Regenerative Media Filter

Abstract

A regenerative filter includes a filter housing having an inlet zone and an outlet zone, a fluid pathway between the inlet zone and the outlet zone, and a plurality of filter elements, each having an outer filter media applied thereto, for filtering particles or contaminants from a fluid. An inlet port arrangement is disposed in the filter housing communicating with the inlet zone and is constructed and arranged to direct the fluid pathway into the filter housing to maintain controlled turbulence in the inlet zone. The inlet port arrangement includes a pair of inlet ports juxtaposed to the inlet zone, each having one end through which the fluid flow enters. The present invention can include a single inlet and two or more outlets, two or more inlets and a single outlet, or two or more inlets and two or more outlets.

Description

[Technical Field]

[0001] Related Applications Priority to this application is hereby claimed under 35 U.S.C. §119(e) to commonly owned, co-pending U.S. Provisional Patent Application No. 63 / 418,384, filed October 21, 2022, which is incorporated by reference herein in its entirety.

[0002] The present invention relates generally to regenerative media filters, and more particularly to regenerative media filters with a two-port configuration on either the inlet or outlet side. [Background technology]

[0003] Prior art regenerative media filters have been single inlet / single outlet designs. Regenerative media filters are unique in that they undergo a "regeneration cycle" triggered by one or more of filtration time, differential pressure, and / or other sensed indications. In a typical cartridge, bag, or grate filter, the element is removed and replaced or cleaned. Granular-type filters may be backwashed. Regenerative media filters gently shake the media while the filter tank is filled with water or some other liquid media, with the pump turned off, the outlet valve closed, and the regeneration (precoat) valve open. In accordance with the concept of the present invention, in one embodiment, a shutoff valve and bypass valve pair is provided on each outlet line. Summary of the Invention [Problem to be solved by the invention]

[0004] The object of the present invention is therefore to be able to manufacture regenerative filters or any pressure vessel with this unique configuration that allows for several innovations. Below we will outline the possible options of the present invention: A. Single entrance / two or more exits B. Two or more entrances / single exit C. Two or more entrances and two or more exits [Means for solving the problem]

[0005] According to one embodiment of the present invention, a regenerative filter is provided, comprising: a filter housing having an inlet zone and an outlet zone; a fluid pathway between the inlet zone and the outlet zone; a plurality of filter elements, each having an outer filter media applied thereto and functioning to filter particles or contaminants from the fluid pathway; and a tube sheet supported across the filter housing and positioned immediately before the outlet zone to support the plurality of filter elements. The plurality of filter elements are arranged in an array, the array defining interstitial spaces between adjacent filter elements. The regenerative filter also includes an inlet nozzle arrangement disposed within the filter housing in the inlet zone, the inlet nozzle arrangement configured and arranged to direct the fluid pathway away from the plurality of filter elements to help maintain controlled turbulence in the inlet zone. According to the present invention, the inlet nozzle arrangement includes a pair of inlet tubes juxtaposed in the inlet zone, each inlet tube having one end through which fluid flow enters the respective inlet tube from outside the filter housing.

[0006] According to another aspect of the present invention, the inlet pipe is enclosed but includes at least one outlet slot that directs fluid flow downwardly away from the plurality of filter elements, the regenerative filter is controlled by a valve system such that one of the pair of inlet nozzles can be suspended for maintenance while the other of the pair of inlet nozzles continues to function, the pair of inlet pipes are arranged one above the other, the pair of inlet pipes are positioned in opposing positions, the inlet pipes have a cylindrical body, at least one slot is positioned in a side wall of the cylindrical body, and at least one slot is positioned facing the bottom surface of the housing.

[0007] According to another aspect of the present invention, there is provided a regenerative filter comprising a filter housing having an inlet zone and an outlet zone, a fluid pathway between the inlet zone and the outlet zone, and a plurality of filter elements, each having an outer filter media applied thereto and operative to filter particles or contaminants from the fluid pathway. The plurality of filter elements are arranged in an array, the array defining interstitial spaces disposed between adjacent filter elements. The regenerative filter further includes an inlet port arrangement disposed in the filter housing communicating with the inlet zone, the inlet port arrangement being constructed and arranged to direct the fluid pathway into the filter housing to maintain controlled turbulence in the inlet zone. According to the present invention, the inlet port arrangement comprises a pair of inlet ports juxtaposed to the inlet zone, each having one end through which a fluid flow enters.

[0008] According to yet another aspect of the present invention, there is included a first inlet nozzle in one of the pair of inlet ports and a second inlet nozzle in the other of the pair of inlet ports, the first inlet nozzle being surrounded but including at least one outlet slot that directs fluid flow away from the plurality of filter elements, and a tube sheet supported across the filter housing and positioned immediately proximate the outlet zone and supporting the plurality of filter elements.

[0009] In accordance with yet another aspect of the present invention, there is provided a filter control system comprising: a filter housing having an inlet zone and an outlet zone; a fluid pathway provided between the inlet zone and the outlet zone; a plurality of filter elements, each having an outer filter media applied thereto and operative to filter particles or contaminants from the fluid pathway; the plurality of filter elements arranged in a parallel array; and an inlet port arrangement disposed in the filter housing communicating with the inlet zone, the inlet port arrangement constructed and arranged to direct the fluid pathway into the filter housing, the inlet port arrangement comprising a pair of inlet ports each having one end for receiving fluid flow, each inlet port including a pump and at least one associated shut-off valve.

[0010] According to yet another aspect of the invention, there is included a controller for controlling the shut-off valves associated with each inlet pump, the controller operative in one mode to open both shut-off valves to provide flow through both pumps, and the controller operative in another mode to open one shut-off valve to provide flow through its respective pump while the other shut-off valve is closed to stop flow for servicing the associated pump; there is also provided an outlet port arrangement disposed in an outlet zone of the filter housing, the outlet port arrangements comprising a pair of outlet ports disposed in opposing positions in the outlet zone, each including a respective outlet line having a further shut-off valve disposed therein; a respective precoat line associated with each pump feeding from the respective outlet line to the associated pump; a third shut-off valve associated with each pump connected between the respective precoat line and the pump; each of the pair of inlet ports comprising an inlet tube, the pair of inlet tubes arranged in longitudinal alignment, each having an end cap;

[0011] It should be understood that the drawings are provided for illustrative purposes only and are not intended to define the limits of the present disclosure. The foregoing and other objects and advantages of the embodiments described herein will become apparent from the following detailed description when considered in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic diagram of a first embodiment of the invention using two inlet ports and two outlet ports. [Figure 2] FIG. 1 is a top view schematic of the port arrangement of a regenerative filter in which the inlet and outlet ports are aligned. [Figure 3] Schematic diagram associated with FIG. 1 showing inlet and outlet ports. [Figure 4] FIG. 1 is a perspective view of a preferred nozzle design. [Figure 5] FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 3, further showing the filter array. [Figure 6] FIG. 10 is a schematic diagram of an alternative embodiment of the present invention in which the inlet nozzles are juxtaposed one above the other. [Figure 7] FIG. 1 is a schematic diagram showing inlet ports and associated nozzles 120 degrees apart. [Figure 8] FIG. 10 is a diagram of yet another embodiment of the present invention in which the filter housing is square or rectangular and the inlet port and nozzle are positioned at 90 degrees to each other. [Figure 9] FIG. 1 is a schematic diagram illustrating the use of three inlet ports and associated nozzles located on separate centerlines. [Figure 10] FIG. 1 is a schematic diagram of a filter system of the present invention using separate pump and valve control for each inlet port P1 and P2. [Figure 11A] FIG. 1 is a top view of the filter control system. [Figure 11B] FIG. 2 is a perspective view of a control system for the filter. [Figure 11C]FIG. 2 is a front view of the filter control system. [Figure 11D] FIG. 2 is a side view of the filter control system. [Figure 12] 1 is an illustrative block diagram useful in explaining processes related to the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0013] The following represent specific innovations associated with the inventive concept: Below is a list of important features:

[0014] 1. Reducing the diameter of the pumping chamber piping by splitting the flow into two or more circuits, thereby, for example, replacing one large pipe with two or more smaller diameter pipes required to keep the flow rate below an acceptable limit (typically 3 meters / second (10 feet / second)).

[0015] 2. Two or more smaller lines transport the same volume of liquid requiring filtration at a substantially reduced cost. For example, if 23 L / m (6000 gpm) is required, an 18-inch diameter pipe is typically used. With the present invention, for example, two 12-inch diameter pipes can be used. The total cost of two 12-inch diameter pipes is approximately half the cost of an 18-inch pipe. Increasing flow rates, with a single pipe diameter of 20 inches or more, represents even greater economic savings. According to the present invention, the innovation of multiple pipes on both the inlet and outlet sides of the filter is preferred.

[0016] 3. In the prior art, if maintenance needs to be performed on a pump or other auxiliary equipment, the system must be shut down. In the new embodiment, each leg (port) can be isolated, while the other continues to push water through the regenerative media filter, protecting the filtered liquid and associated downstream components. This applies to equipment on the inlet side of the filter (strainers, valves, pumps, sensing devices, metering devices) and equipment on the outlet side of the filter (disinfection devices such as ultraviolet light, ozone, and chemical injection, heat exchangers, flow meters, temperature sensors, regulators, feeders, etc.). Because commercial plumbing leaks are largely preventable through good design and installation practices, this new embodiment enhances all maintenance activities, including leak prevention. A leak in a 46-centimeter (18-inch) pipe is (comparatively) more catastrophic than a system designed with two 30-centimeter (12-inch) diameter pipes.

[0017] 4. In the new embodiment, more energy is saved when compared to a single pump / motor and variable frequency drive required to maintain a desired flow rate because two or more smaller variable frequency drives and pump motors are less susceptible to losses present in the prior art of these devices.

[0018] 5. Welding two or more smaller diameter nozzles to a pressure vessel generally allows for a thinner overall material, eliminating the attachment point of a large single nozzle and offsetting the requirement for a reinforcing pad to support the imposed stress loads. Thus, two 30-centimeter (12-inch) OD pipes have a circumference of 192 centimeters (75.4 inches) with a single pass weld line, or about 381 centimeters (150 inches) if two passes (inside and outside) are required, while a single 46-centimeter (18-inch) OD pipe has a single pass of 144 centimeters (56.5 inches), but requires four passes, resulting in a weld line of over 508 centimeters (200 inches).

[0019] With the above improvements in mind, reference is now made to the drawings of this application. As previously indicated, there are several options for providing multiple inlet and outlet ports in a regenerative filter housing. These possible embodiments include: 1) single inlet / two or more outlets; 2) two or more inlets / single outlet; and 3) two or more inlets and two or more outlets.

[0020] One advantage of the present invention is that separate inlet ports can be isolated from one another so that one port can be taken down for maintenance while the other port continues to function, as will be described in more detail in connection with Figures 10 and 11.

[0021] FIG. 1 shows a filter housing at 10 and a pair of nozzles N1 and N2, each having a respective series of slots S1 and S2. See also FIG. 4 of the present application for a perspective view of nozzle N, which has a series of slots S. The nozzle preferably includes an end cap P and a vent V. Vent V may be in the form of a small hole that serves to vent air at the top of the nozzle. Note the respective caps C1 and C2 and associated vents V1 and V2 in FIG. 5. FIG. 5 also shows a filter array at F. Details of the filter array are not disclosed herein. However, reference is made to U.S. Pat. No. 10,814,256, which clearly identifies the filter array and its location relative to the nozzle structure, and is incorporated by reference. Also incorporated by reference are FIGS. 14-17A of the '256 patent, which describe the complete nozzle structure. In this regard, each arcuate nozzle slot S is arranged in pairs, as described in the '256 patent, separated by a wall so that the input flow is directed laterally to minimize turbulence.

[0022] Figure 2 is a top view of filter housing 10 in which inlet ports P1 and P2 are substantially aligned with outlet ports P3 and P4. This embodiment also uses the nozzle structure shown in Figure 1. Figure 3 is a side view of the filter housing of Figure 1. Figure 3 shows one of the inlet ports, port P1, and the corresponding outlet ports P3 and P4.

[0023] In each of the embodiments described herein, the nozzle structure is intended to have an end cap, and in this particular case, the nozzles are aligned as in Figure 5. As previously indicated, each of these nozzles has a vent V at the top thereof to help vent air.

[0024] 6 is a cross-sectional view of another embodiment of the invention in which nozzles N3 and N4 are arranged one above the other. In this embodiment, nozzles N3 and N4 each have a respective slot S3 and S4. Each of these slots is arcuate, terminated by a wall that directs the flow laterally.

[0025] FIG. 7 is a schematic top view of a further nozzle arrangement in which each of the nozzles N is positioned at a 120-degree angle relative to the other nozzles. Three of these nozzles are depicted in FIG. 7 as inlet nozzles extending through the wall of the filter housing. Note that each of these nozzles includes a vent V. An end cap C may be provided at the inner end of each nozzle N. In FIG. 7, the three nozzles can be considered to be positioned in the same horizontal plane. An alternative arrangement is shown and described in FIG. 9 herein.

[0026] Figure 8 shows an embodiment of the invention in which nozzles N are positioned at 90 degrees relative to one another. Each of the nozzle structures shown in Figure 8 may be substantially identical to that shown in the perspective view of Figure 4, including the arcuate slot S located on the underside. In Figure 8, each of the nozzles N also includes an end vent V.

[0027] Reference is now made to Figure 9, which illustrates three inlet nozzles N1, N2, and N3. These may be arranged in a pattern similar to that shown in Figure 7, positioned at approximately 120 degrees relative to one another. Alternatively, the three nozzles may be positioned at other angular relationships. Note that in this particular embodiment, the centerlines L1, L2, and L3 of each nozzle do not coincide, but instead are at different vertical locations.

[0028] Reference is now made to the schematic diagram of Figure 10, which is important for illustrating the control factors associated with filter housing 10. The filter housing of Figure 10 is similar to that depicted in Figure 2, having a pair of inlet ports P1 and P2 and a pair of outlet ports P3 and P4. Again, each of nozzles N1 and N2 includes a series of downwardly facing slots S1 and S2, respectively. In Figure 10, filter housing 10 is also considered to have a drain port at 12.

[0029] The system shown in Figure 10 includes separate pumps PA and PB associated with ports P1 and P2, respectively. Each of these pumps includes a shut-off valve B and C for control. On the outlet side, there is also a shut-off valve A associated with each of outlet ports P3 and P4. These shut-off valves are associated with both of the respective pumps. As an example, these valves can be controlled so that valves A, B, and C associated with pump PB can be closed so that pump PB can be serviced. At the same time, pump PA can continue to operate with filtering still functioning.

[0030] FIG. 10 also shows check valves D at the input to each of pumps PA and PB. Unfiltered flow from the filtration process passes through each check valve D to the respective pump PA, PB, as represented by arrows X in FIG. 10. In FIG. 10, shutoff valves C connect the output of each pump to inlet ports P1, P2, as shown. FIG. 10 also shows precoat feedback lines L associated with each inlet port P1, P2. Each line L actually connects from the outlet port through a shutoff valve B back to the respective pump PA, PB. In a typical process, the precoat lines L are provided to precoat the filter elements. When one of the pumps is stopped, precoat does not occur.

[0031] Reference is now made to further details related to the control diagram of FIG. 10. FIGS. 11A-11D show various views. For example, FIG. 11A is a top view showing the piping used to connect various components, including the pump and shutoff valves. The pump is labeled P. FIG. 11A also shows ports P1, P2, P3, and P4. FIG. 11B is a perspective view showing the interconnecting piping. FIG. 11B shows the filter housing at 10, two pumps at P, feedback line L, and ports P1, P2, P3, and P4. FIG. 11C is a front view of the same system depicted in FIGS. 11A and 11B. FIG. 11D is a side view of the same system depicted in FIGS. 11A-11C. This view shows the filter 10, precoat line L, pump at P, and ports P1, P2, P3, and P4.

[0032] The pump is preferably connected to a wall-mounted electronic device called a VFD (variable frequency drive), whose purpose is to control the speed, and therefore the flow rate, provided by the pump / motor combination.

[0033] A flow meter in each outlet line is connected to a VFD (variable frequency drive) for a PID (proportional integral derivative) loop, but rather than acting solely on the pump motor, it adjusts the outlet valves to vary or keep constant the flow rate in each outlet line depending on downstream demand. The variable frequency drive takes a standard 60hz electrical supply and outputs a variable frequency between 0-100hz to regulate the motor and therefore the pump output. PID is a proportional integral derivative loop control to regulate the system.

[0034] The innovation of the present invention allows the outlet lines to be separated or joined beyond the outlet valves, such as when pump PA needs to be serviced, while pump PB delivers filtered liquid to only outlet line A, or to both outlet lines which can be combined at a single bypass valve downstream of the outlet valves of both outlet lines.

[0035] Reference is now made to the simplified block diagram of FIG. 12, which illustrates an alternative process of the present invention in which valve control is such that valves A, B, and C associated with pump PB can be closed so that pump PB can be serviced. At the same time, pump PA can continue to operate with filtering still functioning. Pump PA therefore has its associated shutoff valves open, thereby allowing flow. In FIG. 12, the filter is represented by block Y and the controller by block Z. Note that filter Y can be considered to have separate sides, identified as sides U and V, to which respective signals Ul and Vl emanating from controller Z connect to control shutoff valves A, B, and C (see FIG. 10). When the filter is operating normally, both signals Ul and Vl control all shutoff valves to open, thereby allowing flow through both pumps. To service one of the pumps, one of lines Ul or Vl controls one pump to operate while the other pump is stopped. At any one time, at least one of lines Ul and Vl is operating so that filtration continues. Control via lines or signals Ul and Vl may be by manual control, a set pattern, or electronic control based on one or more factors.

[0036] While only a limited number of embodiments of the present invention have been described, it will be apparent to those skilled in the art that many other embodiments and modifications thereof are contemplated within the scope of the present invention as defined by the appended claims.

Claims

1. a filter housing having an inlet zone and an outlet zone; a fluid path provided between the inlet zone and the outlet zone; a plurality of filter elements, each having an outer filter media applied thereto, operable to filter particles or contaminants from the fluid path; a tube plate supported across the filter housing and positioned immediately proximate the outlet zone, the tube plate supporting the plurality of filter elements; Equipped with the plurality of filter elements are arranged in an array, the array defining interstitial spaces disposed between adjacent filter elements; an inlet nozzle arrangement disposed within the filter housing at the inlet zone, the inlet nozzle arrangement constructed and arranged to direct the fluid path away from the plurality of filter elements to assist in maintaining controlled turbulence in the inlet zone; a regenerative filter, wherein the inlet nozzle arrangement comprises a pair of inlet tubes juxtaposed in the inlet zone, each inlet tube having one end through which fluid flow enters the respective inlet tube from outside the filter housing.

2. 2. The regenerative filter of claim 1, wherein the inlet pipe is enclosed but includes at least one outlet slot that directs the fluid flow downwardly away from the plurality of filter elements, and the regenerative filter is controlled by a valve system such that one inlet nozzle of the pair of inlet nozzles can be shut down for maintenance while the other inlet nozzle of the pair of inlet nozzles continues to function.

3. 2. The regenerative filter of claim 1, wherein the pair of inlet pipes are arranged one above the other.

4. 2. The regenerative filter according to claim 1, wherein the pair of inlet pipes are disposed at opposite positions.

5. 2. The regenerative filter of claim 1, wherein the inlet pipe has a cylindrical body, at least one slot is positioned in a sidewall of the cylindrical body, the at least one slot being positioned facing a bottom surface of the housing.

6. a filter housing having an inlet zone and an outlet zone; a fluid path provided between the inlet zone and the outlet zone; a plurality of filter elements, each having an outer filter media applied to the plurality of filter elements, operable to filter particles or contaminants from the fluid path; a plurality of filter elements arranged in an array, the array defining interstitial spaces disposed between adjacent filter elements; an inlet port arrangement disposed on the filter housing communicating with the inlet zone, the inlet port arrangement constructed and arranged to direct the fluid path into the filter housing to maintain controlled turbulence in the inlet zone; Equipped with A regenerative filter, wherein the inlet port arrangement comprises a pair of inlet ports juxtaposed in the inlet zone, each having one end through which the fluid flow enters.

7. 7. The regenerative filter of claim 6, further comprising a first inlet nozzle at one of said pair of inlet ports and a second inlet nozzle at the other of said pair of inlet ports.

8. 8. The regenerative filter of claim 7, wherein the first inlet nozzle is surrounded but includes at least one outlet slot that directs the fluid flow away from the plurality of filter elements and a vent distal to the nozzle.

9. 7. The regenerative filter of claim 6, including a tube sheet supported across said filter housing and positioned immediately prior to said outlet zone to support said plurality of filter elements.

10. a filter housing having an inlet zone and an outlet zone; a fluid path provided between the inlet zone and the outlet zone; a plurality of filter elements, each having an outer filter media applied to the plurality of filter elements, operable to filter particles or contaminants from the fluid path; a plurality of filter elements arranged in a parallel array; an inlet port arrangement disposed on the filter housing communicating with the inlet zone, the inlet port arrangement constructed and arranged to direct the fluid path into the filter housing; Equipped with the inlet port arrangement comprises a pair of inlet ports each having one end through which the fluid flow enters; A filter control system wherein each inlet port includes a pump and at least one associated shut-off valve.

11. 11. The filter control system of claim 10, including a controller for controlling a shut-off valve associated with each inlet pump.

12. 12. The filter control system of claim 11, wherein the controller operates in one mode to open both isolation valves to provide flow through both pumps.

13. 12. The filter control system of claim 11, wherein the controller operates in another mode to open one isolation valve to provide flow through its respective pump while the other isolation valve is closed to stop flow for servicing the associated pump.

14. 14. The filter control system of claim 13, also comprising an outlet port arrangement disposed in the filter housing outlet zone.

15. 15. The filter control system of claim 14, wherein the outlet port arrangement comprises a pair of outlet ports disposed at opposite positions in the outlet zone, each including a respective outlet line having an additional shut-off valve disposed therein.

16. 16. The filter control system of claim 15 including a respective precoat line associated with each pump and feeding said associated pump from a respective outlet line.

17. 17. The filter control system of claim 16, including a third shutoff valve associated with each pump and connected between the respective precoat line and the pump.

18. 11. The filter control system of claim 10, wherein each of the pair of inlet ports comprises an inlet tube, the pair of inlet tubes being longitudinally aligned and each having an end cap.

19. 11. The filter control system of claim 10, wherein each of the pair of inlet ports includes an inlet pipe, and the pair of inlet pipes are arranged one above the other.

20. 11. The filter control system of claim 10, wherein each of the pair of inlet ports includes an inlet tube, the inlet tubes being arranged in a radial array.

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