Integrated sludge optimizing and reducing device for activated sludge process

Abstract

The invention relates to the technical field of sewage treatment equipment, in particular to an integrated sludge optimization and reduction device for an activated sludge process, comprising: a pretreatment unit having an inlet for receiving returned sludge and an outlet for discharging pretreated sludge; the fluid distribution unit is connected with a pumping mechanism, the inlet end of the fluid distribution unit is communicated with the outlet of the pretreatment unit, and the outlet end of the fluid distribution unit comprises at least one interface; and the at least one separation unit is provided with a material inlet, a light material outlet and a heavy material outlet which are communicated with the interface at the outlet end of the fluid distribution unit. The pretreatment unit, the separation unit and the dehydration decrement unit are integrated into a whole through the fluid distribution unit, the structure is compact, the pumping mechanism is integrated in the fluid distribution unit, uniform pressurization of fed materials is achieved, the operation energy consumption of the equipment is reduced, the separation unit is distributed around the fluid distribution unit, the fed materials are distributed uniformly, and the separation efficiency is improved. The pipeline length is shortened and the flow resistance is reduced.

Description

Technical Field

[0001] This invention relates to the field of wastewater treatment equipment technology, and in particular to an integrated sludge optimization and reduction device for activated sludge processes. Background Technology

[0002] The activated sludge process is one of the most widely used mainstream processes in the field of wastewater treatment. This process maintains the concentration of microorganisms in the system and ensures the stability of the treatment effect by returning sludge from the secondary sedimentation tank to the biological treatment tank. In actual operation, the returned sludge needs to undergo pretreatment to remove impurities such as hair and fibers, then pass through a hydrocyclone separator to separate the carrier and sludge, and finally the remaining sludge is dewatered and reduced in volume to achieve stable disposal of the sludge.

[0003] Currently, the treatment of returned sludge typically employs separate unit equipment, including pretreatment equipment for removing impurities, hydrocyclones for separating carriers, and screw presses for sludge dewatering. These devices are set up independently, which not only occupies a large plant area, but also requires materials to be lifted and transported multiple times, resulting in complex pipeline systems, high equipment investment, and high operating energy consumption. In addition, the connecting pipelines between the various devices are long and prone to blockage, increasing the difficulty and frequency of operation and maintenance. Summary of the Invention

[0004] In view of this, the purpose of this invention is to provide an integrated sludge optimization and reduction device for activated sludge processes to solve the above-mentioned technical problems.

[0005] To achieve the above objectives, the present invention provides an integrated sludge optimization and reduction device for activated sludge processes, comprising: The pretreatment unit has an inlet for receiving returned sludge and an outlet for discharging pretreated sludge. A fluid distribution unit connected to a pumping mechanism has its inlet end connected to the outlet end of the pretreatment unit, and its outlet end includes at least one interface. At least one separation unit has an inlet, a light material outlet, and a heavy material outlet that communicate with the outlet end of the fluid distribution unit. A lightweight material collection unit, which is in fluid communication with each of the lightweight material outlets, is used to collect lightweight materials; A heavy material collection unit, which is in fluid communication with each of the heavy material outlets, is used to collect heavy materials; The dehydration and weight reduction unit has its inlet connected to the outlet of the light material collection unit and is used to dehydrate and reduce the weight of the light material.

[0006] As a preferred embodiment of the present invention, the interfaces at the outlet end of the fluid distribution unit are distributed circumferentially, and at least one of the separation units is distributed around the fluid distribution unit.

[0007] As a preferred embodiment of the present invention, both the lightweight material collection unit and the heavy material collection unit are annular cavity structures arranged around the separation unit, and the fluid distribution unit is located in the central region of the annular cavity structure.

[0008] As a preferred embodiment of the present invention, a first switching unit is provided between the outlet of the pretreatment unit and the inlet of the fluid distribution unit, and the inlet of the fluid distribution unit is selectively connected to the outlet of the pretreatment unit or an untreated sludge source through the first switching unit.

[0009] As a preferred embodiment of the present invention, a second switching unit is provided between the outlet of the lightweight material collection unit and the inlet of the dehydration and weight reduction unit. The second switching unit is used to selectively transport the lightweight material to the dehydration and weight reduction unit or to discharge it directly.

[0010] As a preferred embodiment of the present invention, the separation unit is a cyclone separator, which includes: The separation cavity has at least two conical segments with different cone angles, wherein the cone angle of the upper conical segment is greater than that of the lower conical segment; A light material outlet is located at the top of the separation unit; The feed chamber is connected to the feed inlet, and its internal flow channel is gradually narrowed and is equipped with a flow stabilizing structure. The heavy material outlet is located at the bottom of the separation chamber.

[0011] As a preferred embodiment of the present invention, the device further includes a support platform, which includes: a platform plate and pillars fixed to the four corners of the bottom of the platform plate, and a staircase is provided on one side of the platform plate; the pretreatment unit is fixedly installed above the platform plate by three support legs, the fluid distribution unit and the separation unit are disposed on the upper surface of the platform plate, and the dehydration and weight reduction unit is disposed below the platform plate.

[0012] As a preferred embodiment of the present invention, the preprocessing unit includes: The shell has a feed inlet, a sludge outlet and a residue outlet, wherein the sludge outlet is connected to the inlet end of the fluid distribution unit; The filter liner is rotatably disposed inside the shell, and its peripheral wall is provided with filter mesh. Spiral guide plates are fixed to the inner wall of the filter cartridge; The second drive motor has its output shaft connected to the filter inner tank via a transmission. A funnel is located downstream of the residue discharge port, and the lowest end of the funnel is connected to a discharge channel.

[0013] As a preferred embodiment of the present invention, the dewatering and volume reduction unit includes a screw press sludge dewatering machine, which has a flocculation mixing tank. The flocculation mixing tank is equipped with a stirring shaft and an anti-sedimentation circulation device. The anti-sedimentation circulation device includes: A piston pump, the inlet end of which is connected to the bottom of the flocculation mixing tank through a suction pipe, and the outlet end of which is connected to the top of the flocculation mixing tank through a spray pipe; The transmission mechanism includes a crank fixed to the stirring shaft and a rocker arm with one end hinged to the crank and the other end hinged to the piston of the piston pump.

[0014] As a preferred embodiment of the present invention, the suction pipe connected to the inlet end of the piston pump is connected to an annular collection pipe located at the bottom of the flocculation mixing tank. The annular collection pipe is provided with multiple suction ports, which are either duckbill-shaped or tapered holes with a larger outer diameter and a smaller inner diameter. The outlet end of the spray pipe is connected to a spray frame, which is provided with multiple outlets and guide vanes at the outlets.

[0015] The beneficial effects of this invention are as follows: This invention integrates the pretreatment unit, separation unit, and dehydration and weight reduction unit into one unit through a fluid distribution unit, resulting in a compact structure. By integrating a pumping mechanism in the fluid distribution unit, uniform pressurization of the feed is achieved, reducing the operating energy consumption of the equipment. The separation units are distributed around the fluid distribution unit, making the feed distribution more uniform, shortening the pipeline length, and reducing the flow resistance. The light material collection unit and the heavy material collection unit collect the materials centrally, and combined with gravity flow conveying, the pipeline system is simplified and the risk of blockage is reduced. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for this invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the external three-dimensional structure of the present invention; Figure 2 This is a schematic diagram of the half-section structure of the present invention; Figure 3 This is a schematic diagram of the half-section three-dimensional structure of the present invention; Figure 4 This is a partial cross-sectional three-dimensional structural diagram of the lightweight material collection unit, the heavy material collection unit, and the fluid distribution unit of the present invention. Figure 5 This is a three-dimensional structural diagram of the fluid distribution unit, separation unit, light material collection unit, and heavy material collection unit of the present invention. Figure 6 This is a partial cross-sectional three-dimensional structural diagram of the fluid distribution unit, separation unit, light material collection unit, and heavy material collection unit of the present invention. Figure 7 This is a schematic diagram of the three-dimensional structure of the shell of the present invention in half section; Figure 8 This is a partial cross-sectional three-dimensional structural diagram of the flocculation mixing tank of the present invention; Figure 9 This is a bottom-view perspective view of the crank, rocker arm, stirring shaft, piston cylinder, spray frame, and annular collection pipe of the present invention. Figure 10 This is a partial cross-sectional three-dimensional structural diagram of the stirring shaft, crank, rocker arm, and piston cylinder of the present invention; Figure 11 This is a partial three-dimensional structural schematic diagram of the fluid distribution unit of the present invention; Figure 12 This is a schematic diagram of the process flow of the present invention.

[0018] The components in the diagram are labeled as follows: 1. Platform plate; 2. Support column; 3. Staircase; 4. Support leg one; 5. Lightweight material collection unit; 6. Fluid distribution unit; 7. Feeding pipe; 8. Interface; 9. Inlet; 10. Separation unit; 11. Lightweight material outlet; 12. Lightweight sludge discharge end; 13. Support leg two; 14. Heavyweight material collection unit; 15. Heavyweight sludge discharge end; 16. Heavyweight material outlet; 17. Heavyweight sludge discharge pipe; 18. Lightweight sludge discharge pipe; 19. Sludge dewatering machine body; 20. Flocculation mixing tank; 21. Stirring shaft; 22. Drive motor one; 23. Piston cylinder; 24. Piston; 25. Suction pipe; 26. Annular collection pipe; 27. Suction port; 28. Spray pipe; 29. ​​Spray frame; 30. Liquid outlet; 31. Liquid inlet end of sludge dewatering machine; 32. Shell; 33. Support leg three; 34. Feed inlet; 35. Sludge discharge outlet; 36. Filter inner liner; 37. Support; 38. Main shaft; 39. Drive motor two; 40. Spiral guide plate; 41. Residue discharge outlet; 42. Funnel; 43. Discharge channel; 44. Crank; 45. Rocker arm; 46. First switching unit; 47. Second switching unit; 48. Pump; 49. Transition container; 50. Container feed inlet; 51. Container discharge outlet. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0020] It should be noted that, unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0021] like Figure 1 , Figure 2 , Figure 3 and Figure 12 As shown, an integrated sludge optimization and reduction device for activated sludge processes includes: a pretreatment unit having an inlet for receiving returned sludge and an outlet for discharging pretreated sludge; a fluid distribution unit 6 connected to a pumping mechanism, its inlet end communicating with the outlet of the pretreatment unit, and its outlet end including at least one interface 8; at least one separation unit 10 having an inlet 9 communicating with the interface 8 at the outlet end of the fluid distribution unit 6, a light material outlet 11, and a heavy material outlet 16; a light material collection unit 5, which is fluidly communicated with each light material outlet 11 for collecting light materials; a heavy material collection unit 14, which is fluidly communicated with each heavy material outlet 16 for collecting heavy materials; and a dewatering and reduction unit, whose inlet 31 is communicated with the outlet of the light material collection unit 5 for dewatering and reducing the light materials. The above technical solution organically integrates the three functional units of pretreatment, sorting, and dewatering into one unit through the fluid distribution unit 6. Specifically, its working principle is as follows: During operation, the return sludge first enters the inlet of the pretreatment unit. After the pretreatment unit removes large-volume lightweight impurities such as hair and fibers, the pretreated sludge is discharged from the outlet of the pretreatment unit. The pretreated sludge enters the inlet of the fluid distribution unit 6, which is connected to a pumping mechanism. The pumping mechanism inside the fluid distribution unit 6 pressurizes the sludge to obtain a certain initial pressure and flow rate, and then distributes the pressurized sludge to at least one port 8 at its outlet. Each port 8 is connected to the inlet 9 of a separation unit 10 through a pipeline. The pressurized sludge enters the separation unit 10 tangentially. Under the action of centrifugal force, the denser heavy materials (such as carriers and heavy sludge) move towards the wall and are discharged from the heavy material outlet 16 at the bottom; the less dense lightweight materials move towards the center and are discharged from the lightweight material outlet 11 at the top. The light materials discharged from each separation unit 10 are collected by the light material collection unit 5 and finally transported to the inlet 31 of the dehydration and weight reduction unit for dehydration and weight reduction treatment; the heavy materials discharged from each separation unit 10 are collected by the heavy material collection unit 14 and can be recycled back to the biochemical tank for reuse, forming a complete treatment process and reducing the equipment footprint.

[0022] It is necessary to explain in detail that the pumping mechanism of the fluid distribution unit 6 can be a sludge transfer pump such as a screw pump, centrifugal pump, or diaphragm pump, preferably a variable frequency screw pump. The pumping mechanism can be integrated inside the fluid distribution unit 6, i.e., the pump body and the distribution pipe are encapsulated in the same housing; or it can be externally mounted in front of the inlet end of the fluid distribution unit 6, connected to the inlet end of the fluid distribution unit 6 via a flange. For example, the pumping mechanism can be externally mounted, located on the upper surface of the platform plate 1, downstream of the pretreatment unit and before the inlet end of the fluid distribution unit 6, facilitating inspection and maintenance. The outlet of the pumping mechanism is connected to the inlet end of the fluid distribution unit 6 via a pipe, while its inlet is connected to the outlet of the pretreatment unit or an untreated sludge source via the first switching unit 46.

[0023] like Figure 4 , Figure 5 and Figure 6 As shown, in this embodiment, the interface 8 at the outlet end of the fluid distribution unit 6 is distributed circumferentially, and at least one separation unit 10 is distributed around the fluid distribution unit 6. The above technical solution enables a more compact equipment structure and higher space utilization. Specifically, its working principle is as follows: the fluid distribution unit 6 evenly distributes the pressurized sludge circumferentially to the various separation units 10 distributed around it. This circumferential distribution method ensures that the pipeline length from the fluid distribution unit 6 to each separation unit 10 is basically the same, and the flow resistance is similar, thus achieving uniform distribution to each separation unit 10.

[0024] like Figure 5 and Figure 6 As shown, in this embodiment, both the light material collection unit 5 and the heavy material collection unit 14 are annular cavity structures arranged around the separation unit 10. The heavy material collection unit 14 has a heavy sludge discharge end 15 at its lowest end, and correspondingly, the light material collection unit 5 also has a light sludge discharge end 12 at its lowest end. Both the heavy sludge discharge end 15 and the light sludge discharge end 12 are provided with flanges for connecting pipes at their ports. The fluid distribution unit 6 is located in the central area of ​​the annular cavity structure. The above technical solution solves the problems of complex pipeline connections, easy blockage, and large space occupation associated with decentralized collection. Specifically, its working principle is as follows: the light material collection unit 5 and the heavy material collection unit 14 adopt an annular cavity structure, surrounding all the separation units 10, while the fluid distribution unit 6 is located at the center of the entire structure. The light material outlet 11 of each separation unit 10 extends directly into the annular cavity of the outer light material collection unit 5, and the heavy material outlet 16 extends directly into the annular cavity of the heavy material collection unit 14. The annular cavity structure achieves the shortest path collection of light and heavy materials, eliminating the need for additional pipelines. The central feeding and annular collection layout results in a short material flow path, low resistance, and reduced energy loss.

[0025] like Figure 3 and Figure 4As shown, in this embodiment, a first switching unit 46 is provided between the outlet of the pretreatment unit and the inlet of the fluid distribution unit 6. The inlet of the fluid distribution unit 6 is selectively connected to the outlet of the pretreatment unit or the untreated sludge source through the first switching unit 46. Specifically, the first switching unit 46 includes a tee fitting and two valves. The tee fitting has one inlet and two outlets. The inlet is connected to the inlet of the pumping mechanism through a pipe, the first outlet is connected to the sludge discharge port 35 of the pretreatment unit through a pipe, and the second outlet is directly connected to the untreated sludge source through a pipe. The two valves are respectively installed on the pipe connecting the pretreatment unit and the pipe connecting the untreated sludge source. The valves can be manual butterfly valves, electric ball valves, or pneumatic gate valves. When sludge needs to be pretreated, the valve connected to the pretreatment unit is opened, and the valve connected to the untreated sludge source is closed. When sludge needs to directly enter the sorting unit, the valve connected to the pretreatment unit is closed, and the valve connected to the untreated sludge source is opened. By combining the opening and closing of valves, the feed source can be flexibly switched.

[0026] The above technical solution can improve the applicability and flexibility of the equipment. Specifically, its working principle is as follows: During operation, the feed source can be switched through the first switching unit 46 according to the characteristics of the sludge and the treatment requirements: When there are many large impurities such as hair and fibers in the sludge, the first switching unit 46 is switched to connect with the outlet of the pretreatment unit, so that the sludge is pretreated before entering the subsequent unit; when the sludge is relatively clean or does not require pretreatment, the first switching unit 46 is switched to connect directly with the untreated sludge source, so that the sludge bypasses the pretreatment unit and directly enters the fluid distribution unit 6.

[0027] like Figure 11As shown, in this embodiment, the inlet of the fluid distribution unit 6 is connected to the outlet of the pretreatment unit via a pumping mechanism. Specifically, the pumping mechanism includes a pump 48, preferably a screw pump or a centrifugal pump. Its pumping end is connected to the outlet of the pretreatment unit or an untreated sludge source via a first switching unit 46, and its discharge end is fixedly connected to the inlet of the fluid distribution unit 6 via a flange, for pressurizing and conveying the sludge to the fluid distribution unit 6. The first switching unit 46 is a three-way pipeline structure with two inlet ports and one outlet port. The outlet port is connected to the pumping end of the pump 48 via a flange. One inlet port is connected to the container outlet 51 of a transition container 49 via a pipe, and the other inlet port is equipped with a valve and directly connected to the untreated sludge source. The transition container 49 is conical, with a container inlet 50 at its top, which is connected to the sludge outlet 35 of the pretreatment unit. The transition container 49 is also equipped with a liquid level control system for monitoring and controlling the liquid level in the container. The transition container 49 can buffer the flow fluctuation of the pretreatment unit's output, ensure the continuous and stable feeding of the pump 48, and avoid pump idling or cavitation caused by instantaneous interruption of feeding. Using the above technical solution, the pump 48 pressurizes the sludge and then delivers it to the fluid distribution unit 6, which distributes it to each separation unit 10, thus achieving coordinated operation of feed pressurization and fluid distribution. At the same time, through the cooperation of the first switching unit 46 and the transition container 49, pre-treated sludge or untreated sludge can be selectively fed in, while ensuring the stability of the feed flow rate and improving the reliability of system operation.

[0028] like Figure 3 and Figure 4 As shown, in this embodiment, a second switching unit 47 is provided between the outlet of the lightweight material collection unit 5 and the inlet 31 of the dewatering and weight reduction unit. The second switching unit 47 is used to selectively transport lightweight materials to the dewatering and weight reduction unit or directly discharge them. Specifically, the second switching unit 47 includes a three-way fitting and two valves. The three-way fitting has one inlet and two outlets. The inlet is connected to the lightweight sludge discharge end 12 of the lightweight material collection unit 5 through a pipe. The first outlet is connected to the inlet 31 of the dewatering and weight reduction unit through a pipe, and the second outlet is connected to the direct discharge pipe. The two valves are respectively installed on the pipe connecting the dewatering and weight reduction unit and the direct discharge pipe. When it is necessary to dewater and reduce the lightweight sludge, the valve connected to the dewatering and weight reduction unit is opened, and the direct discharge valve is closed. When it is not necessary to dewater and reduce the weight, the valve connected to the dewatering and weight reduction unit is closed, and the direct discharge valve is opened. The valve type is the same as that of the first switching unit 46, and manual or electric control can be selected according to the degree of automation required. The above technical solution increases the flexibility of the device, enabling it to operate in both full-process mode (pretreatment + sorting + reduction) and non-reduction mode (pretreatment + sorting). Specifically, its working principle is as follows: During operation, the destination of light materials can be switched through the second switching unit 47 according to actual needs: when light sludge needs to be reduced, the second switching unit 47 is switched to connect with the inlet 31 of the dewatering and reduction unit, allowing the light materials to enter the dewatering and reduction unit; when only sorting is required and no reduction is needed, the second switching unit 47 is switched to the direct discharge channel, allowing the light materials to be directly discharged from the system.

[0029] like Figure 5 and Figure 6 As shown, in this embodiment, the separation unit 10 is a cyclone separator, which includes: a separation chamber having at least two cone segments with different cone angles, wherein the cone angle of the upper cone segment is greater than that of the lower cone segment; a light material outlet 11, i.e., an overflow pipe, which is located at the upper part of the separation unit 10; a feed chamber communicating with the feed inlet 9, wherein the internal flow channel is gradually narrowed and a flow stabilizing structure is provided; and a heavy material outlet 16, i.e., an underflow pipe, which is located at the bottom of the separation chamber. The above technical solution solves the problems of easy displacement and overflow of flaky carriers, and low recovery rate, when traditional hydrocyclones process flaky carriers such as red mud and shell powder. Specifically, its working principle is as follows: the separation unit 10 adopts a structure optimized for flaky carriers (such as red mud and shell powder). During operation, pressurized sludge enters the gradually narrowing feed chamber from the feed inlet 9. The flow stabilization structure stabilizes the flow before it enters the separation chamber tangentially. Under the action of the large cone angle of the upper cone section, the fluid accelerates its rotation, and the flaky carriers migrate rapidly towards the wall. After entering the small cone angle of the lower cone section, the carrier's downward speed slows down, avoiding the "jumping" phenomenon caused by excessive speed and preventing the carrier from being drawn into the overflow by the rising inner vortex. Finally, the carrier and heavy sludge are discharged from the heavy material outlet 16, and the light sludge is discharged from the light material outlet 11.

[0030] like Figure 1 , Figure 2 and Figure 3 As shown, in this embodiment, the device also includes a support platform, which includes: a platform plate 1 and pillars 2 fixed to the four corners of the bottom of the platform plate 1. A staircase 3 is provided on one side of the platform plate 1. The pretreatment unit is fixedly installed on the upper part of the platform plate 1 by the support leg 33. The fluid distribution unit 6 and the separation unit 10 are provided on the upper surface of the platform plate 1. The dehydration and weight reduction unit is provided below the platform plate 1. The above technical solution solves the problem of inaccessible and difficult-to-maintain internal components once the integrated equipment is assembled. Specifically, its working principle is as follows: During operation, operators can climb onto the platform 1 via stairs 3 to inspect, sample, and maintain the pretreatment unit, fluid distribution unit 6, and separation unit 10 located above the platform. The pretreated sludge is distributed to each separation unit 10 via the fluid distribution unit 6. The separated light materials are collected by the light material collection unit 5 and then flow by gravity to the dewatering and volume reduction unit located below the platform 1 for further processing. The equipment is divided into upper, middle, and lower layers by the supporting platform, which makes full use of the three-dimensional space and further reduces the floor space.

[0031] like Figure 7 As shown, in this embodiment, the pretreatment unit includes: a housing 32, which has an inlet 34, a sludge outlet 35, and a residue outlet 41, the sludge outlet 35 being connected to the inlet end of the fluid distribution unit 6; and a filter liner 36, which is rotatably disposed within the housing 32, and has filter mesh holes on its peripheral wall; specifically, both ends of the filter liner 36 are supported on the housing 32 by bearings. Specifically, one end of the housing 32 is provided with an end cap, on which a rolling bearing or a sliding bearing is installed, and the end shaft of the filter liner 36 is inserted into the inner ring of the bearing to achieve rotational support. A rotary sealing device is provided between the filter inner liner 36 and the housing 32. This sealing device includes a first annular flange located on the outer edge of the filter inner liner 36 and a second annular flange located on the inner wall of the housing 32. A sealing ring is provided between the mating surfaces of the two annular flanges, and the sealing ring is embedded in the sealing ring groove on the annular flange to prevent unfiltered sludge from leaking into the filtrate chamber through the rotary gap. A spiral guide plate 40 is fixed to the inner wall of the filter inner liner 36. Specifically, the spiral guide plates 40 are evenly distributed circumferentially along the inner wall of the filter inner liner 36, with 3-6 sets, and are spaced apart axially along the filter inner liner 36. The axial distance between adjacent guide plates is 10-20 cm, the height of the guide plate is 5-10 cm, and the helix angle of the guide plate is 15-30°. The guide plates are made of stainless steel and are welded to the inner wall of the filter inner liner 36 or fixed with bolts. When the filter inner liner 36 rotates at a speed of 10-30 rpm, the guide plate generates a continuous axial thrust on the trapped residue, pushing it towards the residue discharge port 41 to achieve continuous automatic slag discharge; the drive motor 39 has its output shaft connected to the filter inner liner 36; the funnel 42 is located downstream of the residue discharge port 41, and the lowest end of the funnel 42 is connected to the discharge channel 43; The above technical solution can solve the problems of easy clogging, need for shutdown for cleaning, and inability to continuously and automatically discharge sludge in traditional bar screens or static filters. Specifically, its working principle is as follows: During operation, the return sludge enters the filter inner tank 36 from the feed inlet 34; the drive motor 39 drives the filter inner tank 36 to rotate, and the sludge water smaller than the mesh size passes through the filter screen and enters the filtrate chamber outside the filter inner tank 36 under the action of centrifugal force and pressure difference, and is finally discharged from the sludge outlet 35; while larger impurities such as hair and fibers are trapped inside the filter inner tank 36; at the same time, the spiral guide plate 40 fixed on the inner wall rotates with the filter inner tank 36, generating axial thrust, which continuously pushes the trapped impurities to the residue outlet 41 and discharges them. The discharged residue falls into the funnel 42 below and is collected centrally through the discharge channel 43, effectively removing impurities such as hair and fibers that are easy to clog, and protecting the downstream hydrocyclone separator and dewatering unit; the funnel 42 and the discharge channel 43 realize the centralized collection of residue and avoid secondary pollution.

[0032] like Figure 3 and Figure 8 As shown, in this embodiment, the dewatering and volume reduction unit includes a screw press sludge dewatering machine, which has a flocculation mixing tank 20. The flocculation mixing tank 20 is provided with a stirring shaft 21 and an anti-sedimentation circulation device. The anti-sedimentation circulation device includes: a piston pump, whose inlet end is connected to the bottom of the flocculation mixing tank 20 through a suction pipe 25, and whose outlet end is connected to the upper part of the flocculation mixing tank 20 through a spray pipe 28; and a transmission mechanism, which includes a crank 44 fixed on the stirring shaft 21, and a rocker arm 45 with one end hinged to the crank 44 and the other end hinged to the piston 24 of the piston pump. The above technical solution solves the problem of flocculants easily settling and clumping at the bottom of the mixing tank, leading to reduced effective concentration, pipeline blockage, and waste of reagents. Specifically, its working principle is as follows: During operation, light materials enter the flocculation mixing tank 20, and flocculants are added simultaneously. The drive motor 22 drives the stirring shaft 21 to rotate, stirring and mixing the liquid. At the same time, the crank 44 fixed on the stirring shaft 21 rotates with the shaft, and the rotational motion is converted into the linear reciprocating motion of the piston 24 through the rocker arm 45, driving the piston pump. The inlet end of the piston pump draws liquid from the bottom of the flocculation mixing tank 20 through the suction pipe 25, and the outlet end delivers the liquid back to the top of the flocculation mixing tank 20 through the spray pipe 28, forming an anti-settling circulation. By directly utilizing the rotational power of the stirring shaft 21 to drive the piston pump through the transmission mechanism, the stirring and anti-settling circulation are driven synchronously from the same source, requiring no additional power source, saving energy and having a compact structure. The continuous bottom suction-top spray circulation keeps the concentration of the reagent in the tank uniform at all times.

[0033] like Figure 8 , Figure 9 and Figure 10As shown, in this embodiment, the suction pipe 25 connected to the inlet end of the piston pump is connected to the annular collection pipe 26 located at the bottom of the flocculation mixing tank 20. The annular collection pipe 26 is provided with multiple suction ports 27, which are duckbill-shaped or tapered holes with a larger outer diameter and a smaller inner diameter. The outlet end of the spray pipe 28 is connected to a spray frame 29, which is provided with multiple outlets 30, and guide vanes are provided at the outlets 30. The above technical solution can solve the problems of uneven suction from a single suction port, dead zones, and interference between the return flow and the main stirring flow, which weakens the mixing efficiency. Specifically, its working principle is as follows: During operation, the negative pressure generated by the piston pump is transmitted to the entire annular collection pipe 26 through the suction pipe 25. Multiple suction ports 27, which are evenly distributed in various areas of the bottom of the tank, simultaneously suck up the sediment. The sucked-up liquid is pressurized by the piston pump and enters the spray frame 29. It is evenly sprayed back to the upper part of the mixing tank through multiple liquid outlets 30. The guide vanes at the liquid outlets 30 guide the direction of the sprayed liquid flow to match the direction of the vortex generated by the stirring. The design of the annular collection pipe 26 and multiple suction ports 27 enables large-area coverage suction at the bottom of the tank, which helps to eliminate suction dead zones; the duckbill-shaped or conical suction ports 27 have anti-clogging function, and even if soft flocs are attached, they can be easily peeled off by negative pressure; the spray rack 29 and guide vanes enable the return liquid to be evenly distributed and work synergistically with the main stirring flow, strengthening the overall turbulence intensity in the tank and further improving the mixing uniformity and anti-sedimentation effect.

[0034] like Figure 1 , Figure 2 and Figure 3 As shown, in this embodiment, the installation height of the lightweight material collection unit 5 is higher than the inlet 31 of the dehydration and weight reduction unit to form a gravity-fed conveying structure. The above technical solution solves the problem of high energy consumption caused by the need for an intermediate tank and booster pump between the hydrocyclone separator and the dewatering machine in traditional processes. Specifically, its working principle is as follows: During operation, the light sludge collected by the light material collection unit 5 forms a certain height difference between its discharge port and the inlet 31 of the dewatering and reduction unit below. The light sludge automatically flows from the light material collection unit 5 into the dewatering and reduction unit by its own gravity, without the need for an additional conveying pump. The height difference naturally formed by the three-dimensional layout realizes the gravity-driven conveying of light materials, eliminating the need for an intermediate booster pump and saving equipment investment and operating energy consumption. At the same time, it avoids the shearing and damage of sludge flocs during pumping, which is conducive to improving the subsequent dewatering effect. The short pipeline length reduces the risk of blockage.

[0035] like Figure 5 and Figure 6As shown, in this embodiment, there are multiple separation units 10, preferably four in this scheme, and they are evenly distributed in a ring around the fluid distribution unit 6. The outlet 15 of the heavy material collection unit 14 is connected to a heavy material discharge pipe 17 for returning the heavy material to the activated sludge tank. The above technical solution solves the problem of limited processing capacity of a single hydrocyclone. Specifically, its working principle is as follows: During operation, multiple separation units 10 work simultaneously, doubling the processing capacity. The heavy material discharged from each separation unit 10, rich in carriers and activated sludge, is collected by the heavy material collection unit 14 and continuously or intermittently returned to the activated sludge tank through the heavy material discharge pipe 17, realizing the reuse of carriers and microorganisms. The multiple separation units 10 are evenly distributed in a ring, ensuring uniform feed distribution. The heavy material is returned to the biological treatment tank, allowing carriers such as red mud and shell powder to be recycled, reducing carrier addition costs, while maintaining a high microbial concentration in the biological treatment tank and improving wastewater treatment efficiency.

[0036] Those skilled in the art should understand that although this device is described using activated sludge processes with carriers such as red mud and shell powder as a typical application scenario, its scope of application is not limited to this. The core structure of this device, including the integrated design of a pretreatment unit, a fluid distribution unit 6 connected to a pumping mechanism, a separation unit 10, a light material collection unit 5, a heavy material collection unit 14, and a dewatering and volume reduction unit, is also applicable to conventional activated sludge processes without carriers, as well as activated sludge systems with other types of carriers. For conventional activated sludge, the separation unit 10 mainly serves for sludge thickening or classification, the light material collection unit 5 collects light sludge, the heavy material collection unit 14 collects heavy sludge, the dewatering and volume reduction unit treats the light sludge, and the heavy sludge can be returned to the biological treatment tank to maintain sludge concentration. Therefore, any sludge return treatment system employing the structural features of this device, regardless of whether a carrier is added or what the specific type of carrier is, falls within the protection scope of this invention.

Claims

1. An integrated sludge optimization and reduction device for activated sludge processes, characterized in that, include: The pretreatment unit has an inlet for receiving returned sludge and an outlet for discharging pretreated sludge. A fluid distribution unit (6) connected to a pumping mechanism has its inlet end connected to the outlet end of the pretreatment unit, and its outlet end includes at least one interface (8). At least one separation unit (10) has an inlet (9), a light material outlet (11), and a heavy material outlet (16) communicating with an interface (8) at the outlet end of the fluid distribution unit (6). Lightweight material collection unit (5), which is in fluid communication with each of the lightweight material outlets (11), is used to collect lightweight materials; The heavy material collection unit (14) is in fluid communication with each of the heavy material outlets (16) and is used to collect heavy materials; The dehydration and weight reduction unit has its inlet (31) connected to the outlet of the light material collection unit (5) for dehydrating and reducing the weight of light materials.

2. The integrated sludge optimization and reduction device for activated sludge processes according to claim 1, characterized in that, The interface (8) at the outlet end of the fluid distribution unit (6) is distributed circumferentially, and at least one of the separation units (10) is distributed around the fluid distribution unit (6).

3. The integrated sludge optimization and reduction device for activated sludge processes according to claim 2, characterized in that, The lightweight material collection unit (5) and the heavy material collection unit (14) are both annular cavity structures arranged around the separation unit (10), and the fluid distribution unit (6) is located in the central region of the annular cavity structure.

4. The integrated sludge optimization and reduction device for activated sludge processes according to claim 1 or 3, characterized in that, A first switching unit (46) is provided between the outlet of the pretreatment unit and the inlet of the fluid distribution unit (6). The inlet of the fluid distribution unit (6) is selectively connected to the outlet of the pretreatment unit or an untreated sludge source through the first switching unit (46).

5. The integrated sludge optimization and reduction device for activated sludge processes according to claim 1 or 3, characterized in that, A second switching unit (47) is provided between the outlet of the lightweight material collection unit (5) and the inlet (31) of the dehydration and weight reduction unit. The second switching unit (47) is used to selectively transport lightweight materials to the dehydration and weight reduction unit or discharge them directly.

6. The integrated sludge optimization and reduction device for activated sludge processes according to claim 1, characterized in that, The separation unit (10) is a cyclone separator, which includes: The separation cavity has at least two conical segments with different cone angles, wherein the cone angle of the upper conical segment is greater than that of the lower conical segment; A light material outlet (11) is located at the top of the separation unit (10); The feed chamber is connected to the feed inlet (9), and its internal flow channel is gradually narrowed and is equipped with a flow stabilizing structure; The heavy material outlet (16) is located at the bottom of the separation chamber.

7. The integrated sludge optimization and reduction device for activated sludge processes according to claim 1, characterized in that, The device also includes a support platform, which includes: a platform plate (1) and pillars (2) fixed to the four corners of the bottom of the platform plate (1). A staircase (3) is provided on one side of the platform plate (1). The pretreatment unit is fixedly installed above the platform plate (1) by support legs (33). The fluid distribution unit (6) and the separation unit (10) are provided on the upper surface of the platform plate (1). The dehydration and weight reduction unit is provided below the platform plate (1).

8. The integrated sludge optimization and reduction device for activated sludge processes according to claim 1, characterized in that, The preprocessing unit includes: The shell (32) is provided with a feed inlet (34), a sludge outlet (35) and a residue outlet (41), wherein the sludge outlet (35) is connected to the inlet end of the fluid distribution unit (6); The filter inner liner (36) is rotatably disposed inside the shell (32), and its peripheral wall is provided with filter mesh; A spiral guide plate (40) is fixed to the inner wall of the filter inner liner (36); The second drive motor (39) has its output shaft connected to the filter inner liner (36) via a transmission. A funnel (42) is located downstream of the residue outlet (41), and the lowest end of the funnel (42) is connected to a discharge channel (43).

9. The integrated sludge optimization and reduction device for activated sludge processes according to claim 1, characterized in that, The dewatering and volume reduction unit includes a screw press sludge dewatering machine, which has a flocculation mixing tank (20). The flocculation mixing tank (20) is equipped with a stirring shaft (21) and an anti-sedimentation circulation device. The anti-sedimentation circulation device includes: The piston pump has its inlet end connected to the bottom of the flocculation mixing tank (20) through a suction pipe (25), and its outlet end connected to the upper part of the flocculation mixing tank (20) through a spray pipe (28). The transmission mechanism includes a crank (44) fixed to the stirring shaft (21) and a rocker arm (45) with one end hinged to the crank (44) and the other end hinged to the piston (24) of the piston pump.

10. The integrated sludge optimization and reduction device for activated sludge processes according to claim 9, characterized in that, The inlet end of the piston pump is connected to a suction pipe (25) which is connected to an annular collection pipe (26) located at the bottom of the flocculation mixing tank (20). The annular collection pipe (26) is provided with multiple suction ports (27), which are either duckbill-shaped or tapered holes with a larger outer diameter and a smaller inner diameter. The outlet end of the spray pipe (28) is connected to a spray frame (29), which is provided with multiple outlets (30). The outlets (30) are provided with guide vanes.

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