WO2022250623A1

WO2022250623A1 - A combination equipment for sludge separation, dewatering, and drying

Info

Publication number: WO2022250623A1
Application number: PCT/TR2021/050659
Authority: WO
Inventors: Tuğba ŞİMŞEK
Original assignee: Teknomet Ki̇mya Sanayi̇ Ve Ti̇caret Li̇mi̇ted Şi̇rketi̇
Priority date: 2021-05-28
Filing date: 2021-06-25
Publication date: 2022-12-01

Abstract

The present invention allows all industrial wastes, especially wet paint, to be sludged and separated from water, dewatered, and dried in a SINGLE COMBINATION MACHINE at the place where the waste comes out, wherein the said invention is aimed to be used in various industries such as automotive, automotive sub-industry, textile, food, general industry, plastic parts dyeing lines, white goods, pipe profile manufacturing, as well as in wastewaters in organized industrial sites, and in general treatment facilities and companies that apply wet paint. The present invention relates to a combination machine that can be utilized instead of 3 different devices. The present disclosure describes a multi-unit combination system that is designed to raise awareness of the environment in industrial facilities and factories, protect water, and allow each company to manage its own waste right at its facility (on the basis of Zero Waste Projects).

Description

A COMBINATION EQUIPMENT FOR SLUDGE SEPARATION, DEWATERING, AND

DRYING

TECHNICAL FIELD

The invention allows all industrial wastes, especially wet paint, to be sludged and separated from water, dewatered, and dried in a SINGLE COMBINATION MACHINE at the place where the waste comes out, wherein the said invention is aimed to be used in companies that apply wet paint, as well as general treatment facilities. The present invention relates to the combination machine that can be utilized instead of 3 different devices. BACKGROUND ART

In the state of the art, there are alternative machines for separating waste paint or waste industrial sludge in many sectors. The basic common feature of these machines is to separate waste and water from each other and send the waste to disposal and the water to discharge.

In the state of the art, there are two types of methods for sludge removal: a- Flotation systems:

The water containing waste is taken from the main system by means of a pump and conveyed to the relevant machine. In this machine, the sludge floating thanks to the addition of chemicals therein is removed from the surface of the water with a pneumatic or chain scraper. Subsequently, the resulting waste is collected in big bags and kept in the waste storage area. The water that drains from the big bag via gravity is sent to the discharge. It is not possible to perform dewatering and drying processes using the same machine. Additional investment in machinery or equipment is needed for the dewatering process.

In the state of the art (in flotation systems), the water in the sludge can be removed in three different ways: • In proportion to its flow and retention time,

• With additional machines (such as hydraulic press, filter press),

• By being sent to a waste company without any further process. b- Precipitation systems:

DAF tank: The water containing waste is taken from the main system by means of a pump and conveyed to the relevant machine. In this machine, the sludge precipitating thanks to the addition of chemicals therein is removed from the bottom of the water with a chain scraper. Subsequently, the resulting waste is collected in big bags and kept in the waste storage area. The water that drains from the big bag via gravity is sent to the discharge. It is not possible to perform dewatering and drying processes using the same machine. Additional investment in machinery or equipment is needed for the dewatering process

In the state of the art (in DAF units), the water in the sludge can be removed in three different ways:

• In proportion to its flow and retention time,

• With additional machines (such as hydraulic press, filter press),

• By being sent to a waste company without any further process.

Centrifugation: A centrifuge is installed in the main tank of the system. The sludge, which is precipitated by the use of chemicals, is taken from the bottom with the relevant centrifuge or a pump and transferred to big bags. In the state of the art (in centrifuge units), the water in the sludge can be removed in three different ways:

• In proportion to its flow and retention time,

• With additional machines (such as hydraulic press, filter press),

• By being sent to a waste company without any further process.

To conclude, all these systems and methods are only based on the principle of separating waste and water. None of these types of machines can be adapted to be utilized in wet paint applications. All of these are suitable for use in chemical and biological general treatment facilities. The existing machines cannot do the following:

• They cannot perform mechanical filtration with micro-sieves and moving plates. Reason: The paint sludge especially is quite dense, sticky, and hard, which makes processing it a challenging task. Disadvantages: Water and chemical loss due to high water content in the sludge, waste cost

• They cannot perform the dewatering (pressing) process.

Reason: The waste paint is sticky and hardens fast. For this reason, processing and dewatering the sludge in the same device are challenging in a continuous system.

Disadvantages: Water and chemical loss due to high water content in the sludge, high amount of waste, need for waste storage area, fight against bacteria, fungus and odor in the sludge kept in storage areas, damage to the environment and people.

• They cannot perform the pre-drying process.

Reason: The required solids rate for pre-drying cannot be achieved with the existing machines. Disadvantages: Water and chemical loss due to high water content in the sludge, waste cost

• Such equipment is not self-cleaning.

Reason: A sustainable method cannot be determined since the sludge does not come at the desired solids rate.

Disadvantages: Additional labor and loss of time.

• They cannot separate, dewater and dry the waste at its point of production, in a single machine. Reason: There is not a combination machine design.

Disadvantages: Unnecessary waste of water, unnecessary waste of chemicals, high amount of hazardous waste, need for specially licensed vehicles to transport hazardous waste, special storage systems and areas, need for additional machinery, loss of physical space, damage to the environment and people (bacteria, fungus, and odor occurring in storage areas), need for additional labor, and loss of time as a result of all the aforementioned reasons. The elements described hereinabove negatively affect all those industrial enterprises that consume water and especially make paint applications.

Described in application no. TR2013/14650 titled “Sludge Dewatering Machine” in the prior art, the invention is summarized as follows: “The waste that has a moisture content of 70-75% and is produced by municipalities and industrial enterprises is taken to a sludge dewatering unit from the entrance. The hot oil conditioned by a heating unit moves to a distributor head with the help of pipes and then heats a double shaft helix, a trough, and a single shaft helix. The moisture content of the sludge that moves along the double shaft helix evaporates due to the heat transfer from the double shaft helix and the trough. While the steam formed throughout this process is sent back to the treatment plant from the dewatering unit, the sludge with increasing dry matter content falls into the single shaft helix from the intermediate outlet. The heat transfer continues along the single shaft helix. The dewatered sludge with a dry matter content of 90-95% is taken from the final outlet. The double shaft helix and the single shaft helix are driven by two separate motors. The sludge with a dry matter content of 25-30% will be pasteurized while being dried to reach up to 90-95% dry matter content in the dewatering unit, and the resulting wastewater steam of 70-75% will not be discharged from the chimney into the environment and will be kept by being condensed. This system prevents the release of the elements that are found in wastewater steam depending on the content of the sludge and are harmful to the environment and human health. The pasteurized solid that will be obtained upon the dewatering process will be sold as fuel to cement factories and be turned into an economic value since it has low- calorie coal properties (2000-2500 Kcal/kg).” Described in application no. CN111072249A titled “Sludge drying treatment device and its drying method” in the prior art, the invention is summarized as follows: “The invention describes a sludge drying treatment device and its drying method, relating to technical drying field. The invention relates to especially a sludge drying treatment technology.” However, also this invention fails to eliminate the abovementioned disadvantages.

In conclusion, the abovementioned shortcomings and the inadequacy of the current practice entail an improvement in the respective technical field. Thus, there is a need for an invention to overcome the described problems.

DESCRIPTION OF THE INVENTION The present invention allows wet paint and industrial wastes to be sludged and separated from water, collected, dewatered, pressed, and pre-dried in a SINGLE COMBINATION MACHINE and right at the place where the waste comes out, wherein the said invention is aimed to be used in companies that apply wet paint, as well as general treatment facilities. It is a combination system containing 3 different devices, wherein it is designed to clean the wastewater, to recycle the water into the system, and to ensure the disposal of the waste with minimum cost in companies manufacturing automobiles, automobile sub-industry products, textile, food (meat, milk, wafer, fish, chocolate, etc.), general industrial products, white goods, and pipes and profiles, as well as in plastic parts dyeing lines, many different industries, and in wastewaters in organized industrial sites.

The present disclosure describes a multi-unit combination system that is designed to raise awareness of the environment in industrial facilities and factories, protect water, and allow each company to manage its own waste right at its facility (on the basis of Zero Waste Projects).

The present disclosure is designed to be utilized in various industries such as automotive, automotive sub-industry, textile, food, general industry, plastic parts dyeing lines, white goods, pipe profile manufacturing, as well as in wastewaters in organized industrial sites.

The present invention has been prepared with the purpose of environmentally- and human-friendly new generation treatment, especially in order to recycle water and reduce water consumption, reduce the amount of hazardous waste sent to disposal, and channel the use of manpower into different areas.

The main purpose is to reprocess and reuse the wastewater at its outlet point, to reduce the rate of hazardous waste, to use the workforce correctly and efficiently, and to reduce costs.

There is no similar locally- or internationally-produced machine that combines and can perform all these functions in a single machine and on the customer’s line (on-site).

The present invention especially reduces the burden and cost of transporting hazardous waste thanks to the on-site separation of waste from water, dewatering, and drying. It decreases the cost of hazardous waste disposal by way of on-site reduction of sludge volume. It ensures that the wastewater is recycled and reused, thus reducing the consumption of clean water in these years when water is of utmost value.

The present invention prevents unnecessary waste of water, unnecessary waste of chemicals, high amount of hazardous waste, need for specially licensed vehicles to transport hazardous waste, special storage systems and areas, need for additional machinery, loss of physical space, damage to the environment and people (bacteria, fungus, and odor occurring in storage areas), need for additional labor, and loss of time as a result of all the aforementioned reasons.

Using one machine instead of three different machines ensures cost savings. Moreover, being the subject of the invention, the combination equipment for sludge separation, dewatering, and drying allows saving space in the facility as it can be manufactured in different sizes.

Other advantages of the present invention include the following: reduced personnel costs thanks to its compatibility with Industry 4.0, remote control and intervention for the sake of digitalization, reduction of the rate of hazardous sludge by 70-80%, reduction of the sludge packaging by 70-80%, 100% efficiency by elimination of the use of the filter cloths, big bags and sacks in which the waste sludge is rested, reduction of the moisture content of the sludge by 50%, and 100% recycling of the wastewater.

DRAWINGS

The embodiments of the present invention, briefly summarized above and discussed in more detail below, can be understood by referring to the exemplary embodiments of the invention described in the accompanying drawings. However, it should be noted that the accompanying drawings illustrate only the typical embodiments of the present invention and therefore are not deemed to limit its scope as it may allow other equally effective applications.

Figure 1: It is a perspective view of the sludge separation, dewatering, and drying equipment of the invention.

Figure 2: It is a perspective view of the sludge separation apparatus.

Figure 3: It is a perspective view of the mechanical filtration apparatus. Figure 4: It is a perspective view of the sludge conveying apparatus.

Figure 5: It is a perspective view of the main dewatering and pre-pressing apparatus.

For the sake of clarity, identical reference numbers are used wherever possible, to indicate identical elements common to the figures. The figures are not drawn to scale and can be simplified for clarity. It is contemplated that the elements and features of an application can be usefully incorporated into other applications without the need for further explanation.

Explanation of the Details in the Drawings

Explanations of reference numbers shown in the drawings are given below.

1. Sludge Separation Apparatus 1.1. Body outer surface

1.2. Body

1.3. Sluice 2. Mechanical Filtration (Micro-Sieve-Pre-dewatering) Apparatus

2.1. Body part

2.2. Piston

2.3. Micro-sieve 3. Sludge Conveying Apparatus

3.1. Body skeleton

3.2. Mounting flange

3.3. Conveying belt 4. Main Dewatering and Pre-pressing Apparatus

4.1. Body frame

4.2. Helix

4.3. Main Dewatering and Drying Part DETAILED EXPLANATION OF THE INVENTION

The preferred alternatives of the embodiment of the sludge separation, dewatering, and drying equipment of the present disclosure, which are mentioned in this detailed description, are only intended for providing a better understanding of the subject matter, and should not be construed in any restrictive sense.

Being a sludge separation, dewatering, and drying equipment, the present invention performs all of the following processes in one machine: Sludge separation (1)

Mechanical filtration (Micro-Sieve-Pre-dewatering) (2)

Sludge conveying (3)

Main dewatering and drying (4) The invention consists of a sludge separation apparatus (1) where wastewater is separated, a body outer surface (1.1) where all machine-related elements are located or are taken therein, a body (1.2) where the wastewater from the system is separated, a sluice (1.3) through which the sludge separated from the water is channeled to a mechanical filtration area, a mechanical filtration (Micro-Sieve-Pre-dewatering) apparatus (2) where the sludge floating over the machine is filtered and the density of the said sludge is increased by reciprocating motion, a body part (2.1) where all machine-related elements are located or are taken therein, a piston (2.2) that ensures the movement of the scraper plate on the machine, a micro-sieve (2.3) where the sludge floating over the machine is filtered and the density of the said sludge is increased by reciprocating motion, a sludge conveying apparatus (3) that ensures the transfer of the sludge from the mechanical filtration apparatus (2) to the next area, a body skeleton (3.1) where all machine-related elements are located or are taken therein, a mounting flange (3.2) to mount a belt conveyor on the machine, a conveying belt (3.3) that guides the dissolved sludge - which is poured on the machine - on the relevant belt, a main dewatering and drying apparatus (4) to which the sludge from the sludge conveying apparatus (3) is sent for dewatering and drying, a body frame (4.1) where all machine-related elements are located or are taken therein, a helix (4.2) that ensures that the dissolved sludge received into the machine is compacted via the movement, thereby separating the remaining water therein, and a main dewatering and drying part (4.3) where the sludge in the machine is dewatered and dried.

The sludge separation function starts with the treatment of the wastewater, which is taken via a pump connected to the main system, by use of coagulating chemicals, and then the transfer of it to the sludge separation apparatus (1). The sludge coagulated therein is pushed to the water surface thanks to the chemicals employed in this step.

In the process performed with the sludge separation apparatus (1), the wastewater comes from the main system tank into the conical body (1.2) with the help of a pump. In the meantime, chemicals are introduced into the wastewater. Thus, thanks to the difference in density, the waste in the water floats and moves in the direction of the sludge sluice (1.3). The transition to the mechanical filtration (micro-sieve) structure continues with the pushing of the sludge to the water surface and lumping thereon. The micro filtration apparatus (1) starts the filtration process by separating the sludge and water. Thanks to its interconnected and moving special design that brings the sludge to the appropriate solids ratio for pressing, the micro filtration apparatus (1) takes out the water in the sludge and carries the pre-dewatered sludge to the next area. It thus ensures rapid drying of the sludge in the pressing unit and increases the press efficiency.

For the mechanical filtration apparatus (2), the dissolved sludge floating on the surface is conveyed to the micro-sieve (2.3) by the movement of the scraper piston (2.2). The micro-sieve (2.3) performs the filtering process by moving around its axis thanks to its specially designed interlocking and moving feature. The transfer to the sludge conveying apparatus (3) is thus performed.

The sludge arriving at the sludge conveying apparatus (3) moves forward here. The compacted sludge is brought to the special drying area by means of a conveyor. The sludge arriving at the sludge conveying apparatus (3) travels for a desired period of time and is thereby sent to the main dewatering and drying apparatus (4).

The sludge arriving at the main dewatering and pre-pressing apparatus (4) is gradually compacted in a multi-point movement with a special twisted structure that is resistant to the sticking of paint. In this way, loss of water is increased and the preliminary preparation for drying is completed as the sludge is subjected to a second compacting process.

In the main dewatering and drying apparatus (4), the sludge traveling by the movement of the helix (4.2) arrives at the main dewatering and drying part (4.3). The sludge drying process is completed by subjecting the sludge to mechanical and heat treatment in the main dewatering and drying part (4.3). The drying area works in accordance with the principle of drying the sludge by removing the water therein by way of heating the special twisted structure to 40-60 °C by using the appropriate method (steam, hot oil, electricity, natural gas, etc.) to be determined according to the application area. The dried sludge will be compacted in the final press room, thereby reducing its volume and obtaining the sludge that is ready for disposal. The resulting highly dehumidified sludge (with 70-75% solids ratio) is poured into waste barrels without the use of big bags or cloths and then sent to disposal. In addition to the treated water, the water collected from the sludge is fed back into the system as well. Thus, both the consumption of fresh water is reduced, and chemicals expenses are reduced since the wastewater will be recycled into the system.

Thanks to its ability to simultaneously perform more than one process within itself, the present invention will carry out dewatering and drying processes in addition to taking waste with its three different units within the same period of time in a smaller space compared to similar machines. Thus, it will be working more efficiently for the user and the environment.

Bigger, smaller, narrower, and wider versions, and different sizes and dimensions of the sludge dewatering and drying equipment of the present disclosure can be manufactured.

Claims

1. Combination equipment for sludge separation, dewatering, and drying, which allows all industrial wastes, especially wet paint, to be sludged and separated from water, dewatered, and dried in a single combination machine at the place where the waste comes out, wherein the said invention is aimed to be used in companies that apply wet paint, as well as general treatment facilities, its feature is that it is characterized in that it consists of a sludge separation apparatus (1) where wastewater is separated, a mechanical filtration (Micro- Sieve-Pre-dewatering) apparatus (2) where the sludge floating over the machine is filtered and the density of the said sludge is increased by reciprocating motion, a sludge conveying apparatus (3) that ensures the transfer of the sludge from the mechanical filtration apparatus (2) to the next area, a main dewatering and drying apparatus (4) to which the sludge from the sludge conveying apparatus (3) is sent for dewatering and drying.

2. The sludge separation apparatus (1) described in Claim 1, its feature is that it is characterized in that it consists of a body outer surface (1.1) where all elements related to the sludge separation apparatus (1) are located or are taken therein, a body (1.2) where the wastewater from the system is separated, and a sluice (1.3) through which the sludge separated from the water is channeled to a mechanical filtration area.

3. The mechanical filtration (Micro-Sieve-Pre-dewatering) apparatus (2) described in Claim 1, its feature is that it is characterized in that it consists of a body part (2.1) where all elements related to the mechanical filtration apparatus (2) are located or are taken therein, a piston (2.2) that ensures the movement of the scraper plate on the machine, and a micro-sieve (2.3) where the sludge floating over the machine is filtered and the density of the said sludge is increased by reciprocating motion.

4. The sludge conveying apparatus (3) described in Claim 1 , its feature is that it is characterized in that it consists of a body skeleton (3.1) where all elements related to the sludge conveying apparatus (3) are located or are taken therein, a mounting flange (3.2) to mount a belt conveyor on the machine, and a conveying belt (3.3) that guides the dissolved sludge - which is poured on the machine - on the relevant belt.

5. The main dewatering and drying apparatus (4) described in Claim 1 , its feature is that it is characterized in that it consists of a body frame (4.1) where all elements related to the main dewatering and drying apparatus (4) are located or are taken therein, a helix (4.2) that ensures that the dissolved sludge received into the machine is compacted via the movement, thereby separating the remaining water therein, and a main dewatering and drying part (4.3) where the sludge in the machine is dewatered and dried.