Note: Descriptions are shown in the official language in which they were submitted.
i 1162~48
This invention relates generally to the use, treat-
ment and reuse of water employed in the manufacture of
fiber glass insulation products. More specifically it
is concerned with the treatment of water used (i) in
the cleaning of the flights, or chains, which are an
intergral part of the forming station in a fiber glass
insulation manufacturing production line, (ii) the air
scrubbers and, if used, the elèctrostatic precipitator
in such a line, and (iii) resin (i.e. binder) contaminated
water.
BAC~GROUND OF THE INVENTION
Purification of water used in fiber glass insulation
manufacturing processes is an increasingly difficult pro-
blem in view of the strict environmental standards imposed
on such operations. The need to operate such facilities
on~a continuous, three-shift operation plus the prohibition
against dt~ping anything except neutralized or pure water
into streams or other natural water sources, including
potential additives to ground water sources, has generated
20 ~ a ritical need for a safe, highly efficient and reliable
system for purifying water and water based liquids used in
::
the fiber glass insulation manufacturing process.
Accordingly, a primary object of the invention is to
provide a process and system for purification of water used
Ln fiber glass insulation manufacturing processes which is
efficient, economical and environmentally acceptable.
Another object is to provide a method and system as
above described which treats the water and contaminates
in such fashion that no water is discharged from the system
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to a ground level location, and solid, or semi-solid,
contaminates are discharged in a condition suitable
for disposal in environmentally acceptable dry land
fills.
A further object is to provide a method and
system as above described in which the water and
water-based fluids under treatm~nt are kept constantly
in motion so that the particulate material and the
solids (which, in the case of fiber glass, have a
specific gravity o~ approximately 2.3) are never
allowed to plug or clog orifices or qpray nozzles
at any time or place in the system.
Other objects and advantages of the invention
will become apparent from a reading of the ~ollowing
exemplary description thereof.
DESCRIPTION OF THE INVENTION
Figure 1 is a diagrammatic view of the invention
illustrating, in this instance, a single make-up water
source servicing foux fiber glass insulation production
~20 Lines;
Figure 2 is a schematic view of the precipitator
water recycle portion of the Line 1 of Figure l;
Figure 3 is a schematic view of the precipitator
pit, also known as the finish cleaner pit, of Figure 2;
~; ~5 and
Figure 4 is a plan view of the precipitator pit of
Figure 3, wherein certain parts are illustrated in
di~grammatic form.
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The water treatment system of this invention, and
its mode of operation in conjunction with a fiber
glass insulation manufacturing process, is illustrated
in its e~tirety in Figure lo This Figure illustrates
the method and system of the invention used in con-
junction with, in this instance, four individual
fiber glass insulation manufacturing production lines.
It should be understood however that the principles of
the invention are applicable to a greater or lesser
number of lines, and that the specific example chosen
for illustration is intended to be illustrative only.
The essential purpose of this system is to clean
the forming chains or flights in the forming station
of the fiber glass insulation manufacturing process~
the scrubbers and prPcipitator, if one is used, and
the resin-contaminated water so that said water can
be reused, particularly in the application of the
binder to the insulation at the forming station.
It should also be noted that an essential ~eature
20 ~ of the method and system is the maintenance of a supply
of soft water, and the further maintenance of a balance
of water added to water removed, along with continuous
filtration for solids xemoval. Specifically, it will
be noted that at all possible entry points of water into
the recycle washwater system, only soft water is admittedO
In this co~mection it should be understood that
the terms "soft water" and "city water" have rather well-
defined meanings. Specifically, "soft water" indicates
~ 16204~
water softened, as by conventionaI Zeolite softeners,
in a water house or other softening syst~m adjacent
to the fiber glass insulation manufacturing process.
The term "city water" indicates water which is received
at the water softening station, and will of course
vary from area to area throughout the country. The
definition of other waters will become apparent from
their mode of usage hereafter in this specification.
Referring now specifically to Figure 1, it will
be noted that a source of city water is indicated at
1, and a source of soft water, here a water softening
station, is indicated at 2. In this instance a Zeolite
softener will be assumed. It should be noted that soft
water has the capability of washing phenols off the
components of equipment in the system more efficiently
than conventional city water.
Softened water from softening station 2 is admitted
into each of the four fiber glass insulation manufacturing
production lines, indicated generally as Line 1, Line 2,
.
Line 3 and Line 4 in Figure 1. For clarity of description
and ease of understanding Lines 4 and 1 will be described
in detail, and thereafterr each Line, to the extent it is
unique, will be descxibed individually.
Softened water from softening station 2 i5 fed
into a hydrolaser indicated at 3. The hydrolaser is,
in effectr a high pressure pump. Said pump mayr for
example be capable of generating a pressure on the
order of 8rO00 pounds. The purpose of this high
pressure is to provide a high pressure stream or jet
of water for spot washing equipment during the
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manufacturing process. In this instance high
pressure soft water from hydrolaser 3 is used to
wash the chains of Line 4. After the washing action,
the water flows by gravity to the basement or
collection pit 5 of Line 4, from whence it again
discharges by gravity to sewer 6 which in turn
discharges into the lift station in a water house
which, for example, includes a pump 7 which is
set to pump both water and a small quantity of air
so that any "floaters" in the lift station are sucked
into the pump and moved along the system.
Pump 7 moves the water to hydrosieves 8 which
function to remove solids, such as the fibers, for
disposal at a convenient site such as an environ-
mentally acceptable dry land fill. Any fbrm of
hydrosieve may be employed which serves this function.
The type which includes a series of sloped screens
has been found to be effective.
The water from which the solids have been
separated drains through the hydrosieves into the
screened water tank 9 where it is available for
usage in the system.
A pump 10 at the outlet of the screened water
tank 9 forces the water through line lOA to each o~
the fiber glass insulation manufacturing systems
represented by Line 3 and Line 1. Preliminary,
it should be noted that in the event screened water
tank 9 receives more water then is re~uired in Lines
1 and 3, a float control switch operates to cause a
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I lB20~8
solenoid valve to open so that excess water in screened
water tank 9 can flow into the surge tankO A metering
pump in the line between the surg~ tank and the lift
station then forces water at an appropriate time to the
lift station where it is again circulated in the system
under the pxessure supplied by pump 7.
Screened water under pressure generated by pump 10
is fed into the chain-wick wire system 12 of Line
3. The used water drains from chain washing station
represented at 12 directly into a roughing qcrubber
pit. The trash pump in the roughing scrubber pit
forces the contents of the roughing scrubber pit
into the lift station where the water is again cir-
culated under pressure generated by pump 7.
Screened water also is admitted to the suction
box, the ducts, the washers and the strippers, all
indicated generally at 11, in Line 3. Water discharged
from station 11 drains into the roughing scrubber from
where it is circulated as heretofore described. It
should be noted that one o the primary functions of
the trash pump in the roughing scrubber pit is to
move sunken material to the lit station so that a
build-up of the material having a specific gravity
greater then 1.0 never accumulates in the roughing
scrubber pit; instead, all liquids and solids are
maintained in continual motion.
It will also be noted that soft water is fed into
hydrolaser 14 of which the output is used as a spot
cleaner of the chains in the production line. The used
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0~8
water drains to the roughing scrubber pit where it
is recirculated as heretofore described.
Referring now to Line 1, it will be noted that
screened water is admitted to station 15 which is
the numeral which designates generally the operations
more specifically identified as the suction box, the
plenum ducts, and the washers and scrubber. Screened
water which has passed through this station then drains
into a roughing scrubber pit 16 which functions as a
collection station, and which includes a trash pump
17 which functions to convey the sinkers to the lif~
station.
Soft water from softening station 2 is directed
to the precipitator pit station 21 through 10at
control valve 18. The precipitator pit is illustrated
in further detail in Figures 2, 3 and 4 from where it
will be noted that a level in a surge pit is ~ain-
tained by the float control valve 18. The precipitator
~pit also includes a pump pit, a recirculation ~ump,
and a trash sump, as illustrated best in Figure 3.
From Figure 4 it will be noted that screened
water which has passed through the screens on the
right of the Figure into the screen underflow channel
is deposited into the recirculation sump29. In this
connection it will be noted that float control valve
18 maintains the level in surge sump 20, as used or fresh
water is admitted to the recirculation sump 29- A
pair of recirculating pumps 22, shown best in Figure ~,
pulls suction from circulation sump 29, delivers water to
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precipitator 25 shown in Figure 2, and the forming fans
forming ducts station 24 and Rotoclone 28 in Figure l.
Forming air from the forming ducts goes, along with oven
gases, to the electrostatic precipitator 25. As above
described the water passing through screens 26 goes to re-
circulation sump 29. In this connection it should be noted
that water pumped to the forming fan and forming ducts
24 drains back to screens 26. A scavenger pump is
indicated at 27, the pump drawing from the bottom of
the surge sump 20 and delivering to the screening area 26.
It will be noted that soft water rom the source is
delivered to the recirculation sump 29 through float
control valve 18, illustrated best in Line l of Figure lB.
From the recirculation sump 29, the water pases via a float
controlled valve 33 to the Ro~oclone 28. From the Rotoclone
28, the water passes through the time controlled valve 30
to the roughing scrubber pit 16.
Fresh soft water from softener station 2 is used
; to wash the flight sprays 31 and the used water drains
into the roughing scrubber pit 16. Soft water also is
admitted to the hydrolaser 32 and, after usage, also
drains into the roughing scrubber pit 16 for recircula-
tion back to the lift station.
Turning now to Line 2 shown at the right side of
Figure lB, it will be noted that no screened water is
supplied to this sytem. Rather, only soft water from
softening station ~ is admitted into this line.
Soft water is fed by float control valve 33 into
the Rotoclone 34, the float control valve maintaining
the desired level within the Rotoclone. As will be
appreciated by those knowledgeable in the art, the
Rotoclone cools the air admitted to it, serves as a
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2~4L 8
. g
fire stop, keeps the ducts clean and causes pollutant
vapor condensation.
Water discharged from the Rotoclone goes via
a float control valve 35 through the operating
screens 46 and into the precipitator pit 36. It
will be noted that float control valve 35 controls
the level in surge sump 50, Figure 2, and delivers
water to recirculation sump 51. A recirculating
pump S2 directs water to the forming fans 53, forming
ducts 54 and to precipitator 55.
Each of forming fans 53, forming ducts 54 and
precipitator 55 drains onto the screens 46 which
removes the fibers and large particulate matter, with
the treated water then being recirculated as described
immediately hereinabove. The balance of the treated
water passes through a meter and float control valve
onto screens 87 which in turn drain into the roughing
scrubber pit 86 associated with this production line.
Discharge from the roughing scrubber pit is through
~20 pump 82 which delivers the water through a meter 84
to the accumulator tank 830
Soft water is also sprayed onto the flights 60
from which it drains into the screens 46.
Screened water from the precipitator pit also
passes from pump 52 through float control valve
and an associated meter to surge sump 80. Recirculation
pumps 82 force water to the suction box 83, the
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plenum chamber, the suction ducts and the venturi
scrubbers. Water drains from this system onto the
screens 87, equivalent to screens 26 shown in Figure
- 4. The water then drains to the roughing scrubber
sump 86~ Pump 82 forces water to accumulator tank
83 and then into a coagulation and vacuum filtration
system which cleans up the water for use in the
binder making process. ~
Speciica11y, water passing through accumulator
tank 83 goes into a pair of treatment tanks, the
oukput of which is passed through vacuum filters,
and then collected into the treated water storage
tank. As needed, water is drawn from this ~torage
tank to be mixed with the binder which goes into
the process at thé forming station.
From the above description it will be apparent
that a method and system have been provided wherein
freshly screened water is continually in motion,
and a skimming operation i~ operative to thereby
minimize coagulation and prevent blockage of spray
tips, ducts, fans and, when used, the electrostatic
precipltator.
Other objects and advantages of the invention
will become apparent to those skilled in the art
: ~: :
25~ from a reading of the foregoing description.
; ~ Accordingly it is intended that the scope of the
;~ ~ invention be limited by the scope of the hereinafter
appended claims~ when interpreted in light of the
; pertinent prior art, and not in light of the foregoing
exemplary description.
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