Composite three-phase separator module for preventing sludge calcification and anaerobic reactor thereof

Abstract

The utility model relates to the field of sewage treatment, in particular to a composite three-phase separator module for preventing sludge calcification and an anaerobic reactor thereof, which comprise an outer separation module, an inner separation module, a water outlet module and a backflow module, according to the composite three-phase separator module provided by the utility model, a remarkable technical breakthrough is realized through structural innovation and process optimization. The traditional IC reactor is limited by the arrangement mode of a three-phase separator, and the effective sludge level height is less than 50% of the total height of the reactor, so that the upper volume is idle. The composite three-phase separator module is integrated at the top of the reactor, and the height of a sludge layer is increased to 70%-80% of the total height of the reactor through the double-layer separation design of the outer separation module and the inner separation module, so that the microbial biomass and the treatment load are greatly improved. Meanwhile, methane is released through forced collision of a V-shaped separation plate of the outer separation module, so that the content of carbon dioxide in reflux liquid is reduced by more than 80%, and calcium carbonate crystallization conditions are effectively destroyed by combining forced mixing of inlet water with a circulating pump.

Description

Technical Field

[0001] This utility model relates to the field of wastewater treatment, and in particular to a composite three-phase separator module for preventing sludge calcification and its anaerobic reactor. Background Technology

[0002] In the field of wastewater treatment, anaerobic reactors have been widely used as a highly efficient device for treating high-concentration organic wastewater. However, traditional IC (Internal Circulation) anaerobic reactors have revealed a series of technical bottlenecks during long-term operation, which have seriously affected their treatment efficiency and stability.

[0003] First, in traditional IC anaerobic reactors, the three-phase separator is typically located in the middle of the reactor, which results in the ineffective utilization of the upper volume of the reactor. The effective sludge level height usually does not exceed 50% of the total reactor height, limiting the increase in microbial biomass within the reactor and consequently affecting the treatment load and efficiency.

[0004] Secondly, sludge calcification is another major challenge faced by traditional IC anaerobic reactors. The air-lift reflux mechanism leads to the mixing of reflux liquid with high concentrations of carbon dioxide with the influent, easily forming calcium carbonate precipitates inside the reactor. This not only reduces sludge activity but can also cause blockage of internal pipes, severely affecting the normal operation of the system. Furthermore, the unstable flow rate of traditional air-lift reflux methods easily causes sludge deposition within the reactor, reducing sludge-water mixing efficiency. Simultaneously, traditional water distribution system designs often fail to ensure uniform distribution of wastewater within the reactor, further impacting treatment effectiveness. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides a composite three-phase separator module and reactor designed to prevent sludge calcification. The aim is to overcome the technical bottlenecks faced by traditional IC anaerobic reactors through structural innovation and process optimization, thereby improving wastewater treatment efficiency and stability.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is: a composite three-phase separator module for preventing sludge calcification, comprising an external separation module, an internal separation module, an effluent module, and a reflux module;

[0007] The external separation module consists of a first frame and a first three-phase separator built into the first frame. The bottom of the first frame is provided with a first opening, through which sewage enters the first frame and releases biogas after being collided by the first three-phase separator. The sludge naturally settles and flows out of the first frame, while the biogas and wastewater continue to flow upward.

[0008] The reflux module includes a reflux pipe and a reflux module frame, wherein the reflux module frame is located inside a first frame, and the top of the reflux module frame is lower than the top of the first frame, and the reflux module frame extends outside the first frame through the reflux pipe.

[0009] The internal separation module includes a second frame and a second three-phase separator built into the second frame. The bottom of the second frame is provided with a second opening (the second frame is an open structure at the bottom). Wastewater enters the second frame through the second opening and releases biogas after being collided by the second three-phase separator. The sludge naturally settles outside the second frame and falls into the return pipe. The biogas and wastewater continue to flow upward.

[0010] The effluent module is located within the second frame and is used to divert the separated wastewater to the outside of the reactor.

[0011] Furthermore, the first three-phase separator includes several V-shaped separation plates. The angle between the two sides of each V-shaped separation plate and the horizontal plane is 45° to 60°. The bottom of the V-shaped separation plate is provided with an opening. The V-shaped separation plates are arranged in multiple layers with a spacing of 200 to 300 mm between the same layer and the upper and lower layers are arranged in a staggered and overlapping manner.

[0012] Furthermore, the second three-phase separator includes several inverted V-shaped separation plates. The angle between the two sides of a single inverted V-shaped separation plate and the horizontal plane is 45° to 60°. The inverted V-shaped separation plates are arranged in multiple layers with a spacing of 150 to 250 mm between the same layer and the upper and lower layers are arranged in a staggered and overlapping manner.

[0013] Furthermore, both the V-shaped separation plate and the inverted V-shaped separation plate are arranged in five layers, with spacing between the layers of 250mm and 200mm, respectively.

[0014] Furthermore, the water outlet module includes a branch water tank, a main water tank, and an outlet pipe. The branch water tank has a sawtooth outlet weir structure. One end of the branch water tank is connected to the main water tank, and the main water tank is connected to the outlet pipe. The outlet pipe passes through the second frame, the return module frame, and the first frame in sequence and extends to the outside.

[0015] An anaerobic reactor comprising a composite three-phase separator module, characterized in that it includes:

[0016] The reactor shell is equipped with a sealing cover at the top, and the sealing cover is connected to the biogas collection cabinet through a biogas collection pipe.

[0017] The composite three-phase separator module is installed inside the reactor shell;

[0018] The water distribution system, located at the bottom of the reactor shell, is used to evenly distribute water into the reactor.

[0019] An inlet booster pump, connected to the water distribution system, is used to transport wastewater to the water distribution system;

[0020] The circulating pump has its inlet connected to the return pipe of the composite three-phase separator module and its outlet connected to the inlet main pipe of the water distribution system, and is used to mix the return liquid with the inlet water.

[0021] Furthermore, the water distribution system is a perforated pipe water distributor or a radial water distributor, with a water distribution hole diameter of 10-20 mm and a hole spacing of 50-100 mm.

[0022] The beneficial effects of this utility model are as follows:

[0023] 1. The composite three-phase separator module provided by this utility model addresses the technical bottlenecks of traditional IC anaerobic reactors, such as low effective sludge level, sludge calcification, and insufficient treatment efficiency, achieving significant technological breakthroughs through structural innovation and process optimization. Traditional IC reactors, limited by the arrangement of the three-phase separator, have an effective sludge level height of less than 50% of the total reactor height, resulting in unused upper volume. This utility model integrates the composite three-phase separator module at the top of the reactor. Through a double-layer separation design of external and internal separation modules, the sludge layer height is increased to 70%–80% of the total reactor height, significantly improving microbial biomass and treatment load.

[0024] 2. Addressing the persistent industry problem of sludge calcification, traditional IC reactors suffer from calcium carbonate precipitate formation due to the mixing of high-concentration carbon dioxide reflux liquid with influent water caused by air stripping reflux. This invention utilizes the V-shaped separation plate of the external separation module to forcefully release biogas through collision, reducing the carbon dioxide content in the reflux liquid by over 80%. Combined with a circulating pump forcibly mixing the influent water, it effectively disrupts the conditions for calcium carbonate crystallization.

[0025] 3. Regarding sludge-water mixing efficiency, traditional air-lift reflux flow rates are unstable and prone to sludge deposition. This invention addresses this issue by installing a reflux pipe at the bottom of the reflux module, connecting it to the bottom of the reactor. This, combined with a circulating pump, mixes with the incoming water to create directional turbulence. Furthermore, a radial water distribution hole design enhances hydraulic flushing. These improvements increase sludge-water contact efficiency, improve pollutant removal rates, and enhance the system's resistance to shock loads. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the composite three-phase separator module.

[0027] Figure 2 This is a schematic diagram of the overall structure of an anaerobic reactor.

[0028] Reference numerals: 1. External separation module; 11. First frame; 12. V-shaped separation plate; 121. Opening; 13. First opening; 2. Internal separation module; 21. Second frame; 22. Inverted V-shaped separation plate; 23. Second opening; 3. Water outlet module; 31. Branch water tank; 32. Main water tank; 33. Water outlet pipe; 4. Return module; 41. Return pipe; 42. Return module frame; 5. Reactor shell; 51. Sealing cover; 511. Biogas collection pipe; 52. Biogas collection cabinet; 6. Water distribution system; 7. Inlet water lift pump; 8. Composite three-phase separator module; 9. Circulation pump. Detailed Implementation

[0029] Please see Figures 1 to 2 As shown, this utility model provides a specific embodiment of a composite three-phase separator module 8 for preventing sludge calcification and its anaerobic reactor. The technical solution of this utility model will be further described in detail below with reference to the accompanying drawings:

[0030] The external separation module 1 consists of a first frame 11 and an internal V-shaped separation plate 12. The first frame 11 is a square stainless steel frame, and its bottom has an open structure, hence the first opening 13. The V-shaped separation plates 12 are arranged in five staggered layers with a single layer spacing of 250mm. The angle between the two sides of each V-shaped plate and the horizontal plane is 55°, and there are openings 121 with a diameter of 50mm at every 200mm interval at the bottom. The V-shaped plates are made of PP material and are fixed to the internal support beam of the frame with bolts.

[0031] When sludge-containing wastewater enters the outer separation module 1 at a certain flow rate (described in detail later), it first impacts the multi-layer V-shaped separation plates 12. Since the two sides of the V-shaped plates form a 55° angle with the horizontal plane, the sludge particles collide with the plate surface due to inertia, releasing encapsulated biogas. The biogas detaches from the sludge surface in the form of tiny bubbles and floats upwards, while the sludge particles slide down the plate surface to the bottom of the first frame 11 and continue to fall back to the bottom of the reactor. The openings 121 at the bottom of the V-shaped separation plates 12 serve a dual purpose: on the one hand, they allow wastewater with removed biogas and some sludge to pass through, forming a directional flow; on the other hand, the size and distribution of the openings 121 control the flow velocity, preventing local turbulence that could cause secondary sludge suspension. Furthermore, the V-shaped separation plates 12 are arranged in multiple layers with staggered overlap, a design that extends the flow path of the wastewater within the separation module. As the wastewater flows between the layers, it needs to change direction multiple times. Tiny sludge particles that are not completely separated collide with the upper separation plate again due to inertia, further releasing residual biogas and settling.

[0032] The inner separation module 2 comprises a second frame 21 and inverted V-shaped separation plates 22. The inverted V-shaped separation plates 22 are arranged in five staggered layers with a single-layer spacing of 200mm, and the angle between the two side plates and the horizontal plane is 50°. The inner separation module 2 is nested inside the return module frame 42. The 50° angle design of the inverted V-shaped separation plates 22 causes the wastewater to split into two streams upon impact with the plate surface: one stream flows downwards along the plate surface, carrying sludge to the bottom of the second frame 21; the other stream flows upwards along the plate surface, forming a local turbulent region that promotes the aggregation and release of microbubbles. The five layers of inverted V-shaped separation plates 22 are staggered with a 200mm spacing, and the spacing between each layer is optimized by fluid dynamics to ensure that the wastewater forms a "impact-baffle-re-impact" path when flowing between layers. The first to third layers of separation plates mainly intercept large-diameter sludge particles and bubbles, the fourth layer captures escaped microbubbles, and the fifth layer achieves flocculation and sedimentation of residual sludge through turbulent disturbance. The inverted V-shaped structure allows the released biogas to converge at the top of the module along the angle of the plate surface, and then be discharged through the biogas collection pipe 511 of the sealing cover plate 51, avoiding pressure drop loss caused by gas retention. The settled sludge slides down the inverted V-shaped plate surface to the bottom of the second frame 21 and is discharged through the return pipe 41 of the return module 4, preventing sludge from accumulating inside the module.

[0033] The reflux module frame 42 of the reflux module 4 is located inside the outer separation module 1, with its top end 400mm lower than the top end of the first frame 11. The reflux pipe 41 is made of DN350 stainless steel and extends from the bottom of the reflux module frame 42 to the bottom of the reactor, connecting to the inlet flange of the circulation pump 9. The outlet of the circulation pump 9 is connected in parallel to the inlet header of the water distribution system 6 via a DN200 pipe.

[0034] The branch water tank 31 of the water outlet module 3 adopts a sawtooth stainless steel weir plate with a tooth height of 50mm and a tooth spacing of 100mm. The main water tank 32 has a U-shaped trough structure, and the DN250 water outlet pipe 33 passes through the second frame 21, the return module frame 42 and the first frame 11 in sequence. The end of the water outlet pipe 33 is equipped with a flange to connect to the external treatment unit.

[0035] After deep treatment by the internal separation module 2, the wastewater enters the branch channel 31. Its sawtooth effluent weir structure divides the water flow into multiple thin liquid films through regularly spaced convex and concave grooves. This design creates a uniform laminar flow on the weir surface, avoiding the eddies and short-circuiting phenomena common with traditional straight weirs, ensuring stable effluent quality. The branch channel 31 connects to the main channel 32 at a certain slope, using gravity to drive the wastewater towards the effluent pipe 33. The entire process requires no additional power equipment. The effluent pipe 33 adopts a through-type design, passing sequentially through the second frame 21, the return module frame 42, and the first frame 11. The connections between the frames are sealed with both mechanical seals and flexible packing, ensuring the reactor's internal airtightness to maintain biogas pressure and preventing leakage risks as the wastewater passes through the frames. The end of the effluent pipe 33 extends to the outside of the reactor, connecting to the main drain pipe via a 90° elbow, preventing direct impact of the water flow on the reactor shell and reducing structural vibration and noise.

[0036] It also includes an anaerobic reactor containing a composite three-phase separator module 8, comprising:

[0037] The reactor shell 5 has a sealing cover 51 on the top, and the sealing cover 51 is connected to the biogas collection cabinet 52 through the biogas collection pipe 511.

[0038] The composite three-phase separator module 8 is installed inside the reactor shell 5; the top of the composite three-phase separator module 8 is 300-500mm above the reactor liquid level, and the top of the composite three-phase separator module 8 is 300-500mm away from the sealing cover plate 51.

[0039] The water distribution system 6 is located at the bottom of the reactor shell 5 and is used to evenly distribute water into the reactor shell 5.

[0040] The inlet booster pump 7 is connected to the water distribution system 6 and is used to transport wastewater to the water distribution system 6;

[0041] The circulating pump 9 has its inlet connected to the return pipe 41 of the composite three-phase separator module 8 and its outlet connected to the inlet water header of the water distribution system 6, and is used to mix the return liquid with the inlet water.

[0042] The design of the composite three-phase separator module 8, with its top raised above the liquid level, significantly increases the amount of anaerobic granular sludge that can be accommodated inside the reactor. In traditional IC reactors, where the three-phase separator is located in the middle, the sludge layer height is limited by a safety distance, typically not exceeding 50% of the reactor height. This design, by raising the top of the module, increases the sludge layer height to 70%–80% of the total reactor height, increasing the sludge concentration from ≤40g / L to 60g / L and the microbial biomass by 50%. The 300–500mm gap between the top of the module and the sealing cover 51 creates a dedicated biogas accumulation zone. Biogas is evenly distributed and rises steadily within this space, avoiding sludge entrainment caused by airflow disturbance. This improves biogas stripping efficiency and reduces sludge loss.

[0043] Anaerobic reactor operation process

[0044] Wastewater is pumped through inlet booster pump 7 at a speed of 150m³. 3 A flow rate of / h is delivered to the radial water distribution system 6. The water distribution system 6 uses a DN200 stainless steel main pipe with water distribution holes of 15mm in diameter and 80mm in spacing, distributed radially along the bottom of the reactor.

[0045] After the wastewater is mixed with the anaerobic granular sludge in the reactor, the biogas produced causes the sludge to float to the surface. The mixed liquid enters the external separation module 1 at an upward flow rate of 6 m / h. After colliding with the V-shaped separation plate 12, the sludge releases biogas and sinks to the bottom of the reactor. The biogas enters the gas collection chamber above the sealing cover plate 51 through the liquid surface.

[0046] The separated wastewater enters the return module 4 through the guide plate. 50% of the flow is drawn into the circulating pump 9 via the return pipe 41, mixing with the influent to enhance sludge-water contact. The remaining 50% rises to the inner separation module 2, where it undergoes secondary separation by the inverted V-shaped separation plate 22. The effluent then flows evenly into the branch trough 31 through the sawtooth weir plate and is finally discharged through the outlet pipe 33. (It should be noted that the return module 4 is completely submerged, while the inner separation module 2 is partially above the liquid surface. Therefore, as long as continuous influent is maintained, an equal flow rate will enter the inner separation module 2. The water in the return module 4 is only used for circulation to enhance the sludge-water mixing efficiency at the bottom of the anaerobic tower.)

[0047] The top of the composite three-phase separator module 8 extends 400mm beyond the liquid surface of the reactor, and the distance between the top of the module and the sealing cover plate 51 is 400mm, forming a stable gas-liquid separation space. The sludge layer height inside the reactor reaches 75% of the total reactor height, and the sludge concentration is maintained at 60g / L.

[0048] In summary, the overall solution delivers numerous beneficial effects. Through a dual-layer separation design of external separation module 1 and internal separation module 2, the sludge layer height is increased to 70%–80% of the total reactor height, significantly improving microbial biomass and treatment load, thereby substantially enhancing wastewater treatment efficiency. Simultaneously, the improved sludge-water mixing efficiency also enhances pollutant removal rates and gives the system stronger resistance to shock loads.

[0049] Regarding operating costs, this module features an innovative design to address the issue of sludge calcification. The V-shaped separation plate of the external separation module 1 releases biogas through forced collision, reducing the carbon dioxide content in the return liquid by more than 80%, effectively reducing maintenance costs and replacement frequency caused by sludge calcification. In addition, the design of the circulating pump 9, which forces the mixing of the incoming water, also disrupts the conditions for calcium carbonate crystallization, further reducing operating costs.

[0050] In terms of system stability, the design of the composite three-phase separator module 8 creates a stable biogas accumulation zone inside the reactor, ensuring uniform distribution and stable rise of biogas, avoiding sludge entrainment, and thus improving system stability. Meanwhile, the cooperation between the reflux module 4 and the circulating pump 9 also enhances the system's resistance to shock loads, enabling more stable system operation.

[0051] The above embodiments are merely preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Various modifications and improvements made by those skilled in the art to the technical solutions of the present utility model without departing from the spirit of the present utility model should fall within the protection scope defined by the claims of the present utility model.

Claims

1. A composite three-phase separator module for preventing sludge calcification, characterized in that: It includes an external separation module (1), an internal separation module (2), an effluent module (3), and a return module (4); The external separation module (1) consists of a first frame (11) and a first three-phase separator built into the first frame (11). The bottom of the first frame (11) is provided with a first opening (13), in which sewage enters the first frame (11) through the first opening, and after being collided with the first three-phase separator, biogas is released. The sludge naturally settles and flows out of the first frame (11), and the biogas and wastewater continue to flow upward. The reflux module includes a reflux pipe (41) and a reflux module frame (42), wherein the reflux module frame (42) is located inside the first frame (11), and the top of the reflux module frame (42) is at a height lower than the top of the first frame (11), and the reflux module frame (42) extends to the outside of the first frame (11) through the reflux pipe (41); The internal separation module (2) includes a second frame (21) and a second three-phase separator built into the second frame (21). The second frame (21) is located inside the return module frame (42), and a second opening (23) is provided at the bottom of the second frame (21). Wastewater enters the second frame (21) through the second opening (23), and after being collided with the second three-phase separator, biogas is released. The sludge naturally settles outside the second frame (21) and falls into the return pipe (41). The biogas and wastewater continue to flow upward. The effluent module (3) is located inside the second frame (21) and is used to divert the separated sewage to the outside of the reactor.

2. The composite three-phase separator module for preventing sludge calcification according to claim 1, characterized in that: The first three-phase separator includes several V-shaped separation plates (12). The angle between the two sides of each V-shaped separation plate (12) and the horizontal plane is 45°~60°. The bottom of the V-shaped separation plate (12) is provided with an opening (121). The V-shaped separation plates (12) are arranged in multiple layers with a spacing of 200~300mm between the same layers. The upper and lower layers are arranged in a staggered and overlapping manner.

3. The composite three-phase separator module for preventing sludge calcification according to claim 2, characterized in that: The second three-phase separator includes several inverted V-shaped separation plates (22). The angle between the two sides of each inverted V-shaped separation plate (22) and the horizontal plane is 45°~60°. The inverted V-shaped separation plates (22) are arranged in multiple layers with a spacing of 150~250mm between the same layer and the upper and lower layers are arranged in a staggered and overlapping manner.

4. The composite three-phase separator module for preventing sludge calcification according to claim 3, characterized in that: Both the V-shaped separation plate (12) and the inverted V-shaped separation plate (22) are arranged in five layers, with the spacing between the layers being 250mm and 200mm, respectively.

5. The composite three-phase separator module according to claim 1, characterized in that: The water outlet module (3) includes a branch water tank (31), a main water tank (32) and an outlet pipe (33). The branch water tank (31) is a sawtooth outlet weir plate structure. One end of the branch water tank (31) is connected to the main water tank (32), and the main water tank (32) is connected to the outlet pipe (33). The outlet pipe (33) passes through the second frame (21), the return module frame (42), and the first frame (11) in sequence and extends to the outside.

6. An anaerobic reactor comprising the composite three-phase separator module according to any one of claims 1-5, characterized in that, include: The reactor shell (5) is provided with a sealing cover (51) on the top, and the sealing cover (51) is connected to the biogas collection cabinet (52) through the biogas collection pipe (511). The composite three-phase separator module (8) is installed inside the reactor shell (5). The top height of the composite three-phase separator module (8) exceeds the liquid level of the reactor shell (5) by 300~500mm, and the top of the composite three-phase separator module (8) is 300~500mm away from the sealing cover plate (51). The water distribution system (6) is located at the bottom of the reactor shell (5) and is used to distribute water evenly into the reactor shell (5); The inlet booster pump is connected to the water distribution system (6) and is used to transport wastewater to the water distribution system (6). The circulating pump (9) has its inlet connected to the return pipe (41) of the composite three-phase separator module (8) and its outlet connected to the water inlet header of the water distribution system (6), and is used to mix the return liquid with the inlet water.

7. The anaerobic reactor according to claim 6, characterized in that: The water distribution system (6) is a multi-hole pipe water distributor or a radial water distributor, with a water distribution hole diameter of 10~20mm and a hole spacing of 50~100mm.

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