stream ranging from 2000-9000 gallons per minute.

8. The continuous dewatering and recirculation system of claim 2 further comprising adjustable height weirs connected the plurality of lamella settling plates so as to adjust the height of the water in the container so as to improve the efficiency of the filtering by the plurality of lamella settling plates.

9. The continuous dewatering and recirculation system of claim 8 further comprising a screen attached to the adjustable height weir to filter larger, buoyant particles from the coal combustion residue water stream.

10. A continuous dewatering and recirculation system for reducing the particulate in a coal combustion residue water stream of at least 2000 gallons per minute comprising: a) A first and second container operatively connected to one another for receiving the coal combustion residue water stream, wherein the second container is capable of both secondarily filtering particulate in a coal combustion residue water stream, and maintaining a substantially constant water level in the first container for filtering the coal combustion residue water stream, and the first and second containers may be switched in operation such that the first container is capable of maintaining a substantially constant water level in the second container for filtering the coal combustion residue water stream; b) A conveyor system in the each of the first and second container for dewatering and removing settled particulate therefrom; and c) A plurality of lamella settling plates located within each of the first and second continuous dewatering and recirculation containers for filtering the coal combustion residue water stream, wherein the flow of the coal combustion residue water stream, the number and geometry of plates in the plurality of lamella settling plates generates a Reynolds number within the plurality of lamella settling plates of at least 500.

11. The continuous dewatering and recirculation system of claim 10, wherein the conveyor system comprises a drag chain.

12. The continuous dewatering and recirculation system of claim of claim 11, further comprising a control unit for adjusting the speed of the drag chain in response to the rate of solids entering the first and second containers.

13. The continuous dewatering and recirculation system of claim 12, wherein the control unit measures values corresponding to the force on the chain.

14. The continuous dewatering and recirculation system of claim 10, wherein the first and second container each include an energy dissipating baffle located at an inlet for receiving the coal combustion residue water stream.

15. The continuous dewatering and recirculation system of claim 10, wherein the first and second container each include a further inlet port adjacent the energy dissipating baffle for receiving a flocculant to mix with the coal combustion residue water stream prior to filtering by the plurality of lamella settling plates.

16. The continuous dewatering and recirculation system of claim 10, containing an inlet pipe connected to the first and second containers, the inlet pipe providing a coal combustion residue water stream and a coagulant from a location remote from the first and second containers.

17. The continuous dewatering and recirculation system of claim 11, wherein each of the first and second containers includes a separate drag chain so as to create separate piles of particulate removed from each of the first and second containers so as to enable further dewatering.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 shows a perspective view of a continuous dewatering circulation system in accord with a first embodiment of the present invention.

[0034] FIG. 2 shows a first cross section view of the continuous dewatering circulation system in accord with a first embodiment of the present invention taken along section line 2-2 in FIG. 1.

[0035] FIG. 3 shows a second cross section view of the continuous dewatering circulation system in accord with a first embodiment of the present invention taken along section line 3-3 in FIG. 1.

[0036] FIG. 4 is a detail view of the adjustable weir feature in conjunction with a detail of lamella plates in accord with another embodiment of the present invention that is shown in FIG. 3 taken along detail circle 4.

DETAILED DESCRIPTION OF THE INVENTION

[0037] Set forth below is a description of what is currently believed to be the preferred embodiment or best examples of the invention claimed. Future and present alternatives and modifications to this preferred embodiment are contemplated. Any alternatives or modifications which make insubstantial changes in function, in purpose, in structure or in result are intended to be covered by the claims in this patent.

[0038] FIG. 1 shows a first preferred embodiment constructed in accordance with the present invention. The continuous dewatering system 10 includes a bottom ash hopper 20, a first continuous dewatering and recirculation container 30 and a second continuous dewatering and recirculation container 40. A recirculation system of this type is appropriate where high conveying capacities are required and minimal outage time is needed for conversion. Each of the continuous dewatering and recirculation containers 30, 40 in this embodiment include a submerged flight conveyor 32, 42 including a drag chain 34, 44 for ash particulate from the coal combustion residue water stream received from the bottom ash hopper 20. Each of the dewatering and recirculation containers 30, 40 further includes sets of lamella plates 36, 46 which are responsible for removing the ash/coal combustion residue from the coal combustion residue water stream.

[0039] In practice, the coal combustion residue water stream is pumped from the bottom ash hopper 20 via a pump 50 through piping 52. The typical flow rates for systems practicing the present invention is at least 2000 gallons per minute, with a typical flow range being from approximately 2000-9000 gallons per minute. The piping 52 splits into a tee delivery configuration, with each of the ends of the tee feeding into the respective continuous dewatering and recirculation containers 30, 40. The control of which continuous dewatering and recirculation container receives the coal combustion residue water stream is enabled by a control unit (not shown) and/or direct, manual control of valves 54, 56, which control the flow of the coal combustion residue water stream. As shown in the example of FIG. 1, continuous dewatering and recirculation container 30 is receiving the coal combustion residue water stream, but continuous dewatering and recirculation container 40 is not.

[0040] As shown in FIG. 2, the coal combustion residue water stream is delivered out of the ends of the T of piping 52 and impacts upon an energy dissipating baffle 58, 60, which works in conjunction with a flocculant injection tube 62, 64. The flocculant injection tube 62, 64 selectively add a limited amount of flocculant to the coal combustion residual water to better separate particulate from the water stream and to enable removal of larger particles from the stream such that they are captured by the flights or plates 66 of the drag chain 34, 44 so as to be removed from the stream. Furthermore, the speed of the drag chain 34, 44 is optionally adjustable, for instance, in response to the rate of solids entering the containers 30, 40.

[0041] As shown in FIG. 3, the present embodiment further removes particulate from the coal combustion residue water stream as the stream travels down the length of the continuous dewatering and recirculation containers 30, 40 by interacting with the sets of lamella plates 36, 46. These sets of plates typically comprise between 150 and 1000 plates for each continuous dewatering and recirculation container 30, 40, and are further typically spaced on the order of two inches apart or more from one another and are preferably angled around 60 degrees from the horizontal (bottom) of the continuous dewatering and recirculation containers 30, 40. Those of skill in the art will understand that the flow of the coal combustion residue water stream, and the number and geometry of plates in the plurality of lamella settling plates, 36, 46 will influence the degree of turbulence. In fact, even using a high flow rate of the coal combustion residue water stream, and employing the number and geometry of plates a described above, the practice of the present invention is nonetheless believed to operate with advantage despite having a turbulent fluid regime (i.e., a Reynolds number of 500+) within the region of lamella settling plates 36, 46.

[0042] One important feature in this embodiment in the present invention, as shown in FIG. 3, is the ability to control the level of the coal combustion residue water stream in at least one of the continuous dewatering and recirculation containers 30, 40, i.e., in order to maintain the efficacy of the lamella plates 36, 46. The structures used for maintaining a substantially constant water level along the length of the continuous dewatering and recirculation containers 30, 40 are overflow crossovers 72, 74 and valves 76, 78. These structures enable the system 10 to handle changes in the flow rate of the coal combustion residue water stream while maintaining a constant water level for the container (30 or 40) selected for receiving the coal combustion residue water stream in the first instance (i.e., container 30 in the example of FIG. 1). This constancy in water level provides for improved efficiency of system 10 whereby the lamella plates 36, 46 can settle or filter further particulate in down into the bottom of the containers 30, 40 so as to be captured by the flights or plates 66 of the drag chain 34, 44 for removal. As shown in FIG. 1, the water from the now cleaned coal combustion residue water stream is removed from the containers 30, 40 through clean water supply piping 80, and selectively passed through valves 82, 84 for recirculation in the system 10.

[0043] Optionally, a further feature that can be used in alternative embodiments of the present invention to incorporates an adjustable weir 90 with integral overflow troughs 91, as shown in FIG. 4. The adjustable weir 90, allows for the overflow to be balanced among several modules of plates 36, 46 in the overall system 10. This weir 90 is designed for overflow from the sides of the plates 36, 46 (rather than over the top as implemented on existing technology). The weir 90 can also incorporate screens 92 to handle larger buoyant particles or floaters.

[0044] The above description is not intended to limit the meaning of the words used in the following claims that define the invention. Rather, it is contemplated that future modifications in structure, function or result will exist that are not substantial changes and that all such insubstantial changes in what is claimed are intended to be covered by the claims. For instance, the present invention could be employed in a system including just a single container 30 in conjunction with a surge tank (not shown). In addition, the present invention could operate with three or more containers, and can further include a sun shield for the containers to protect from UV exposure and/or structures to enable the plates 36, 46 to be used in a modular fashion and to be walked upon during use. Likewise, it will be appreciated by those skilled in the art that various changes, additions, omissions, and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. All such modifications and changes are intended to be covered by the following claims.