Sludge collecting unit

Abstract

This invention relates to a sludge collection unit comprising a pressure tank (2) having a hollow interior and a top cover (3) adapted to pressurelessly seal the hollow interior, wherein the pressure tank (2) is adapted to insert and seal a cylinder (8) within the hollow interior, wherein the interior of the cylinder (8) is connected (10, 11, 20a) to an engine purge air exhaust section via an engine purge air exhaust connection (20a) to collect material within the engine purge air exhaust section, wherein the hollow interior is connected to the engine purge air exhaust connection (20a) via pressure connections (12, 21). For collecting reusable oil, the outlet of the pressure tank (2) is adapted to be connected to the outside via a connection (20b) to allow fluid materials such as oil to overflow from the engine purge air exhaust section.

Description

Technical Field

[0001] This invention relates to pressure-fixed sludge collection tanks suitable for containing containers, such as standard 208L (55-gallon) steel drums. The invention is particularly suitable for exhaust systems that discharge flushing air from engines (e.g., two-stroke crosshead type engines). This is also referred to as a "purge air space" or "piston underside space." The invention is also applicable to exhaust systems that discharge from the engine's flushing air canister, also referred to as a "purge air receiver." The invention can be used for retrofitting existing engines and installations, as well as for installing new engines and installations. The invention can be used for both pressurized and unpressurized (open) tank and piping systems.

[0002] This invention relates particularly to engines on ships, but is not limited thereto. Background Technology

[0003] For example, in a crosshead-type two-stroke engine, it is known that varying amounts of a medium called sludge are produced during operation. This medium primarily consists of a mixture of lubricating oil and solid particles in the form of unburned particulate matter. These solid or sluggish liquid components tend to settle / deposit under gravity and accumulate at the bottom of pipes, containers, and tanks. This causes the relatively heavier solid material to settle layer by layer relatively quickly. The accumulated material is almost identical to hardened compacted soil. This phenomenon occurs because the density of the flowing portion of the medium (oil) is significantly lower than that of the solid particles in the sludge.

[0004] As is well known, the medium from the engine (a mixture of lubricating oil and heavy solid particles) is transferred to an intermediate tank via a descending pipe. This tank is commonly referred to as a "purge air discharge tank." These tanks typically have a volume of approximately 500-2000L and are characterized by their ability to withstand overpressure (typically 0.2-4 bar) corresponding to the engine purge air pressure. The air pressure from the engine (purge air) passes through a sludge discharge pipe and pressurizes the tank during engine operation. The purpose of the tank is partly to collect and retain the solid particles (sludge) of the medium, and partly as an observation tank where the daily discharge can be measured by measuring the water depth in the tank. Furthermore, this tank is usually equipped with a level alarm that sounds if the tank's filling level exceeds the desired level. The intermediate tank is typically emptied daily by manually opening a valve to form a pipe connection from the bottom of the intermediate tank to a larger storage tank. Thus, the medium flows from the intermediate tank to the storage tank by gravity and positive pressure differential.

[0005] Therefore, in this well-known and widely used system, the intermediate tank requires regular manual cleaning. The intermediate tank must be opened simply by removing the manhole cover. What follows is a tedious and dirty process of manually excavating the tank. Excavation of solid particles (sludge) is typically done using shovels and scrapers of various manufactures. The sludge is scooped into buckets, which are usually hoisted by hand to the nearest deck (if on a ship). Here, the sludge is typically poured into open 208L steel drums. After excavation, the tank is manually cleaned with a cloth. It is often necessary to climb into the tank to achieve thorough cleaning. Manual excavation and cleaning involve potentially hazardous work. The work positions are also often uncomfortable and, by today's standards, inadequate. This excavation of the intermediate tank is typically performed every 2-4 weeks. Regular excavation is necessary to ensure the proper functioning of the system. If excavation is not carried out in a timely manner, the sludge will reach a certain level, and the pipes connecting to the large storage tank may become clogged. Then it will be necessary to separate and clean the intermediate tank and pipe connections.

[0006] There is a distinction between the liquid component (lubricating oil) and the solid component (sludge) of the medium. Both components are transported to approved companies for processing. Lubricating oil is often valuable and frequently receives payment because it can be relatively easily reused for other purposes.

[0007] On the other hand, high prices are paid for solid particles (sludge) because they are troublesome to handle. Therefore, it is advantageous to effectively separate sludge and lubricating oil, which can avoid paying high taxes for unnecessary high lubricating oil content in sludge.

[0008] Sludge can be discharged (see, for example, published patent application WO2018 / 233789) and placed into a container. Standard containers, such as 208L (55-gallon) steel oil drums, are designed or constructed to withstand significant underpressure or overpressure. Therefore, these standard containers cannot withstand overpressure (typically 0.2-4 bar), such as that found in the exhaust systems of crosshead-type two-stroke engines. Consequently, it is not possible to directly connect standard containers to the exhaust system, allowing solid particles to settle inside. Therefore, one object of the present invention is to prevent container deformation, damage, or even bursting. Summary of the Invention

[0009] The purpose of this invention is to prevent messy manual cleaning of intermediate tanks and to safely and efficiently separate lubricating oil and heavy solid particles. This invention achieves this by having relatively heavy particles settle directly in transport containers for further solid transport. This invention significantly reduces the time required for manual cleaning.

[0010] Furthermore, this invention significantly reduces the consumption of cleaning agents and diesel fuel compared to manual cleaning of tanks and pipelines. Additionally, it prevents blockages in the pipeline system from intermediate tanks used for storage. Moreover, it reduces or eliminates sludge buildup in large and hard-to-reach storage tanks.

[0011] The absence of sediment / deposits in these storage tanks has historically eliminated the need for extensive manual cleaning and the fundamental problem of further pumping out the tank contents. Last but not least, this invention provides a significant improvement in the working environment for relevant personnel. It should be mentioned that facilities (ships) using crosshead type two-stroke engines most often have ample supplies of empty steel drums. This is because the lubricating oil consumption supplied by these standard 208L drums is relatively high.

[0012] There is currently no known system in which sludge from a two-stroke engine purge air exhaust system can be pressurized and collected directly in a standard 208L (55-gallon) steel drum.

[0013] A key feature of this invention is its ability to be quickly installed in exhaust systems that discharge purge air from, for example, crosshead-type two-stroke engines via purge air belts and purge air canisters. A further feature is the inclusion of a standard 208L (55-gallon) steel drum surrounded by a pressure tank. Furthermore, this invention allows for the direct collection of engine sludge under pressure into a standard drum, such as a 208L (55-gallon) steel drum. Another feature of this invention is the constant pressure equalization arrangement between the inner and outer surfaces of the steel drum.

[0014] The present invention aims to provide a sludge collection unit comprising a pressure tank having a hollow interior and a top cover adapted to pressurelessly seal the hollow interior. The pressure tank is characterized in that a cylinder is inserted into and sealed within the hollow interior, wherein both the interior of the cylinder and the hollow interior of the pressure tank are connected to an engine purge air exhaust section. This ensures that the pressure on both sides of the cylinder is the same. Therefore, the interior of the cylinder can be connected to an engine purge air exhaust section via an engine purge air exhaust connection to collect material within the engine purge air exhaust section, wherein the hollow interior is connected to the engine purge air exhaust connection via a pressure connection.

[0015] The pressure tank can be adapted so that the outlet of the cylinder is connected to the outside via a connector to allow fluid material to overflow from the engine purge air exhaust. This allows for the collection of usable oil fed into the cylinder. For this purpose, the connector to the outside can be adapted to connect to an intermediate tank for collecting overflowing fluid material or oil in a pressure-proof, sealed manner. It needs to be tightened so as not to affect the pressure balance on the cylinder surface.

[0016] The pressure connection can be attached to the engine purging unit at a location that allows gaseous air but substantially prevents solid materials from entering, and wherein it connects to the interior of the pressure tank at a location that allows solid / liquid materials to enter. This allows heavy sludge material to be fed into the tank, while the hollow interior of the pressure tank outside the tank allows only gas to enter. One way to make this arrangement is to make a pressure connection attached to the upper side of the engine purging air exhaust connection.

[0017] The top cover may be perforated, and these perforations are suitable for connectors that are connected to the cylinder in a pressure-free manner through the top cover.

[0018] To allow for variations in the height of different inserts, tolerances are ensured by using insert-type connectors that are properly secured to the inserts within the bore. These insert connectors can be sealed to the top cover via a guide bushing, and also allow for horizontal and vertical movement during operation and installation of the inserts.

[0019] To ensure proper positioning and fixation of the pressure tank within the hollow interior, the sludge collection unit may include a positioning plate adapted to connect to the upper surface of the cylinder and the inner surface of the hollow interior.

[0020] The positioning plate may have an extension adapted to extend to the side surface of the cylinder to fit between the outer surface of the cylinder and the inner surface of the pressure vessel. This ensures no rotation and allows it to fit within an internal shape formed on the inner surface of the pressure vessel. Furthermore, this arrangement maintains the correct positioning of the cylinder and ensures sufficient space for the sliding of a cylinder lifting tool.

[0021] The positioning plate can be formed with holes adapted to match the holes on the top cover, so as to allow connection to the cylinder through both the top cover and the positioning plate.

[0022] To control the pressure inside the pressure tank, the top cover may have an opening that connects to an overpressure valve located on the outer surface of the top cover.

[0023] The engine purge air exhaust connection can be connected to the cylinder via an inlet connection device, which also includes a sensor piston with a sensor element positioned within the cylinder. The purpose of the sensor piston (14) is to allow it to be pressed down below the top of the cylinder (8) by force, for example by hand. Therefore, when the sensor piston (14) encounters solid particles accumulated in the upper part of the cylinder (8), the sensor piston will encounter increased resistance. In this way, when the cylinder (8) is filled with solid (sediment) sludge, it can be detected simply and safely. During operation, the sensor piston (14) will be held in the upper position due to overpressure in the inlet connection of the cylinder (8).

[0024] The pressure vessel can be a standard 208L (55-gallon) steel oil drum. Attached Figure Description

[0025] Figure 1 It is a pressure tank for a sludge collection unit according to an embodiment of the present invention.

[0026] Figure 2 This is a top view of an embodiment of a positioning plate that is part of a sludge collection unit.

[0027] Figure 3A , Figure 3B These are the side view and top view of the pressure tank, with the cylinder positioned inside and a positioning plate installed therein.

[0028] Figure 4 This is a top view of the pressure tank, with the top cover closed.

[0029] Figure 5A , Figure 5B An inlet connection device attached to the top cover of the pressure tank is shown for connecting to the engine purge air exhaust connection, wherein the sensor piston is in two different positions. Detailed Implementation

[0030] It should be understood that while the detailed description and specific embodiments illustrate embodiments of the invention, they are given by way of illustration only.

[0031] Figure 1 An embodiment of the sludge collection unit (SCU) (1) according to the invention is shown, intended for use in pressurized discharge systems (discharge from engine wash belts and containers), but it can also be used to collect unpressurized sludge discharge systems.

[0032] The present invention includes a pressure vessel (2) (which may be cylindrical or circular, but may also be polygonal) fitted with a top cover (3) which can be opened to a vertical position by means of, for example, a hinged yoke (4) via a handle. The hinged yoke (4) may be influenced by two air springs (5) or other means suitable for balancing the weight of the top cover (3), making opening to the vertical position easy and comfortable. The lifting yoke (4) can be arranged such that a safety split can be inserted when the cover (3) is in the open position. The hinged yoke (4) can be replaced by any device suitable for opening and closing the top cover (3).

[0033] The top cover (3) is adapted to be secured to the pressure vessel (2) in the closed position, for example by bolts or other means. In the illustrated embodiment, openings (15) are formed at the edge of the upper opening of the pressure vessel (2) and at the edge of the top cover (3) for inserting bolts to secure the pressure vessel and the top cover together.

[0034] The top cover (3) may also be equipped with an overpressure valve (6) (see Figure 4 The diagram shows an overpressure valve (6) located outside the top cover (3), which communicates with the interior of the tank (2) through an opening (7). This ensures that the pressure in the pressure tank does not exceed the design pressure or the set maximum pressure. The pressure tank (2) is designed for use in applications such as barrels (8) (in... Figure 1 A barrel (not visible in the center) is fitted into the tank (2), such as, but not limited to, a standard 208L (55-gallon) steel drum or other standard drum, which will be generally referred to as barrel (8) below. The tank (2) is designed such that the volume between the outer surface of the barrel (8) and the internal volume of the pressure tank (2) is relatively minimized. However, some tolerances are allowed so that a barrel (8) with slight deformation (small protrusions) can still be immersed in the pressure tank (2).

[0035] Use the positioning plate (9) to keep the barrel (8) centered and correctly positioned in the pressure tank (2), or see also Figure 2 , 3A And 3B.

[0036] See Figure 2 In the top view of the embodiment, the positioning plate (9) may be a flat plate adapted to mate with the inner side of the upper barrel edge (8a) and has an extension (9a) adapted to extend beyond the upper barrel edge (8a) to the outer side of the upper barrel edge, wherein the extension fits between the outer surface of the upper barrel edge (8a) and the inner surface of the pressure tank (2) to keep the barrel (8) tightly in place. Furthermore, the extension may be adapted to fit within an internal shape (2a) formed on the inner surface of the pressure tank (2) to define the orientation of the barrel (8). Figure 3A A side view of the barrel (8) inside the pressure tank (2) is shown, wherein the extension is pressed between the upper barrel edge (8a) and the inner surface of the pressure tank (2). Figure 3B This is a top view in which the positioning plate (9) is positioned to connect with the barrel (8) and the pressure vessel (2). The top view shows one embodiment of the internal shape (2a), which is formed as a protrusion extending into the hollow interior of the pressure vessel (2), but may also be a recess extending into the surface, or formed in other suitable ways.

[0037] A seal (2b) may be formed on the upper edge of the top cover (3) or pressure vessel (2) (as shown in the figure), which is adapted to be pressed between the upper edges of the top cover (3) and the pressure vessel (2) when the top cover (3) is in the closed position. This ensures a tight connection when they are fastened together, for example, by bolts.

[0038] The top cover (3) and the positioning plate (9) are provided with holes (10, 11) to form a passage through the top cover (3) of the pressure tank (2) to the connector of the barrel (8). In one embodiment, a tight fastening of the connector of the barrel (8) through the top cover (3) (e.g., threaded) to the external connector (20a, 20b) can be ensured by means of an insert connector (not shown), which may be a threaded connector adapted to be fixed to the barrel (8), for example, a threaded connector fixed to the barrel (8), wherein the standard oil barrel (8) is equipped as a standard with 3 / 4" and 2" internal pipe threads.

[0039] The insert connector is sealed to the connector of the barrel (8) using a sealing ring, and may be sealed to the top cover (3) using a guide bushing with an associated O-ring seal. The guide bushing further allows vertical movement of the connector and insert connector of the barrel (8) to compensate for vertical movement caused by thermal expansion and vertical movement caused by minor deformation of the barrel (8) due to pressure changes.

[0040] Based on manufacturing tolerances, such as those for a standard barrel (8), some vertical and horizontal tolerances are required to compensate for small height differences.

[0041] The bushing can be fastened to the top cover (3) using flanges and bolts.

[0042] The insert connector (related to the oil outlet (overflow) of the barrel (8)) connected to the connector (20b) extending to the outside of the barrel (8) can extend, for example, 70 mm below the top of the barrel. This allows the liquid level in the barrel (8) to be lowered before the insert connector, etc., is removed to avoid oil spillage when the barrel (8) is replaced.

[0043] Figure 4 This is a top view of the cover plate (3), showing the handle (3a), and showing the engine purge air discharge connection (20a) and the connection (20b) for the oil outlet extending to the outside of the barrel, both of which can be pipes, hoses, etc.

[0044] The entry of the medium (lubricating oil mixed with relatively heavy solid particles) occurs through the engine purge air exhaust connection (20a), which connects to the inlet connection of the barrel (8) via a connection hole (10) on the top cover and a hole (11) on the positioning plate. An inlet connection device (13) (possibly Y-shaped, e.g., a 45-degree pipe-Y) is located at the top of the cover plate (3) (see...). Figure 5A and 5BThe inlet connection connects the engine purge air exhaust connection (20a) to the inlet connection of the barrel (8). This design ensures a functional inlet for entry into the barrel while allowing the sensor piston (14) to enter the interior of the barrel (8). The sensor piston (14) can be made with a pressure-resistant shaft seal to allow the sensor element to move effortlessly axially (vertically) within the barrel (8). The sensor piston (14) is designed to allow pressure, for example by hand, to be pressed down below the top of the barrel (8). Therefore, when the sensor piston (14) encounters solid particles accumulated in the upper part of the barrel (8), the sensor piston will encounter increased resistance. In this way, when the barrel (8) is filled with solid (sediment) sludge, it can be detected simply and safely. During operation, the sensor piston (14) will be held in the upper position due to overpressure in the inlet connection of the barrel (8). This overpressure is generated by the air pressure from the engine purge air system, which is transmitted to the barrel (8) via the exhaust system.

[0045] This invention ensures that the pressure inside and outside the barrel (8) is approximately uniform. The interior of the barrel (8) is pressure-impermeable to the engine purge air discharge connection (20a). This allows the barrel (8) to be rapidly filled with a liquid medium by continuous discharge from the engine. Lubricating oil overflows through a connection (20b) to the outside of the barrel (8) to an intermediate tank connected to the outlet of the barrel (8). In the intermediate tank, the pressure is the same as in the pressure tank (2), and correspondingly the same as in the discharge connection (20a). Thus, relatively pure lubricating oil is propelled and flows from the pressure tank (2) to the intermediate tank by overflow and gravity, where it is collected as relatively pure oil for other uses. Relatively heavy particles (sludge) settle layer by layer inside the barrel (8).

[0046] The empty volume between the inside of the pressure tank (2) and the outside of the barrel (8) is also connected by the pressure connector (21) and the hollow interior of the pressure tank (2) but outside the barrel (8) (see also...) Figure 3AThe pressure opening (12) leading to the top side of the engine exhaust connection (20a) is pressurized by pressure balancing air (generator purge air), thereby ensuring that the pressure outside the barrel (8) is the same as the pressure inside. By positioning the connection at the top side of the engine exhaust connection (20a), it is ensured that heavy materials such as sludge do not enter the pressure connection 21. Therefore, the pressure difference between the inside and outside of the barrel (8) can be effectively balanced. Thus, even if the pressure of the engine exhaust system changes, the inside and outside of the barrel (8) always have the same pressure. The pressure balancing air can be guided through the oil mist filter to purify the oil vapor in the air to avoid unnecessary contamination of the outside of the barrel (8). The separated oil mist can be manually discharged from the oil mist filter through the valve at the bottom of the filter. The bottom of the pressure tank (2) is also fitted with an exhaust connection and valve. If the pressure tank (2) is purged from the inside, this allows the liquid to be discharged.

[0047] The bucket can be easily replaced using the following procedure:

[0048] The system is depressurized, which is achieved by closing the main valve from the engine exhaust system. The opening to the atmosphere (which may be a throttle opening or a valve for overpressure control (6)) (see...) Figure 4 The opening (7) (see) Figure 1 Ensure that overpressure is quickly discharged from the intermediate tank, pressure tank (2) and connecting parts (20a, 20b).

[0049] Subsequently, disconnect the connectors (20a, 20b), guide bushings, and connecting inserts, and safely open the top cover (3) to the vertical position. Securely close the barrel (8) using suitable plugs, which are typically threaded standard parts.

[0050] Then, a special, approved lifting tool can be lowered around the barrel (8). The lifting tool slides down from the upper edge (8a) into the space between the barrel (8) and the pressure tank (2). The lifting tool is designed to clamp the barrel (8) while lifting it. Thus, the barrel is lifted out of the pressure tank (2) using a crane or hoist.

[0051] Installing new empty buckets (8) is done mainly in reverse order.

[0052] Figure Labels

[0053] 1-Sludge Collection Unit (SCU)

[0054] 2-Pressure tank

[0055] 2a - Internal shape of the pressure vessel

[0056] 2b-Seal

[0057] 3-Top Cover

[0058] 3a-handle

[0059] 4-Hinge Yoke

[0060] 5- Gas springs or other devices suitable for balancing the weight of the top cover

[0061] 6-Overpressure valve

[0062] 7- Opening for overpressure valve

[0063] 8-barrel

[0064] 8a-Upper edge of the bucket

[0065] 9-Positioning plate

[0066] 9a - Extension of positioning plate

[0067] 10- Holes on the top cover

[0068] 11-Hole on the positioning plate

[0069] 12--Pressure opening

[0070] 13-Inlet Connection Device-Y Type

[0071] 14-Sensor Piston

[0072] 15 - Openings for bolts

[0073] 20a - Engine purge air discharge connection (pipes, hoses, etc.)

[0074] 20b - Connector to the outside of the tank, used for oil outlet.

[0075] 21-Pressure connection.

Claims

1. A sludge collection unit comprising a pressure tank (2) having a hollow interior and a top cover (3) adapted to pressurelessly seal the hollow interior of the pressure tank, wherein, The pressure tank (2) is suitable for inserting and sealing the cylinder (8) inside the hollow interior of the pressure tank, wherein the hollow interior of the cylinder (8) is connected to the engine purge air exhaust section by means of the engine purge air exhaust connector (20a) through the connecting holes (10, 11) to collect the material in the engine purge air exhaust section, and wherein the hollow interior of the cylinder (8) is connected through the connecting holes (10, 11) at a position where solid material is allowed to enter the hollow interior of the cylinder, characterized in that the hollow interior of the pressure tank is connected to the engine purge air exhaust connector (20a) by pressure connectors (12, 21), wherein the pressure connectors (12, 21) are connected to the engine purge air exhaust connector (20a) at a position where gaseous air is allowed but solid material is substantially not allowed to enter the empty volume between the interior of the pressure tank (2) and the exterior of the cylinder (8) through the pressure connectors (12, 21).

2. The sludge collection unit according to claim 1, wherein the outlet of the pressure tank (2) is connected to the outside via a connector (20b) for external connection so that fluid material can overflow from the engine purge air exhaust.

3. The sludge collection unit according to claim 2, wherein the external connection (20b) is adapted to be connected to the intermediate tank for collecting overflow fluid material in a pressure-impermeable seal.

4. The sludge collection unit according to claim 1, wherein the pressure connection (12, 21) is connected to the upper side of the engine purge air discharge connection (20a).

5. The sludge collection unit according to claim 2, wherein the top cover (3) is formed with a connection hole, the connection hole being adapted for the engine purge air exhaust connection (20a) and the external connection connection (20b) to be connected to the cylinder (8) in a pressure-free manner through the top cover (3).

6. The sludge collection unit according to claim 5, wherein the connector connected to the cylinder (8) is a through-insertion connector inserted into the connection hole and suitable for fixing to the cylinder (8).

7. The sludge collection unit according to claim 6, wherein the through-insertion connector is sealed relative to the top cover (3) by a guide bushing.

8. The sludge collection unit according to claim 1, wherein the sludge collection unit includes a positioning plate (9) adapted to be connected to the upper surface of the cylinder (8) and the inner surface of the hollow interior of the pressure tank.

9. The sludge collection unit according to claim 8, wherein the positioning plate (9) has an extension (9a) adapted to extend the side surface of the cylinder (8) to fit between the outer surface of the cylinder (8) and the inner surface of the pressure tank (2).

10. The sludge collection unit according to claim 9, wherein the extension (9a) is adapted to fit into an internal shape (2a) formed on the inner surface of the pressure tank (2).

11. The sludge collection unit according to claim 8, wherein the positioning plate (9) is formed with a connection hole adapted to match the connection hole in the top cover (3).

12. The sludge collection unit according to claim 1, wherein the top cover (3) is formed with an opening (7) that communicates with an overpressure valve (6) located on the outer surface of the top cover (3).

13. The sludge collection unit according to claim 1, wherein the engine purge air discharge connector (20a) is connected to the cylinder (8) via an inlet connection device (13), the inlet connection device further comprising a sensor piston (14) having a sensor element positioned in the cylinder (8).

14. The sludge collection unit according to claim 1, wherein the cylinder (8) to which the pressure tank (2) is applied is a standard 208L steel oil drum.

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