Note: Descriptions are shown in the official language in which they were submitted.
CA 02472507 2004-06-25
IMPROVED SEPARATOR FOR IMMISCIBLE LIQUIDS
BACKGROUND OF THE INVENTION
1. TECHNICAL FIELD
This invention relates in general to a liquid separation devices and,
more particularly, to a device for separating oils and/or grease from water.
2. DESCRIPTION OF THE RELATED ART
In several industries, and in particular the food industry, there is a
need to separate liquid greases, fats and oils from waste water prior to
passing
the water to the sewage system. The waste water could be, for example,
discharge from a washing device for cleaning dinnerware and cooking utensils.
If the greases and fats solidify in the sewage system, a blockage can occur
which
is expensive to remediate.
Additionally, there is a movement in many localities to recycle grease
and oils.
A commercially available separation device of the type described in
European Patent EP 890381 B1 is shown generally in Figures la and lb. Figure
la illustrates an exterior perspective view of the separation device 10.
Effluent
(containing two or more immiscible liquids of different densities, typically
water
entrained with oil, grease dissolved fats and other particles) is received at
inlet 12
providing a passage into housing 14 (including removable lid 15). Effluent is
heated using a probe-type heater 16, which is coupled to an electrical
connection.
As described below, the immiscible liquids separate within housing 14, and the
less dense material (e.g., grease and oils) empties into container 18. The
more
dense liquid (e.g., water) is discharged from water outlet 20. Silt may
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accumulate at the bottom of housing 14. The silt may be periodically
discharged
through silt outlet 22.
Operation of the separation device 10 is described in greater detail in
connection with Figure lb. Figure lb illustrates a cross-sectional side view
of the
separation device 10. A coarse filtration chamber 24 is defined between the
housing 14 and control plate 25, which extends the full width of the housing.
As
effluent enters the coarse filtration chamber 24 through inlet 12, it passes
through
a filtering basket 26 (shown in greater detail in connection with Figure 2),
which
filters out solid particles, such as undissolved fat and other food particles.
After passing through the basket 26, the effluent enters the separation
chamber 28, defined by control plate 25, control plate 30 (which extends the
full
width of the housing), top plate 32 and the bottom of housing 14. There are
two
exits from the separation chamber: (1) through floating ball valve 34 and
through
passage 36, disposed between the bottom of control plate 30 and the bottom of
the housing 14. Top plate 32 is angled upward from the bottom portion of
control plate 25 towards control plate 30.
Weir plate 38, which extends the full width of the housing, defines a
water (high density liquid) release chamber 40, along with control plate 30
and
the housing 14. Outlet 20 is disposed through the housing.
In operation, as the effluent enters the separation chamber 28, the
lower density liquid (grease/oil) rises. The flow through the separation
chamber
28 is set at a rate that allows the lower density liquid to separate from the
water
and float upwards to the surface of the water, where it is contained below the
sloping top plate 32.
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The sloping top plate 32 forces the lower density liquid to accumulate
at the entry to floating ball valve 34. Floating ball valve 34 is shown in
greater
detail in connection with Figure 4. Floating ball valve 34 uses a ball that
floats at
the interface between the high density liquid and the low density liquid. When
the high density liquid reaches a predetermined height, the ball rises to a
height
which stops flow from the separation chamber 28 to the container 18.
As the water flows through the separator 10, it must rise above the top
of weir 38 in order to exit. Accordingly, the water in separation chamber 28
attempts to rise to approximately the same height. Since the top of the
separation chamber 28 is below the top of weir plate 38, the hydrostatic
pressure
of the upward force of the water will push the separated grease/oil at the top
of
the separation chamber 28 through valve 34. The water, however, cannot pass
through the valve 34, because the floating valve will stop its passage. Hence,
once all the separated grease/oil is forced out of the separation chamber, the
valve will remain closed until more grease/oil accumulates.
The separated water passes through passage 36, over weir plate 38 and
out outlet 20. Silt in the water tends to accumulate at the bottom of housing
14,
unable to rise over weir plate 38. Silt valve 22, located at the bottom of
housing
14, can be opened periodically, and the flow of water out of the valve will
flush
out the silt.
In many fields of use for the separator 10, and in particular the food
industry, it can be assumed that the employees who will operate and maintain
the separator will be relatively transient between employers. Accordingly,
aspects of the operation and maintenance of the separator must allow for
unfamiliarity with details. Matters such as periodic cleaning of various
components of the separator, such as the floating ball valve, if performed
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incorrectly, can lead to unwanted consequences, such as allowing water to exit
into the oil/grease container or oil/grease flowing out of the outlet 20.
Also, it would be beneficial to improve the flow of liquids through the
separation chamber, since oil and grease are by their nature sticky and tend
to
accumulate on hard surfaces.
Accordingly, there is a need in the industry for an improved separator.
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BRIEF SUMMARY OF THE INVENTION
In one aspect of the present invention, a separator includes a tank
having an inlet, an inlet chamber, a separation chamber and an outlet chamber,
with the inlet feeding effluent into the inlet chamber, the inlet chamber
being in
communication with the separation chamber through a first passage and the
separation chamber being in communication with the outlet chamber through a
second passage. A basket having at least one tapered side disposed in the
inlet
chamber below the inlet, such that the one tapered side is disposed at an
angle
relative to an adjacent sidewall of the inlet chamber.
In a another aspect of the present invention a baffle directs effluent
into the basket with greater force.
In another aspect of the present invention, an asymmetrical flange
prevents mis-orientation the basket and baffle.
In another aspect of the present invention the continuous seating and
continuous flange on the basket prevents floatable solids bypassing the basket
and floating up with the oil to interfere with the oil valve ball seating.
In another aspect of the present invention a self closing silt valve
eliminates the chance of the silt valve being left open, which may cause the
heater to overheat, burn out and cause smoking of the oil.
In another aspect of the present invention, an improved oil valve
provides a locking mechanism to prevent dislodging of the valve during
cleaning.
In another aspect of the present invention, a valve uses a sensor to
sense an oil/water interface and close the oil valve appropriately.
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In another aspect of the present invention, a top seal allows the
incoming effluent to surcharge in the inlet chamber without leaking over
connection points on with the lid of the housing.
In another aspect of the present invention, an underground unit allows
below floor level installation of the separator.
In another aspect of the present invention, a bidirectional unit can be
installed in such a way to allow flow in either direction, thus eliminating
the
need to manufacture and inventory units that flow either left-to-right or
right-to-
left.
In another aspect of the present invention, a dual purpose tank can be
used to store both separated oil and oil from operations for common removal.
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BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a more complete understanding of the present invention, and the
advantages thereof, reference is now made to the following descriptions taken
in
conjunction with the accompanying drawings, in which:
Figures la and lb illustrate a perspective view and a cross-sectional
view of a prior art separation device;
Figure 2 illustrates a prior art filtration basket used in the device of
Figures la and lb;
Figures 3a through 3d respectively illustrate perspective, top, cross-
sectional front, and cross-sectional side views of an improved basket;
Figure 4 illustrates a prior art floating ball valve used in the separation
device of Figures la and lb;
Figure 5a illustrates a cross-sectional view of an improved floating ball
valve;
Figure 5b illustrates a perspective view of a housing for an improved
floating ball valve;
Figure 5c illustrates a top view of the improved floating ball valve;
Figure 6a illustrate a block diagram of an improved valve for replacing
the ball valve of Figure 4;
Figures 6b through 6d illustrate cross-sectional view of butterfly, gate
and ball valves, respectively;
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Figures 7a through 7c illustrates an improved separation device with
low friction surfaces, improved heating and silt removal, and leakage
prevention;
Figure 8 illustrates an improved separation device that can be used in
an in-ground installation;
Figure 9 illustrates a tool for cleaning the separation device of Figure 8;
Figure 10 illustrates a separation device combined with a large
capacity storage container for unified grease control; and
Figure 11 illustrates a bi-directional separation device.
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DETAILED DESCRIPTION OF THE INVENTION
The present invention is best understood in relation to Figures 1 - 11 of
the drawings, like numerals being used for like elements of the various
drawings.
Figure 2 illustrates a prior art filtration basket 26. The basket has a
front side (facing the housing at inlet 12) and a back side (facing control
plate 25)
that is perforated with holes 50, as is the bottom of the basket. Since the
front
side is relatively flush with housing 14 and the back side is relatively flush
with
control plate 25, and the ends are not perforated, almost all of the effluent
flow is
through the holes in the bottom of the basket. Over time, food particles will
accumulate on the bottom of the basket 26, severely limiting flow into the
separation chamber 28.
Other problems concern removal and replacement of the basket 26.
The prior art uses a handle 52 which terminates through holes on either side
of
the basket. The basket 26 has flanges 54 on either side; flanges 54 normally
rest
on support clips 56 formed on either side of the housing in the coarse
filtration
chamber 24. In order to accommodate the exposed ends of the handle 52 when
the basket is removed or replaced, slots 58 are formed in support clips 56
through which the ends of the handle may pass.
During operation, the slots 58 prevent a complete seal between flanges
54 and support clips 56. Some of food particle in the effluent may pass
through
the slots 58, bypassing basket 26. Food particles may also pass through the
narrow gap between the front edge of the basket and the outer body 14 and the
rear edge of the basket and the control plate 25. Excessive food particles
entering
the separation chamber 28 can clog the floating ball valve 34, resulting in
water
passing into the oil collection chamber 18.
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Figures 3a through 3d illustrate perspective, top, cross-sectional front
and cross-sectional side views of an improved basket 60. The improved basket
increases efficient effluent flow, eliminates solid particles in the effluent
from
bypassing the filtration mechanism of the basket, and enhances effluent
separation in the separation chamber 28.
As distinguished from the vertical sides of basket 26, tapered basket 60
has tapered sides that angle away from housing 14 and control plate 25.
Further,
all four sides are perforated. Accordingly, a larger surface area of the
basket is
separated from a constricting wall for more efficient flow through the basket
60.
Since there is more area for holes 62, the holes 62 can have a smaller
diameter,
without affecting flow of effluent through the basket. In the prior art, holes
50
had a diameter of approximately 11/64 inches, while holes 62 can have a
diameter of approximately 1/16 inches (0.15875 cm). This allows smaller
particles to be trapped by the basket 60 for more effective coarse filtering.
Further, more debris may be collected before the basket needs to be emptied,
since the basket will continue to efficiently filter the effluent even when
the
bottom is covered.
An additional improvement is the addition of inclined baffle plate 64
to the basket 60. Baffle plate 64 deflects water from inlet 12 towards the
bottom
of the basket 60. A cut-out 64a in the baffle plate 64 faces inlet 12. As
effluent
enters the coarse filtering chamber 24, the baffle directs the effluent
downwards
to help drive oils and grease under the control plate 25. Further, as effluent
hits
the baffle plate 64, it is driven through a layer of oil, which helps to
saturate the
chemical emulsions, causing the emulsions to release the oil.
The handle 68 of basket 60 is attached to the top of the baffle plate 64.
Because the handle does not protrude from the sides of the basket 60, the
slots 58,
shown in Figure 2 are no longer necessary.
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With the addition of the baffle plate 64, it is important that the basket
60 is oriented correctly (such that the baffle plate deflects effluent
downward, not
upward). A careless replacement of the basket 60 could thus cause problems
with the operation of the separator 10. To prevent an errant replacement, the
basket 60 has asymmetric flanges 54a and 54 b. As shown in Figures 3a-d,
flange
54a is wider than 54b, and support clip 56a is wider than 56b. If the basket
60 is
replaced in the reverse orientation, the mismatch between the support clips
56a-b
and flanges 54a-b will not allow the basket to seat properly (and the lid will
not
be able to close). This will notify the operator that the basket needs to be
reversed. Front and back flanges 54c and 54d provide an integral lip that
completely surrounds the basket 60 for a complete seal.
Figure 4 illustrates a type of floating ball valve 34 used in the prior art.
Floating ball valve 34 includes a ball 70 within housing 72. Ball 70 is held
within
housing 72 by a grid 74. Insert 76 includes a mating portion 78 for mating
with
the housing 72 above the ball 70 and an outlet portion 79 for communicating
with the oil/grease container 18. A passage 80 is formed in insert 76 through
the
mating portion 78 and outlet portion 79, with a tapered opening 82 at the end
of
the passage 80. Passage 80 is coupled to outlet 84. 0-ring 86 seals mating
portion 78 and housing 72. As described above, the ball 70 is designed to
float at
the interface between two immiscible liquids (e.g., water and oil/grease). As
the
water rises, the oil/grease is pushed into passage 80, where it exits to the
oil/grease container 18 via outlet 84. Once all of the lower density liquid
(oil/grease) has been pushed into the passage 80, the ball 70 presses against
the
tapered opening 82, thereby closing the passage. In this way, only the lower
density liquid can pass through the passage 80.
Since the oils and grease will pass through the passages 80 and 84 to
the oil/grease container 18, the passages 80 and 84 need to be cleaned
periodically to remove congealed substances. To do so, a brush is inserted
into
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the passage 80 from above or passage 84 from the side and an up and down
scrubbing motion is used to dislodge the congealed oil/grease within the
passage 80. During the cleaning process, the mating portion 78 can easily
become dislodged from the housing 72, causing failure of the valve 34.
In Figures 5a illustrates a cross-sectional side view of an improved
floating ball valve 90, which can be used in place of floating ball valve 34.
Floating ball valve 90 includes a mating portion 78, with two protruding
locking
pins 92. Housing 72 includes two vertical channels 94 forming L-shapes with
respective horizontal channels 96 (see Figure 5b) to accept pins 92. The
mating
portion 78 is engaged within housing 72 by aligning the pin 92 with vertical
channel 94, inserting the mating portion 78 into the housing 72 until pin 92
reaches the end of the vertical channel 94, then rotating the pin within the
horizontal channel 96 to lock the mating portion within the housing 72.
Figure 5b shows a perspective view of housing 72, illustrating the
vertical channel 94 and horizontal channel 96. Figure 5c illustrates the
insert 76
in a locked position within housing 72.
Another problem associated with floating ball valve 34 is the problems
which can occur if the ball 70 sticks to the mating portion 82. This is
possible
because of the oil/grease that will coat both surfaces during normal operation
of
the separator 10.
Figure 6a illustrates a schematic of an alternative embodiment of a
valve which can be used to eliminate the need for a floating ball. In Figure
6a, a
sensor 100 senses the location of the interface between the two immiscible
liquids. When the interface has reached a predetermined level, the sensor sets
a
control signal to actuator 102. Responsive to the control signal, the actuator
closes a valve 104 which controls flow between an oil/grease inlet 106 and an
oil/grease outlet 108.
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Figures 6b through 6d illustrate three types of valves that could used
implement valve 104 (other valve types could be used as well). Figure 6b
illustrates a cross-sectional side view of a butterfly valve 110. The
butterfly valve
operates by rotating a disk 114 within cylindrical housing 112. When surface
the
disk 114 is aligned parallel to the axis of the cylindrical housing, the valve
110 is
in an open state; when the surface of the disk 114 is perpendicular to the
axis of
the cylindrical housing 112, the valve 110 is in a closed state.
Figure 6c illustrates a cross-sectional side view of a gate valve 120. In a
gate valve, a gate 122 is positioned within tube 124 to prevent flow and
withdrawn from tube 124 to allow flow.
Figure 6d illustrates a cross-sectional side view of a ball valve 130 (not
to be confused with the floating ball valve 34). The ball valve incorporates a
sphere 132 with a cylindrical bore 134 disposed through the center of the
sphere.
When the bore is aligned with the inlet 136 and outlet 138, liquid can pass
from
inlet to outlet. When the bore 134 is rotated to a position where it does not
communicate between inlet 136 and outlet 138, liquid can no longer pass
through
the valve.
The ball valve 130 is a preferred embodiment for the present invention,
because the operation of the valve rotating between opened and closed
positions
tends to scrape away congealed oil/grease at the inlet and outlet. Therefore,
this
valve is somewhat self-cleaning.
Figure 7a illustrates improvements made to the separator 10 to
improve flow of the liquids (and silt) inside the separation chamber for
improved
operation. First, the inside of housing 14 and surfaces of control plate 25,
top
plate 32, control plate 30 and weir 38 can be coated with a Teflon layer 39,
or
another non-stick coating layer 39, in improve flow and reduce friction and
adhesion between the oil/grease/silt and these surfaces.
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Additionally, Figure 7a illustrates improvements made to heating of
the liquids, particularly in the separation chamber 28. In the prior art, a
probe-
type heating element has been used. This presents several problems. First, the
heater is mounted to the outside of the unit, where it can be inadvertently
hit by
employees, and knocked loose. Second, the surface area of the heater is
relatively small and, therefore, the heat is localized.
In Figure 7a, several alternatives are shown for heating the liquids in
the separation chamber 28. These alternatives could be used separately or
combined. The first alternative uses a heating blanket 140 disposed on the
bottom of housing 14. This eliminates any protruding housing for the heater
and
heats a larger surface area, keeping the temperatures relative constant across
the
separation chamber 28.
A second alternative uses induction heating to heat the top plate 32
and/or valve 34. Since the top plate 32 and valve 34 are in nearly constant
contact with the oil/grease, these elements can be heated by induction to most
effectively provide heat for keeping the oil/grease as liquid as possible. The
induction heating of the top plate 32 and/or valve 34 could be used in
conjunction with the heat blanket 140.
Additionally, in Figure 7a, a self-closing valve 147 is used as the silt
valve. After being placed in an open position to flush out silt, the self-
closing
valve will close without further manual interaction in 2-20 seconds, or other
time
which is sufficient to remove the silt. This protects the device from being
operated with the silt valve open, which could allow effluent to pass directly
out
the silt valve; this could cause the heater to overheat and to burn out and/or
cause the oil to overheat and smoke.
Figures 7a, 7b and 7c illustrate top and bottom seals used in the
improved separator. A top seal 142 is formed on the perimeter of the housing
14
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and on the tops of control plates 25 and 30, providing a continuous seal. In
the
preferred embodiment, the seal 142 is mechanically attached to the housing 14
and control plates in the manner shown in Figure 7c. In Figure 7c, the seal
material, preferably in the form of a hollow neoprene tube or similar flexible
hollow tubing, is affixed to an edge of the housing 14 and control plates 25
and
30 using a mechanical gripping mechanism 144. In the illustrated embodiment,
the mechanical gripping mechanism includes teeth 146 which, when pushed
onto the housing edges, will grab the edges to form a strong mechanical bond.
Any gaps between strips of materials should be filled with a sealing compound.
In operation, the top seal 142 can withstand considerable water
pressure with just the weight of the lid 15 maintaining contact with the seal
142.
Thus, if an surge of water is received through inlet 20, water is maintained
within the housing 14, and is kept from overflowing from either the coarse
filtration chamber 24 or the water release chamber 40 into the interior
chamber
148 of the housing 14, where it can become rancid.
Prior art mechanisms use a compressive foam that is affixed to the
lower edge of the lid by means of a self adhesive strip, and a seal is created
by
the use of lid clamps to hold the lid to the body. The claims make the user
access
to the unit difficult. Also, the clamped lid discourages the operators from
properly maintaining the unit.
An additional bottom seal 149 is affixed around the bottom edge of the
housing 14. Once again, the bottom seal 149 is preferably in the form of a
hollow
neoprene tube affixed to the edges of the housing 14 using a mechanical
gripping
mechanism 144 as shown in Figure 7c.
Prior art methods for sealing the separator to a floor, such as by
caulking, have adhesion problems, particularly in the grout lines. Since units
will often be retrofit to existing restaurants, the grease embedded in the
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CA 02472507 2004-06-25
resists adhesion, allowing water from floor cleaning to seep under the unit.
Also,
caulking complicates moving of the unit. Placing the unit on legs such that
the
floor can be cleaned under the unit can add height to the unit, reducing the
positive fall of the effluent from sink and dishwasher drains.
The bottom seal 149 has been shown to effectively seal the unit to the
floor, and is particularly effective in sealing the grout lines, since the
weight of
the unit holds the bottom seal 149 firmly within the grout lines.
Figure 8 illustrates an embodiment of a separator 150 which has the
advantage that it can be used in an in-ground embodiment. For illustration
purposes, separator 150 is shown with the prior art heater 16 and floating
ball
valve 34, it being understood that the other improvements described herein
could be used in the place of these elements.
In Figure 8, basket 60 performs coarse filtering on effluent received
through inlet 12. Control plate 25 has an angled portion 152 to provide an
improved flow through basket 60 (this improvement can be used in other
configurations as well). A downward sloping bottom control plate 154 has a V-
shape (or channel) to catch silt, and is preferably Teflon coated. The V-shape
bottom control plate transitions into weir 156, maintaining a V-shape which is
slanted upwards to the desired predetermined height to provide hydrostatic
pressure on the separated oil at valve 34. Control plate 158, is coupled to
the top
of housing 14 and provides a channel 160 through which the separated water
flows. Control plate 158 includes an enlarged portion 162. Heater 16 is
disposed
through top plate 32, within compartment 164. Apart from compartment 164, the
area above top plate 32 can be used as a sump 166 to store oil/grease from
oil/grease valve 34, preferably in a removable container. Access to the
tapered
basket 60, sump 166, compartment 164 and oil valve 34 can be made by removing
one or more lids (not shown) on the top of housing 14. If silt is to be
separate
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from the water, a water outlet 168 is placed above a silt valve 170.
Alternatively,
a single outlet can be provided, which disposes of both water and silt. A mesh
screen 172 is positioned in front of water outlet 168 to filter out silt.
In operation, silt from the effluent will gather at the bottom plate 154,
and will be drawn towards the lowest portion of the "V" shaped plate 154 at
the
interface with the weir 156. The flow of water through channel 160 will push
the
silt up the channel 160. The enlarged portion 162 of the channel will create
turbulence and additional suction to pull silt up and over the top of weir
156.
Silt will fall to silt valve 170, which can be periodically opened to a silt
outlet or
collected separately in a container coupled to the silt valve 170. The
remainder of
the water flows out of water outlet 168 into the sewage system.
Over time, some silt may collect on weir 156. Figure 9 illustrates a
scraper which matches the profile of weir 156 to remove this silt.
Preferably, all inside surfaces of separator 150 are Teflon coated to
decrease resistance and improve flow.
Figure 10 illustrates a diagram of a separator with a large grease
container for containing both grease/oil separated from the effluent and for
containing used grease/oil from operations, such as from frying machines. In
this embodiment, an underground separator 150 (an above ground separator of
the type shown in Figures 1-7a-c could also be used) is coupled to a storage
tank
170 which is large enough to hold all the discard oil/grease from effluent and
operations. Pipe 172 couples the valve 34 to the storage tank 170. Opening 174
allows workers to pour the oil/grease into the storage tank from an oil caddy,
for
example. Alternatively, the oil/grease from operations could be pumped
directly to the tank 170. Heater 176 heats the contained oil so that it does
not
solidify. Valve 178, typically a quick disconnect valve, provides a suitable
connection to an oil pump used to pump oil/grease from the tank 170 for
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reclamation. Pipe 180 is disposed between valve 178 and the bottom of the tank
170.
In operation, the embodiment shown in Figure 10 allows a business to
consolidate all oil/grease waste for removal by a collection company,
typically
an outside contractor or municipality. The unified design allows the
collection
company to collect all of the used oil/grease from a restaurant. By using the
underground configuration, oil drums/dumpsters could be eliminated from the
back of the restaurant, or other business.
Figure 11 illustrates an embodiment for an above-ground bidirectional
separator 182 (with lid 15 removed), i.e., the valve 34 and heater 16 can be
located on either side of the housing 14. The housing 14 includes two oil
valve
housings 72, one of which will receive a valve 34 and the other of which will
have a plug installed. Container 18 is mounted through opening 186 on the side
of the valve 34, the other opening 186 is closed with a blank. The holes 186
have
slotted holes adjacent to them to enable either the container 18 or support or
blank plate to be mounted. Threaded connections 188 are made on either side of
the housing 14 for receiving the heater 16; the side not receiving the heater
is
closed with a threaded plug.
The embodiment shown in Figure 11 allows the separator 182 to be
installed in either flow direction, which reduces the cost of inventory that
must
be maintained and allows the most efficient installation within a business.
Further, the direction of the separator 182 can be switched if a kitchen is
remodeled (on average, a commercial kitchen is remodeled every five years) to
accommodate a change in flow through the pipes.
Although the Detailed Description of the invention has been directed
to certain exemplary embodiments, various modifications of these embodiments,
as well as alternative embodiments, will be suggested to those skilled in the
art.
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The invention encompasses any modifications or alternative embodiments that
fall within the scope of the Claims.
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