Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEM FOR DECONTAMINATING WATER AND GENERATING WATER VAPOR
DESCRIPTION
BACKGROUND OF THE INVENTION
[Para 1] The present invention relates to a system for
decontaminating water
and generating water vapor. More particularly, the present invention relates
to
an improved method that utilizes a series of sensors and a control system to
vaporize water, remove dissolved solids and maximize recovery of potable water
from contaminated water via a horizontal water processing vessel.
[Para 2] Desalinization (also desalination or desalinisation)
refers to one of
many processes for removing excess salt, minerals and other natural or
unnatural contaminants from water. Historically, desalinization converted sea
water into drinking water onboard ships. Modern desalinization processes are
still used on ships and submarines to ensure a constant drinking water supply
for
the crew. But, desalinization is increasingly being used in arid regions
having
scarce fresh water resources. In these regions, salt water from the ocean is
desalinated to fresh water suitable for consumption (i.e. potable) or for
irrigation.
The highly concentrated waste product from the desalinization process is
commonly referred to as brine, with salt (NaCI) being a typical major by-
product.
Most modern interest in desalinization focuses on developing cost-effective
processes for providing fresh water for use in arid regions where fresh water
availability is limited.
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[Para 3] Large-scale desalinization is typically costly and
generally requires
large amounts of energy and an expensive infrastructure. For example, the
world's largest desalinization plant primarily uses multi-stage flash
distillation
and can produce 300 million cubic meters (m3) of water per year. The largest
desalinization plant in the United States desalinates 25 million gallons
(95,000
m3) of water per day. Worldwide, approximately 13,000 desalinization plants
produce more than 12 billion gallons (45 million m3) of water per day. Thus,
there is a constant need in the art for improving desalinization methods,
namely
lowering costs and improving efficiency of the related systems.
[Para 4] Desalinization may be performed by many different
processes. For
example, several processes use simple evaporation-based desalinization
methods such as multiple-effect evaporation (MED or simply ME), vapor-
compression evaporation (VC) and evaporation-condensation. In general,
evaporation-condensation is a natural desalinization process performed by
nature during the hydrologic cycle. In the hydrologic cycle, water evaporates
into
the atmosphere from sources such as lakes, oceans and streams. Evaporated
water then contacts cooler air and forms dew or rain. The resultant water is
generally free from impurities. The hydrologic process can be replicated
artificially using a series of evaporation-condensation processes. In basic
operation, salt water is heated to evaporation. Salt and other impurities
dissolve
out from the water and are left behind during the evaporation stage. The
evaporated water is later condensed, collected and stored as fresh water. Over
the years, the evaporation-condensation system has been greatly improved,
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especially with the advent of more efficient technology facilitating the
process.
But, these systems still require significant energy input to evaporate the
water.
An alternative evaporation-based desalinization method includes multi-stage
flash distillation, as briefly described above. Multi-stage flash distillation
uses
vacuum distillation. Vacuum distillation is a process of boiling water at less
than
atmospheric pressure by creating a vacuum within the evaporation chamber.
Hence, vacuum distillation operates at a much lower temperature than MED or VC
and therefore requires less energy to evaporate the water to separate the
contaminants therefrom. This process is particularly desirable in view of
rising
energy costs.
[Para 5] Alternative desalinization methods may include membrane-
based
processes such as reverse osmosis (RO), electrodialisys reversal (EDR),
nanofiltration (NF), forward osmosis (FO) and membrane distillation (MD). Of
these desalinization processes, reverse osmosis is the most widely used.
Reverse
osmosis uses semi-permeable membranes and pressure to separate salt and
other impurities from water. Reverse osmosis membranes are considered
selective. That is, the membrane is highly permeable to water molecules while
highly impermeable to salt and other contaminants dissolved therein. The
membranes themselves are stored in expensive and highly pressurized
containers. The containers arrange the membranes to maximize surface area
and salt water flow rate therethrough. Conventional-osmosis desalinization
systems typically use one of two techniques for developing high pressure
within
the system: (1) high-pressure pumps; or (2) centrifuges. A high-pressure pump
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helps filter salt water through the membrane. The pressure in the system
varies
according to the pump settings and osmotic pressure of the salt water. Osmotic
pressure depends on the temperature of the solution and the concentration of
salt dissolved therein. Alternatively, centrifuges are typically more
efficient, but
are more difficult to implement. The centrifuge spins the solution at high
rates
to separate materials of varying densities within the solution. In combination
with a membrane, suspended salts and other contaminants are subject to
constant radial acceleration along the length of the membrane. One common
problem with reverse osmosis in general is the removal of suspended salt and
clogging of the membrane over time.
[Para 6] Operating expenses of reverse osmosis water desalinization
plants
are primarily determined by the energy costs required to drive the high-
pressure
pump or centrifuge. A hydraulic energy recovery system may be integrated into
the reverse osmosis system to combat rising energy costs associated with
already energy intensive processes. This involves recovering part of the input
energy. For example, turbines are particularly capable of recovering energy in
systems that require high operating pressures and large volumes of salt water.
The turbine recovers energy during a hydraulic pressure drop. Thus, energy is
recovered in a reverse osmosis system based on pressure differentials between
opposite sides of the membrane. The pressure on the salt water side is much
higher than the pressure on the desalinated water side. The pressure drop
produces considerable hydraulic energy recoverable by the turbine. Thus, the
energy produced between high pressure and low pressure sections of the reverse
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osmosis membrane is harnessed and not completely wasted. Recovered energy
may be used to drive any of the system components, including the high-pressure
pump or centrifuge. Turbines help reduce overall energy expenditures to
perform desalinization.
[Para 7] In general, reverse osmosis systems typically consume less
energy
than thermal distillation and is, therefore, more cost effective. While
reverse
osmosis works well with somewhat brackish water solutions, reverse osmosis
may become overloaded and inefficient when used with heavily salted solutions,
such as ocean salt water. Other, less efficient desalinization methods may
include ionic exchange, freezing, geothermal desalinization, solar
humidification
(HDH or MEH), methane hydrate crystallization, high-grade water recycling or
RF
induced hyperthermia. Regardless of the process, desalinization remains energy
intensive. Future costs and economic feasibility continue to depend on both
the
price of desalinization technology and the costs of the energy needed to
operate
the system.
[Para 8] In another alternative method of desalinization, U.S.
Patent No.
4,891,140 to Burke, Jr. discloses a method of separating and removing
dissolved
minerals and organic material from water by destructive distillation. Here,
water
is heated to a vapor under controlled pressure. Dissolved salt particles and
other
contaminants fall out of the solution as water evaporates. An integrated
hydrocyclone centrifuge speeds up the separation process. The heated, high
pressure clean water transfers energy back to the system through heat exchange
and a hydraulic motor. Net energy use is therefore relatively lower than the
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aforementioned processes. In fact, net energy use is essentially equivalent to
pump loss and heat loss from equipment operation. One particular advantage of
this design is that there are no membranes to replace. This process removes
chemicals and other matter that would otherwise damage or destroy membrane-
based desalinization devices.
[Para 9] Another patent, U.S. Patent No. 4,287,026 to Wallace,
discloses a
method and apparatus for removing salt and other minerals in the form of
dissolved solids from salt and other brackish waters to produce potable water.
Water is forced through several desalinization stages at high temperature and
at
high centrifugal velocities. Preferably, the interior components spin the
water at
speeds up to Mach 2 to efficiently separate and suspend dissolved salt and
other
dissolved solids from the vaporized water. The suspended salt and other
minerals are centrifugally forced outward to be discharged separately from the
water vapor. The separated and purified vapor or steam is then condensed back
to potable water. The system requires significantly less operational energy
than
reverse osmosis and similar filtration systems to efficiently and economically
purify water. One drawback of this design is that the rotating shaft is built
into a
vertical chamber. As a result, the rotating shaft sections are only solidly
anchored to the base unit by a bearing and a bearing cap. At high rotational
speeds (e.g. over Mach 1), vibrations cause excessive bearing shaft and seal
failure. Another drawback is that a series of chambers are bolted together in
housing sections. The perforated plates are coupled to these sections by an 0-
ring seal. The housing and 0-ring seals tend to wear over time due to salt
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penetration because the multiple chambers and housing sections are connected
via a plurality of nuts and bolts. In particular, the assembly of the Wallace
design
is particularly laborious. Maintenance is equally labor intensive as it takes
significant time to disassemble each of the housing sections, including the 0-
rings, nuts and bolts. Of course, the device must be reassembled after the
requisite maintenance is performed. Each housing section must be carefully put
back together to ensure proper sealing therebetween. The system is also prone
to a variety of torque and maintenance problems as the device ages, such as 0-
ring leakage. Moreover, the rotating shaft is connected to the power source by
a
gear drive, which contributes to the aforementioned reliability problems
associated with the bearings, shafts and seals. The system also fails to
disclose
a means for regulating the speed of the rotating shaft sections according to
the
osmotic pressure of the salt water being desalinated. The static operation of
the
Wallace desalinization machine is therefore not as efficient as other modern
desalinization devices.
[Para 10] Thus, there is a need in the art for an improved system
that includes
sensors for monitoring real-time system information and controls for adjusting
the mechanical operation of the system to maximize decontamination of the
water, such as desalinization of the water, and minimize energy consumption.
Such a system should further incorporate multiple recycling cycles to increase
the
recovery of potable water from approximately eighty percent to between
approximately ninety-six percent to ninety-nine percent, should incorporate a
polymer aided recovery system to extract trace elements of residue compounds
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and should consume less energy than other desalinization systems known in the
art. The present invention fulfills these needs and provides further related
advantages.
SUMMARY OF THE INVENTION
[Para 11] The present invention is directed to a system for
processing fluids,
such as decontaminating or desalinating water, and generating water vapor,
including steam. The system for decontaminating a fluid and recovering vapor
begins with a waste water supply fluidly connected to a waste water filter-
strainer device. The waste water filter-strainer device is fluidly connected
to a
waste water feed tank. A waster water inlet on a purification unit receives
the
filtered output from the filter-strainer device to separate the waste water
into a
contaminate flow and a vapor flow.
[Para 12] The purification unit has a generally horizontal elongated
vessel with
a plurality of alternately spaced rotating trays and fixed baffles disposed
vertically along the elongated vessel between a first end of the elongated
vessel
proximate to the waste water inlet and second end of the elongated vessel
proximate to a contaminant outlet and a clean water vapor outlet. A
contaminant
tank is fluidly connected to the contaminant outlet for storage of the same. A
vapor pipeline is fluidly connected to the clean water vapor outlet.
[Para 13] The waste water feed tank may include a heat exchanger
that is
configured to receive the vapor pipeline. The vapor pipeline fluidly passes
through the heat exchanger so as to condense the clean water vapor output from
the purification unit. A decontaminated water recovery tank is fluidly
connected
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to the vapor pipeline after passing through the heat exchanger and is
configured
to store the condensed water for later processing or distribution.
[Para 14] As an alternative to passing the vapor pipeline through a
heat
exchanger, the vapor pipeline may be fluidly connected to a steam generator
for
converting the vapor flow into a steam flow. The output from the steam
generator may then be fluidly connected to a steam turbine for converting the
steam flow into electricity. The electricity generated by the steam turbine
may be
connected to an electrical grid or a storage battery for later use. In certain
circumstances, the steam turbine may receive the vapor flow directly from the
vapor pipeline, by-passing or omitting the need for the steam generator.
[Para 15] Instead of going into a steam turbine, a steam pipeline
from the
steam generator may be fluidly connected to a steam injector on an oil
wellhead
or similar structure fluidly connected to a subsurface oil zone. An oil-water
separator may receive the combined oil-water flow extracted from the oil zone,
so as to separate the same into an oil product flow and a waste water supply.
A
gas separator may be fluidly disposed between the oil wellhead and the oil-
water
separator so as to separate gasses entrained in the combined oil-water flow.
[Para 16] Within the vaporizer-desalination or purification unit,
each of the
rotating trays has a plurality of scoops each having an inlet of a first
diameter
and an outlet of a second smaller diameter, and each of the fixed baffles has
a
plurality of apertures each having an inlet of a first diameter and an outlet
of a
second smaller diameter. The purification unit may further include an internal
sleeve disposed in the elongated vessel downstream of the plurality of
alternately
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spaced rotating trays and fixed baffles, the internal sleeve forming an
annular
passageway to the contaminate outlet.
[Para 17] The present invention is also directed to a method for
processing
and recycling water used in an oil zone steam processing cycle. The method
begins with injecting a steam flow into a subsurface oil zone for stimulating
and
increasing a rate of oil production therefrom. A combined crude oil and water
flow is extracted from the subsurface oil zone. The combined crude oil and
water flow is separated into a crude oil flow and a contaminated water flow.
The
contaminated water flow is filtered through a macro particle filtration device
so
as to produce a filtered water flow. The filtered water flow is processed
through
a vaporizer-desalination unit, wherein the vaporizer-desalination unit
separates
the filtered water flow into a contaminant flow and a clean vapor flow.
Finally,
the clean vapor flow is pumped through a steam generator so as to produce the
steam flow.
[Para 18] The method may further include introducing an external
water flow
into the steam generator macro so as to introduce sufficient water to prime
the
oil zone steam processing cycle. The method may also include disposing of the
contaminant flow in a disposal well separate from the subsurface oil zone. The
crude oil flow may be stored in a storage tank for subsequent processing and
commercial distribution. The method may further include degassing the
combined crude oil and produced water flow prior to performing the separating
step.
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[Para 19] The vaporizer-desalination unit preferably has a generally
horizontal
elongated vessel having a plurality of alternately spaced rotating trays and
fixed
baffles disposed vertically along the elongated vessel between a first end and
a
second end of the elongated vessel. The plurality of alternately spaced
rotating
trays and fixed baffles may further include a plurality of scoops on each of
the
plurality of rotating trays, each scoop having an inlet of a first diameter
and an
outlet of a second smaller diameter, and a plurality of apertures on each of
the
plurality of fixed baffles, each aperture having an inlet of a first diameter
and an
outlet of a second smaller diameter. The vaporizer-desalination unit may
include
an internal sleeve disposed in the elongated vessel downstream of the
plurality of
alternately spaced rotating trays and fixed baffles, the internal sleeve
forming an
annular passageway to the contaminate outlet.
[Para 20] The vaporizer-desalination unit preferably comprises an
elongated
vessel defining an inner chamber. The vessel is oriented generally
horizontally.
An inlet is formed in the vessel for introducing fluid therein. A plurality of
trays
is disposed within the inner chamber in spaced relation to one another. The
trays include scoops through which fluid - both liquid and vapor - passes. The
scoops preferably include an inlet of a first diameter and an outlet of a
second
smaller diameter. A plurality of baffles, typically apertured plates, is
disposed
between the trays. Each baffle has a plurality of apertures through which
fluid -
both liquid and vapor - passes. Preferably, the apertures have an inlet of a
first
diameter and an outlet of a second smaller diameter. In one embodiment, at
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least one of the trays includes a flow director extending from a front face
thereof
and configured to direct flow of the fluid towards a periphery of the tray.
[Para 21] A rotatable shaft passes through the baffles, and is
attached to the
tray so as to rotate the trays within the inner chamber, while the baffles
remain
stationary. A drive rotates the shaft. Typically, a gap or a layer or sleeve
of low
friction material, or bearings, is disposed between the baffles and the shaft.
[Para 22] A contaminant outlet is formed in the vessel and typically
in fluid
communication with a contaminant water tank. An internal sleeve is disposed in
the inner chamber downstream of the trays and baffles. The internal sleeve is
proximate to the contaminate outlet and forms an annular passageway leading
from the inner chamber to the contaminate outlet. A water vapor outlet is also
formed in the vessel and is in communication with a vapor recovery tank for
condensing the vapor to liquid water. In one embodiment, at least one treated
contaminated water tank is fluidly coupled to the vessel for reprocessing the
contaminated water by passing the treated contaminated water through the
system again.
[Para 23] In one embodiment, a controller may be used to adjust the
speed of
rotation of the shaft or the water input into the vessel. At least one sensor
is in
communication with the controller. At least one sensor is configured to
determine at least one of: 1) speed of rotation of the shaft or trays, 2)
pressure
of the inner chamber, 3) temperature of the fluid, 4) fluid input rate, or 5)
level of
contaminates in the fluid to be processed.
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[Para 24] In one embodiment, a turbine is connected to the vapor
outlet of the
vessel and operably connected to an electric generator. The fluid is heated to
at
least a boiling temperature thereof so as to create steam, and the vapor
and/or
steam is passed through the turbine operably connected to the electric
generator. A treated fluid return may be disposed between the turbine and the
vessel fluid inlet. Alternatively, the shaft may extend out of the vessel and
be
directly or indirectly coupled to an electric generator.
[Para 25] Other features and advantages of the present invention
will become
apparent from the following more detailed description, taken in conjunction
with
the accompanying drawings, which illustrate, by way of example, the principles
of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[Para 26] The accompanying drawings illustrate the invention. In
such
drawings:
[Para 27] FIGURE 1 is a top schematic, and partially sectioned, view
of a
system for decontaminating water and generating water vapor, in accordance
with the present invention;
[Para 28] FIGURE 2 is a side schematic, and partially sectioned,
view of the
system of FIG. 1;
[Para 29] FIGURE 3 is a top view illustrating the water processing
vessel having
an upper portion thereof opened;
[Para 30] FIGURE 4 is an end view of the horizontal water processing
vessel
attached to a portable framework, in accordance with the present invention;
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[Para 31] FIGURE 5 is a top view of a rotating tray having a
plurality of scoops
therein;
[Para 32] FIGURE 6 is a cross-sectional view of a portion of the
tray and a
scoop thereof;
[Para 33] FIGURE 7 is a top view of a baffle, used in accordance
with the
present invention;
[Para 34] FIGURE 8 is a side view of a tray having a water director
placed in
front thereof;
[Para 35] FIGURE 9 is a cross-sectional view of a portion of the
baffle,
illustrating a tapered aperture thereof;
[Para 36] FIGURE 10 is a schematic illustrating the electric motor
coupled to
the transmission and then coupled to the shaft of the water processing vessel,
in
accordance with the present invention;
[Para 37] FIGURE 11 is a schematic illustration of the system of the
present
invention, similar to FIG. 1, but illustrating the incorporation of a control
box and
various sensors, in accordance with the present invention;
[Para 38] FIGURE 12 is a top schematic view of the system of the
present
invention, incorporating a turbine and electric generator;
[Para 39] FIGURE 13 is an end view of the water processing vessel,
illustrating
a vapor outlet thereof;
[Para 40] FIGURE 14 is a side schematic view of the system of FIG.
12;
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[Para 41] FIGURE 15 is a front schematic and partially sectioned
view of an
alternate embodiment of a system for decontaminating water and generating
water vapor, in accordance with the present invention;
[Para 42] FIGURE 16 is a close-up of the trays and baffles of the
system of FIG.
15 indicated by circle 16;
[Para 43] FIGURE 17 is a lower perspective view of the vessel with
inlet and
outlets depicted in the system of FIG. 15;
[Para 44] FIGURE 18 is a cross-section of the vessel of FIG. 17
taken along line
18-18 thereof;
[Para 45] FIGURE 19 is an illustration of the shaft with trays and
baffles of the
system of FIG. 15;
[Para 46] FIGURE 20 is an illustration of a tray of the system of
FIG. 15;
[Para 47] FIGURE 21 is an illustration of a baffle of the system of
FIG. 15;
[Para 48] FIGURE 22 is a side view of a tray indicated by line 22-22
in FIG. 20;
[Para 49] FIGURE 23 is an opposite side view of the tray indicated
by line 23-
23 of FIG. 20;
[Para 50] FIGURE 24 is a side view of a baffle indicated by line 24-
24 in FIG.
21;
[Para 51] FIGURE 25 is a partial cross-sectional view of the shaft,
tray and
baffle as disposed in the vessel;
[Para 52] FIGURE 26 is a cross-sectional view of a tray taken along
line 26-26
of FIG. 20;
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[Para 53] FIGURE 27 is a cross-sectional view of a baffle taken
along line 27-
27 of FIG. 21;
[Para 54] FIGURE 28 is a schematic diagram of a control screen for a
system of
the present invention;
[Para 55] FIGURE 29 is a schematic illustration of the processes
occurring at
various points throughout the water processing vessel of the present
invention;
[Para 56] FIGURE 30 is an illustration of an embodiment of the shaft
with trays
and baffles of the system of FIG. 15 with an increased diameter and an
increase
number of scoops and apertures on the trays and baffles;
[Para 57] FIGURE 31 is a side view of a tray excerpted from FIG. 30;
[Para 58] FIGURE 32 is a side view of a baffle excerpted from FIG.
30;
[Para 59] FIGURE 33 is a schematic illustration of an embodiment of
the
system of the present invention, including a salt water capture system and
storage tank;
[Para 60] FIGURE 34 is a schematic illustration of the salt water
capture system
of the present invention;
[Para 61] FIGURE 35 is a schematic illustration of an embodiment of
the
system of the present invention, including an elevated condenser and holding
tank with a hydro-electric generator;
[Para 62] FIGURE 35A is a schematic illustration of the condenser of
FIG. 35;
[Para 63] FIGURE 36 is a schematic illustration of an embodiment of
the
system of the present invention, including a bring recirculating system and a
brine drying system;
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[Para 64] FIGURE 37 is a schematic illustration of an embodiment of
the
system of the present invention, including a control system with a graphical
display;
[Para 65] FIGURE 38 is a schematic illustration of the control
system with
graphical display of the main screen;
[Para 66] FIGURE 39 is a schematic illustration of the control
system with
graphical display of the graphs screen;
[Para 67] FIGURE 40 is a schematic illustration of the control
system with
graphical display of the trends screen;
[Para 68] FIGURE 41 is a flow chart illustration illustration of a
desalinated
water recovery system and process according to the present invention;
[Para 69] FIGURE 42 is a flow chart illustration of a steam and
electricity
generating system and process according to the present invention; and
[Para 70] FIGURE 43 is a schematic illustration of an oil zone steam
process
according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[Para 71] As shown in the drawings, for purposes of illustration,
the present
invention resides in a system and method for decontaminating water and
generating water vapor. The method and system of the present invention is
particularly suitable for desalinization of salt water, such as ocean or other
brackish waters, as well as, river water or other liquids/slurries. This
preferred
treatment will be used for exemplary purposes herein, although it will be
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understood by those skilled in the art that the system and method of the
present
invention could be used to decontaminate other water sources. The present
invention may be used to remove dissolved or suspended solids
(decontamination), as well as, heavy metals and other pollutants. Moreover, as
will be more fully described herein, the system and method of the present
invention can be used in association with relatively clean water to create
water
vapor, in the form of steam, which has a sufficient pressure and temperature
so
as to be passed through a turbine which is operably connected to an electric
generator for the generation of electricity, or other steam heating
applications.
[Para 72] In the following description, multiple embodiments of the
inventive
method and system for decontaminating water and generating water vapor are
described. Throughout these embodiments and with reference to the drawing
figures, functionally equivalent components will be referred to using
identical
reference numerals.
[Para 73] With reference now to FIGS. 1 and 2, the system - a
vaporization-
desalination unit - generally referred to by the reference number 10, includes
a
water processing vessel or chamber 12 defining an inner chamber 14, wherein
salt and other dissolved solids and contaminants are removed from the water to
produce essentially mineral-free, potable water. In one embodiment, the
processing vessel 12 receives contaminated water from a feed tank 16 through
an inlet valve 18 via a feed tank tube 20. In this illustration, the inlet
valve 18
enters the vessel 12 laterally through a side wall. This inlet valve 18 can be
alternately positioned as described below. The source of water can be sea or
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ocean water, other brackish waters, or even water which is contaminated with
other contaminants. Moreover, the present invention envisions supplying the
contaminated water directly from the source, wherein the feed tank 16 may not
necessarily be used.
[Para 74] With reference now to FIG. 3, in one embodiment, the
vessel 12 is
comprised of a lower shell and an upper shell portion 12b such that the lower
and upper shell portions 12a and 12b can be opened or removed relative to one
another so as to access the contents within the inner chamber 14 of the vessel
12. The vessel 12 may also be constructed as a single unit as opposed to lower
and upper shell portions. The water processing vessel 12 includes, within the
inner chamber 14 a plurality of rotatable trays 22 spaced apart from one
another
and having a baffle 24 disposed between each pair of trays 22. As will be more
fully explained herein, the rotatable trays 22 include a plurality of scoops
26
formed therethrough and the baffles 24 typically comprise plates having a
plurality of apertures 28 formed therethrough. The baffles 24 are fixed to the
vessel 12 so as to be stationary. The baffles 24 may comprise a lower portion
disposed in the lower shell 12a of the vessel and an upper portion attached to
and disposed in the upper shell 12b of the vessel 12 and designed to form a
single baffle when the lower and upper shells 12a and 12b of the vessel 12 are
in
engagement with one another and closed. Alternatively, each baffle 24 may
comprise a single piece that is attached to either the lower shell 12a or the
upper
shell 12b in the earlier embodiment or at multiple points in the single unit
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embodiment. In either embodiment, the baffle 24 will remain generally
stationary as the water and water vapor is passed therethrough.
[Para 75] As shown in FIGS. 2, 10, 11, and 12, a variable frequency
drive 30
may regulate the speed at which electric motor 32 drives a transmission 34 and
a
corresponding shaft 36. The shaft 36 is rotatably coupled to bearings or the
like,
typically non-friction bearings lubricated with synthetic oil, Schmitt
couplers, or
ceramic bearings 38 and 40 at generally opposite ends of the vessel 12. The
shaft 36 extends through the trays 22 and baffles 24 such that only the trays
22
are rotated by the shaft. That is, the trays 22 are coupled to the shaft 36.
Bearings, or a low-friction material, such as a layer or sleeve of Teflon is
disposed between the rotating shaft 36 and the aperture plate baffle 24 to
reduce friction therebetween, yet stabilize and support the spinning shaft 36.
Teflon is not preferred as it could fray and contaminate the fluid.
[Para 76] Alternatively, as shown in FIGS. 2A and 12A, the system 10
may be
controlled by a direct drive motor 32a that is directly coupled to one end of
the
shaft 36. The direct drive motor 32a allows for the use of high speed electric
motors or gas turbine direct drive. By using a direct drive motor 32a one can
avoid the step down in power and force associated with the resistance inherent
in
transmission gearing. For example, in a typical geared drive system a motor at
200 HP and 300 ft-lb could produce rotor parameters of 60 HP and 90 ft-lb
after
gearing. In contrast, a direct drive motor would only need to provide 60 HP
and
90 ft-lb to achieve the same parameters at the rotor - no step down is
experienced because the gearing in the transmission is eliminated.
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[Para 77] Although the inventive system 10 with a geared drive
transmission
may be prepared as fixed installation or a mobile installation, as on a
trailer, the
elimination of the transmission in a direct drive system facilitates the
mobile
aspect of the system 10. A smaller, more compact direct drive system 10 fits
more easily on a trailer that is more easily mobile and transported from site
to
site.
[Para 78] As can be seen from the drawings, the water processing
vessel 12 is
oriented generally horizontally. This is in contrast to the Wallace '026
device
wherein the water processing chamber was oriented generally vertically, and
the
top of the rotating shaft was secured by a bearing and a bearing cap, which
supported the chamber itself. As a result, the rotating shaft sections were
only
solidly anchored to the base of the unit. At high rotational operating speeds,
vibrations within the system cause excessive bearing, shaft and seal failure.
In
contrast, horizontally mounting the water processing vessel 12 to a frame
structure 42 distributes the rotational load along the length of the vessel 12
and
reduces vibrations, such as harmonic vibrations, that could otherwise cause
excessive bearing, shaft and seal failures. Moreover, mounting the vessel 12
to
the frame structure 42 enhances the portability of the system 10, as will be
more
fully described herein. Supporting the very rapidly rotating shaft 36 through
each
baffle 24 further stabilizes the shaft and system and reduces vibrations and
damage caused thereby.
[Para 79] As mentioned above, the shaft 36, and trays 22 are rotated
at a very
high speed, such as Mach 2, although slower speeds such as Mach 1.7 have
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proven effective. This moves the water through the scoops 26 of the trays 22,
which swirls and heats the water such that a water vapor is formed, and the
contaminants, salts, and other dissolved solids are left behind and fall out
of the
water vapor. Most of the intake water is vaporized by 1) vacuum distillation
and
2) cavitation created upon impact with the first rotating tray 22, the
centrifugal
and axial flow compression causes the temperatures and pressures to increase
as
there is a direct correlation between shaft RPM and temperature/pressure
increases or decreases. The water and water vapor is then passed through the
apertures 28 of the baffles 24 before being processed again through the next
rotating tray 22 with scoops 26. The configurations of the trays 22 and
baffles
24 are designed to minimize or eliminate drag and friction in the rotation of
the
shaft 36 by providing sufficient clearance at the perimeter of the trays 22
and
through the central opening 59 of the baffles 24. At the same time leakage
around the perimeter of the trays 22 and through the central opening 59 of the
baffles 24 is to be minimized so as to increase efficiency.
[Para 80] As the water and water vapor passes through each
subchamber of
the vessel 12, the temperature of the water vapor is increased such that
additional water vapor is created and leaves the salts, dissolved solids, and
other
contaminants behind in the remaining water. The centrifugal forces on the
water
and contaminants force it to the wall of the inner chamber 14 and into a set
of
channels 44 which direct the contaminants and non-vaporized water to an outlet
46. The water vapor which is generated passes through a water vapor outlet 48
formed in the vessel 12. Thus, the water vapor and the contaminants and
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remaining water are separated from one another. It is important to note that
the
system 10 produces water vapor - not steam. The water vapor is created
through a combination of decreased pressure and increased temperature. The
system 10 maintains the temperature of the water vapor at temperatures equal
to
or less than that of steam, thus avoiding the latent heat of vaporization and
the
additional energy necessary to convert liquid water to steam. Because of this,
the
energy required to return the water vapor to liquid water is correspondingly
lower.
[Para 81] As mentioned above, the trays 22 are rotated by the shaft
36. The
shaft 36 is supported within the interior of the water processing vessel 12 by
a
plurality of bearings, as mentioned above. The bearings are typically non-
friction bearings lubricated with synthetic oil, steel, or ceramic. Prior art
desalinization systems incorporate standard roller bearings which would fail
under high rotational speeds and high temperatures. Thus, desalinization
systems known in the prior art had high failure rates associated with standard
roller bearings. In the present invention, the lubricated non-friction
bearings,
sealed steel ball bearings, or ceramic bearings 38 and 40 are more durable
than
standard roller bearings and fail less often under high rotational speeds and
temperatures. The bearings 38, 40 may include internal lubrication tubes to
allow for lubricant flow therethrough to minimize wear and tear from
operation.
The bearings 38, 40 also include vibrational sensors (as described below) to
monitor and minimize the amount of vibration occurring during operation.
Moreover, the shaft 36 may be intermittently supported by the low friction
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materials, such as Teflon sleeves or bearings 50 disposed between the baffle
plate 24 and the shaft 36. This further ensures even distribution of weight
and
forces on the shaft 36 and improves the operation and longevity of the system.
[Para 82] With particular reference now to FIGS. 5 and 6, an
exemplary tray 22
is shown, having a plurality of scoops 26 formed therethrough. Although
fourteen scoops 26 are illustrated in FIG. 5, it will be appreciated that the
number may vary and can be several dozen in a single tray 22, thus the dotted
line represents multiple scoops of a variety of numbers.
[Para 83] FIG. 6 is a cross-sectional view of the tray 22 and the
scoop 26
formed therein. In a particularly preferred embodiment, the scoops 26 are
tapered such that a diameter of an inlet 52 thereof is greater than the
diameter
of an outlet 54 thereof. The tapered scoop 26 is essentially a Venturi tube
that
has the vertical opening or inlet 52 substantially perpendicular to the
horizontal
surface of the rotating tray base 22. Liquid and vapor accelerates through the
tapered scoop 26 because the tapered scoop has a larger volume at the entrance
52 thereof and a smaller volume at the exit or outlet 54 thereof. The change
in
volume from the inlet to the outlet of the tapered scoop 26 causes an increase
in
velocity due to the Venturi effect. As a result, the liquid water and water
vapor is
further accelerated and agitated, resulting in increases in temperature and
pressure. This further enables separation of the contaminants from within the
water vapor. The tapered scoop 26 may be attached to the rotating tray 22 by
any means known in the art.
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[Para 84] Once again, it will be appreciated that there will be more
or less
tapered scoops 26 distributed in the entire area of the rotating tray 22, the
particular number and size of the scoops 26 will vary depending upon the
operating conditions of the system 10 of the present invention. Moreover, the
angle of the scoop 26, illustrated as approximately forty-five degrees in FIG.
6,
can be varied from tray to tray 22. That is, by increasing the angle of the
spinning scoop, such as by twenty-five degrees to thirty-one degrees to thirty-
six degrees on the subsequent tray, to forty degrees, forty-five degrees on a
next tray, etc. the increase in angle of the scoop 26 of the spinning tray 22
accommodates increases in pressure of the water vapor which builds up as the
water vapor passes through the vessel 12. The increase in angle can also be
used to further agitate and create water vapor, and increase the pressure of
the
water vapor, which may be used in a steam turbine, as will be more fully
described herein.
[Para 85] With reference now to FIGS. 7 and 9, a baffle 24, in the
form of an
apertured plate, is shown in FIG. 7. In this case, the baffle 24 is formed as
a first
plate member 56 and a second plate member 58 which are connected by
connectors 60 to the inner wall of the vessel 12. The connectors 60 can
comprise bolts, dowels, rods, or any other connecting means which is adequate.
Alternatively, as described above, the baffle 24 can be formed as a single
unit
connected to either the upper or the lower vessel shell 12a and 12b. When
formed as dual plate members 56 and 58, preferably the plate members 56 and
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26
58 inter-engage with one another when the vessel 12 is closed so as to
effectively form a single baffle 24.
[Para 86] As described above, a plurality of apertures 28 are formed
through
the baffle plate 24. FIG. 9 is a cross-sectional view of one such aperture 28.
Similar to the tray described above, the aperture preferably includes an inlet
62
having a diameter which is greater than an outlet 64 thereof, such that the
aperture 28 is tapered which will increase the pressure and velocity of the
water
and water vapor which passes therethrough, further increasing the temperature
and creating additional vapor from the water. Similar to the tray 22 described
above, apertures 28 may be formed in the entire baffle plate, as represented
by
the series of dashed lines. The particular number and size of the apertures 28
may vary depending upon the operating conditions of the system 10.
[Para 87] With reference now to FIG. 8, the shaft 36 is illustrated
extending
through the rotating tray 22. In one embodiment, a cone-shaped water director
66 is positioned in front of the tray 22. For example, the director 66 may
have a
forty-five degree angle to deflect the remaining water and vapor passing
through
the central opening 59 of the baffle 24 from the shaft 36 and towards the
periphery or outer edge of the tray 22 for improved vaporization and higher
percentage recovery of potable water.
[Para 88] Referring again to FIGS. 3 and 4, as mentioned above, in a
particularly preferred embodiment the vessel 12 may be formed into two shells
or sections 12a and 12b. This enables rapid inspection and replacement of
vessel components, as necessary. Preferably, the wall of the inner chamber 14
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and any other components such as the trays 22, baffle plates 24, shaft 36,
etc.
are treated with Melon ite, or other friction reducing and corrosion resistant
substance. Of course, these components can be comprised of materials which
are corrosion resistant and have a low friction coefficient, such as polished
stainless steel or the like. The lower and upper sections 12a and 12b of the
vessel 12 are preferably interconnected such that when closed they are
substantially air and water tight. Moreover, the closed vessel 12 needs to be
able
to withstand high temperatures and pressures due to the water vaporization
therein during operation of the system 10.
[Para 89] With reference now to FIGS. 1, 2 and 10, typically a
transmission 34
interconnects the electric motor 32 and the drive shaft 36. The motor 32 may
be
a combustion engine (gasoline, diesel, natural gas, etc.), electric motor, gas
turbine, or other known means for providing drive. The speed of the
transmission 34 is set by the variable frequency drive 30. The illustrations
in
FIGS. 1, 2 and 10 are only schematic and not representative of the relative
sizes
of the variable frequency drive 30, the motor 32m and the transmission 34. The
variable frequency drive 30 is primarily regulated by a computerized
controller
68, as will be more fully described herein. The shaft 36 may be belt or gear
driven. As described below, the motor 32 may also be directly connected to the
shaft 36. With particular reference to FIG. 10, the shaft 70 of the motor is
connected to an intermediate shaft 72 by a belt 74. The intermediate shaft 72
is
connected to the shaft by another belt 76. The high-speed industrial belt and
pulley system shown in FIG. 10 drives the shaft 36 inside the water processing
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vessel 12. As shown, a plurality of belts 74 and 76 and a set of intermediate
shafts 72 increase the rotational output speed at the shaft 36 by a multiple
of the
rotational input speed applied by the electric motor 32 on the electric motor
driveshaft 70. Of course, the ratio of rotational input speed to rotational
output
speed can be changed by changing the relative rotational velocities of the
belts
74 and 76 and corresponding intermediate shafts 72. By coupling the electric
motor driveshaft 70 to the shaft 36 via belts 74 and 76 and intermediate shaft
72, and adding a Schmitt coupler on the shaft 36 between the transmission 34
and the chamber 12, the present invention is able to avoid the vibrational and
reliability problems that plague other prior art desalinization systems.
[Para 90] With reference again to FIG. 1, as mentioned above, the
water vapor
is directed through a water vapor outlet 48 of the vessel 12. The water vapor
travels through a recovery tube 78 to a vapor recovery container or tank 80.
The
water vapor then condenses and coalesces into liquid water within the vapor
recovery tank 80. To facilitate this, in one embodiment, a plurality of spaced
apart members 82, such as in the form of louvers, are positioned in the flow
pathway of the water vapor such that the water vapor can coalesce and condense
on the louvers and become liquid water. The liquid water is then moved to a
potable water storage tank 84 or a pasteurizing and holding tank 86. If the
water and water vapor in the vessel 12 is heated to the necessary temperature
for
pasteurization, so as to kill harmful microorganisms, zebra mussel larvae, and
other harmful organisms, the liquid water may be held in holding tank 86.
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[Para 91] With reference now to FIGS. 15-27, another preferred
embodiment of
the system 10 and water processing vessel 12 is shown. FIG. 15 illustrates the
overall system 10 including the alternate single piece construction of the
vessel
12. In this embodiment, the vessel 12 has a construction similar to the
previously described embodiment, including elements such as the inner chamber
14, the inlet valve 18, the trays 22 having scoops 26, the baffles 24 having
apertures 28, the brine outlet 46, and the vapor outlet 48. The inlet valve 18
comprises multiple inlets, preferably at least two, to the vessel 12. These
inlets
18 are disposed on the end of the vessel around the shaft 36 so as to more
evenly distribute the fluid across the inner chamber 14. The inlets 18
preferably
enter the vessel 12 in-line with the shaft 36 so as to avoid a steep,
especially a
right angle, of entry into the inner chamber 14 relative to the direction of
movement through the vessel 12. The contaminant outlet 46 is preferably
oversized so as to not restrict the flow of concentrated fluid out of the
system
10. The recirculating feature described below can address any excessive
allowance of liquid that may be permitted to exit the system 10 through the
oversized contaminant outlet 46. A shaft 36 supported by ceramic bearings 38,
40 passes through the center of the trays 22 and baffles 24.
[Para 92] The trays 22 are affixed to the shaft 36 and extend
outward toward
the wall of the inner chamber 14 as described above. The baffles 24 preferably
comprise a single piece extending from the walls of the inner chamber 14
toward
the shaft 36 with a central opening 59 forming a gap between the baffles 24
and
the shaft 36 as described above. The baffles 24 are preferably fixed to the
walls
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of the inner chamber by screws or dowels 60 also as described above. In a
particularly preferred embodiment, the vessel 12 includes six trays 22 and
five
baffles 24 alternatingly dispersed through the inner chamber 14.
[Para 93] In this alternate embodiment, the inner chamber 14
includes an
internal sleeve 45 disposed proximate to the brine outlet 46. The internal
sleeve
45 has an annular shape with a diameter slightly less than the diameter of the
inner chamber 14. The internal sleeve 45 extends from a point downstream of
the last tray 22 to another point immediately downstream of the brine outlet
46.
An annular passageway 47 is created between the internal sleeve 45 and the
outer wall of the inner chamber 14. In a typical construction, the internal
sleeve
45 is about six inches long and the annular passageway 47 is about 1-11/2
inches
wide. This annular passageway or channel 47 captures the brine or contaminate
material that is spun out from the rotating trays 22 to the outer wall of the
chamber 14 as described above. This annular passageway 47 facilitates
movement of the brine or contaminate material to the outlet 46 and minimizes
the chances of contamination of the vapor discharge or buildup of material
within the chamber 14.
[Para 94] FIGURE 16 illustrates a close-up of the trays 22 and
baffles 24. One
can clearly see how the baffles 24 extend from the wall of the vessel 12
through
the chamber 14 and end proximate to the shaft 36. One can also see how the
trays 22 are affixed to the shaft 36 and have scoops 26 disposed therethrough
as
described. A cone 66 is preferably disposed on each tray 22 so as to deflect
any
fluid flowing along the shaft as described above (FIG. 8). FIG. 17 illustrates
an
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external view of the vessel 12 indicating the inlets 18, the outlets 46, 48
and the
shaft 36. Ordinarily, the ends of the vessel 12 would be enclosed and sealed
against leaks. They are depicted open here for clarification and ease of
illustration. FIG. 18 illustrates a cross-section of the vessel 12 shown in
FIG. 17,
further illustrating the internal components, including the trays 22, baffles
24,
internal sleeve 45 and annular passageway 47. FIG. 19 illustrates the shaft 36
with trays 22 and baffles 24 apart from the vessel 12. FIGS. 30, 31, and 32
illustrate an alternate embodiment of the trays 22 and baffles 24 along the
shaft
36. In this alternate embodiment, the trays 22 and baffles 24 are of an
increased
diameter with an increased number of rows - preferably 3 to 4 rows - and a
corresponding increase in the number of scoops and apertures therein. These
increases allow for a larger volume of fluid to be processed per unit of time.
Of
course, the vessel 12 will have a corresponding increase in its diameter to
accommodate the larger trays 22 and baffles 24. This increased diameter
creates
a situation where the outermost edges of the rotating trays 22 have a
significantly greater rotational velocity compared to the trays 22 of smaller
diameter.
[Para 95] FIGURES 20 and 21 illustrate the tray 22 and baffle 24,
respectively.
FIGS. 22, 23 and 26 illustrate various views and cross-sections of the tray 22
in
FIG. 20. FIGS. 24 and 27 similarly illustrate various views and cross-sections
of
the baffle 24 in FIG. 21. As discussed, the tray 22 includes scoops 26 which
pass
through the body of the tray 22. The scoops 26 include a scoop inlet 52 and a
scoop outlet 54 configured as described above. The scoop inlet 52 is
preferably
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32
oriented such that the opening faces into the direction of rotation about the
shaft. This maximizes the amount of fluid that enters the scoop inlet 52 and
passes through the plurality of scoops. The angle of the scoops 26 on
successive trays 22 may be adjusted as described above. The baffle 24 also
includes a plurality of apertures 28 configured and profiled (FIG. 9) as
described
above. FIG. 25 illustrates the shaft 36 and a pairing of a tray 22 with a
baffle 24.
The arrows indicate the direction of rotation of the shaft and accordingly the
tray
22 in this particular figure. The scoops 26 with the scoop inlet 52 are
illustrated
as facing in the direction of the rotation, i.e., out of the page, in the top
half of
the figure. In the bottom half of the figure, the scoop 26 with scoop inlet 52
is
also illustrated as being oriented in the direction of rotation, i.e., into
the page,
as the tray 22 rotates with the shaft 36. The direction of rotation may be
either
clockwise or counter-clockwise. The direction of rotation can be changed
without departing from the spirit and scope of the invention. As described in
the
previous embodiment, the scoop inlet 52 has a larger diameter than the scoop
outlet 54 so as to increase the flow rate and decrease the fluid pressure.
[Para 96] In a particularly preferred embodiment, when the main goal
of the
system 10 is to remove contaminants from the contaminated water, such as salt
water, so as to have potable water, the temperature of the water vapor is
heated
to between one hundred degrees Fahrenheit and less than two hundred twelve
degrees Fahrenheit. Even more preferably, the water vapor is heated to between
one hundred forty degrees Fahrenheit and one hundred seventy degrees
Fahrenheit for pasteurization purposes. However, the water vapor temperature
is
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kept to a minimum and almost always less than two hundred twelve degrees
Fahrenheit such that the water does not boil and become steam, which is more
difficult to condense and coalesce from water vapor to liquid water. Increased
RPMs result in increased temperatures and pressures. The RPMs can be adjusted
to achieve the desired temperatures.
[Para 97] The water is boiled and the water vapor temperature is
brought to
above two hundred twelve degrees Fahrenheit preferably only in instances where
steam generation is desirable for heating, electricity generating, and other
purposes as will be more fully described herein. This enables the present
invention to both pasteurize the water vapor and condense and coalesce the
water vapor into liquid water without complex refrigeration or condensing
systems, which often require additional electricity and energy.
[Para 98] In one embodiment, the contaminated water, referred to as
brine in
desalinization processes, is collected at outlet 46 and moved to a brine
disposal
tank 88. As shown in FIG. 1, polymers or other chemistry 90 may be added to
the brine to recover trace elements, etc. Moreover, the salt from the brine
may
be processed and used for various purposes, including generating table salt,
agricultural brine and/or fertilizer.
[Para 99] In one embodiment of the present invention, the treated contaminated
water is reprocessed by recycling the contaminants and remaining water through
the system again. This may be done multiple times such that the amount of
potable water extracted from the contaminated water increases, up to as much
as
ninety-nine percent. This may be done by directing the contaminants and waste
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water from the outlet 46 to a first brine, or contaminant, reprocessing tank
92.
The remaining waste water, in the form of brine or other contaminants, is then
reintroduced through inlet 18 of the vessel 12 and reprocessed and
recirculated
through the vessel 12, as described above. Additional potable water will be
extracted in the form of water vapor for condensing and collection in the
vapor
recovery tank 80. The remaining contaminants and wastewater are then directed
to a second brine or contaminant reprocessing tank 94. The concentration of
contaminants or brine will be much higher in the reprocessing tank 92. Once a
sufficient level of wastewater or brine has been accumulated in the
reprocessing
tank 92, this contaminated water is then passed through the inlet 18 and
circulated and processed through the system 10, as described above. Extracted
potable water vapor is removed at outlet 48 and turned into liquid water in
the
vapor recovery tank 80, as described above. The resulting contaminants and
wastewater can then be placed into yet another reprocessing tank, or into the
brine disposal tank 88. It is anticipated that an initial pass-through of
seawater
will yield, for example, eighty percent to ninety percent potable water. The
first
reprocessing will yield an additional amount of potable water, such that the
total
extracted potable water is between ninety percent and ninety-five percent.
Passing the brine and remaining water through the system again can yield up to
ninety-nine percent recovery of potable water, by recycling the brine at
little to
no increase in unit cost. Moreover, this reduces the volume of the brine or
contaminants, which can facilitate trace element recovery and/or reduce the
disposal costs thereof.
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[Para 100] With reference now to FIG. 11, in a particularly preferred
embodiment, a computer system is integrated into the system 10 of the present
invention which regulates the variable frequency drive 30 based on
measurements taken from a plurality of sensors that continually read
temperature, pressure, flow rate, rotational rates of components and remaining
capacity of a variety of tanks connected to the water processing vessel 12.
Typically, these readings are taken in real-time.
[Para 1011 For example, temperature and/or pressure sensors 96 may be
employed to measure the temperature of the water or water vapor within or
exiting the vessel 12, as well as the pressure thereof as needed. In response
to
these sensor readings, the control box 68 will cause the variable frequency
drive
30 to maintain the rotational speed of shaft 36, decrease the rotational speed
of
the shaft 36, or increase the rotational speed of the shaft 36 to either
maintain
the temperature and pressure, reduce the temperature and pressure, or increase
the pressure and temperature, respectively, of the water and water vapor. This
may be done, for example, to ensure that the water vapor temperature is at the
necessary pasteurization temperature so as to kill all harmful microorganisms
and other organisms therein. Alternatively, or in addition to, a sensor may be
used to detect the rotational speed (RPMS) of the shaft 36 and/or trays 22 to
ensure that the system is operating correctly and that the system is
generating
the necessary water vapor at a desired temperature and/or pressure. The
computerized controller may also adjust the amount of water input through
inlet
18 (GPMS) so that the proper amount of water is input as to the amount of
water
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36
vapor and wastewater which is removed so that the system 10 operates
efficiently. The control box 68 may adjust the flow rate of water into the
vessel
12, or even adjust the water input.
[Para 102] FIGURE 28 illustrates schematically a computer display 112 or
similar
configuration. This computer display schematically illustrates the vessel 12
with
the various inlets and outlets 18, 46, 48, as well as the shaft 36 and the
plurality
of trays 22. The shaft 36 has multiple vibration and temperature sensors 114
disposed along its length. The bearings 38, 40 also include vibration and
temperature sensors 114. The vibration and temperature sensors 114 are
configured to detect horizontal and vertical vibrations at each point, as well
as,
the temperature of the shaft 36 generated by the friction of rotation. The
bearings 38, 40 include oil supply 116a and return 116b lines to provide
lubrication thereof. The inlets 18 and brine outlet 46 include flow meters 118
to
detect the corresponding flow rates. Temperature and pressure sensors 96 are
disposed throughout the vessel 12. The temperature and pressure sensors 96
are also disposed throughout the vessel 12 to take measurements at various
predetermined points.
[Para 103] As indicated above, the contaminated water may come from a feed
tank 16, or can be from any other number of tanks, including reprocessing
tanks
92 and 94. It is also contemplated that the collected water storage tank could
be
fluidly coupled to the inlet 18 so as to ensure that the water is purified to
a
certain level or for other purposes, such as when generating steam which
requires a higher purity of water than the contaminated water may provide. As
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such, one or more sensors 98 may track the data within the tanks to determine
water or wastewater/brine levels, concentrations, or flow rates into the tanks
or
out of the tanks. The controller 68 may be used to switch the input and output
of the tanks, such as when the brine is being reprocessed from a first brine
reprocessing tank 92 to the second brine reprocessing tank 94, and eventually
to
the brine disposal tank 88, as described above. Thus, when the first brine
reprocessing tank reaches a predetermined level, fluid flow from the feed tank
16
is shut off, and instead fluid is provided from the first brine reprocessing
tank 92
into the vessel 12. The treated contaminants and remaining wastewater are then
directed into the second brine reprocessing tank 94, until it reaches a
predetermined level. Then the water is directed from the second brine
reprocessing tank 94 through the system and water processing vessel 12 to, for
example, the brine disposal tank 88. Brine water in the first reprocessing
tank
92 may be approximately twenty percent of the contaminated water, including
most of the total dissolved solids. The residual brine which is finally
directed to
the brine disposal tank 88 may only comprise one percent of the contaminated
water initially introduced into the decontamination system 10 via the feed
tank
16. Thus, the temperature and pressure sensors, RPM and flow meters can be
used to control the desired water output including water vapor temperature
controls that result in pasteurized water.
[Para 104] The controller 68 can be used to direct the variable frequency
drive
30 to power the motor 32 such that the shaft 36 is rotated at a sufficiently
high
velocity that the rotation of the trays boils the input water and creates
steam of a
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desired temperature and pressure, as illustrated in FIG. 12. FIG. 12
illustrates a
steam turbine 100 integrated into the system 10. The steam turbine 100 may
also be used with the vessel depicted in FIGS. 15-27. Water vapor in the form
of
steam could be generated in the water processing vessel 12 to drive a high
pressure, low temperature steam turbine by feeding the vapor outlet 48 into an
inlet on the turbine 100. The turbine 100 is in turn coupled to an electric
generator 102, for cost- effective and economical generation of electricity.
As
shown in FIG. 12A, the steam turbine 100 may be eliminated with the shaft 36
of
the vessel 12 extended to turn the generator 102 directly or indirectly. In
this
case, the later stages of the trays and baffles inside the vessel 12 act as a
steam
turbine due to the presence of the water vapor which aids the rotation of the
shaft.
[Para 105] In the case of a steam turbine, the water vapor can be heated to in
excess of six hundred degrees Fahrenheit and pressurized in excess of sixteen
hundred pounds per square inch (psi), which is adequate to drive the steam
turbine 100. Aside from the increased velocity of the trays, the incorporation
of
the tapered nature of the scoops 26 of the trays 22, and the tapered nature of
the apertures 28 of the aperture plate baffles 24 also facilitate the
generation of
water vapor and steam. Increasing the angles of the scoops 26, such as from
twenty-five degrees at a first tray to forty-five degrees at a last tray, also
increases water vapor generation in the form of steam and increases the
pressure
thereof so as to be able to drive the steam turbine 100. FIGS. 13 and 14
illustrate an embodiment wherein a steam outlet 104 is formed at an end of the
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vessel 12 and the steam turbine 100 is directly connected thereto such that
the
pressurized steam passes through the turbine 100 so as to rotate the blades
106
and shaft 108 thereof so as to generate electricity via the electric generator
coupled thereto. A water vapor outlet 110 conveys the water vapor to a vapor
recovery container 80 or the like. The recovery tank 80 may need to include
additional piping, condensers, refrigeration, etc. so as to cool the steam or
high
temperature water vapor so as to condense it into liquid water.
[Para 106] Of course, it will be appreciated by those skilled in the art that
the
steam generated by the system 10 can be used for other purposes, such as
heating purposes, removal of oil from oil wells and tar and shale pits and the
like, etc.
[Para 107] It will also be appreciated that the present invention, by means of
the
sensors and controller 68 can generate water vapor of a lower temperature
and/or pressure for potable water production, which water vapor is directed
through outlet 48 directly into a vapor recovery container, and the system
sped
up to create high temperature water vapor or steam for passage through the
steam turbine 100 to generate electricity as needed. For example, during the
nighttime hours, the system 10 may be used to generate potable water when very
little electricity is needed. However, during the daylight hours, the system
10
can be adjusted to generate steam and electricity.
[Para 108] As described above, many of the components of the present
invention, including the variable frequency drive 30, electric motor 32,
transmission 34, and water processing vessel 12 and the components therein can
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be attached to a framework 42 which is portable. The entire system 10 of the
present invention can be designed to fit into a forty foot long ISO container.
This
container can be insulated with a refrigeration (HVAC) unit for controlled
operating environment and shipping and storage. The various tanks, including
the feed tank, vapor recovery tank, portable water storage tank, and
contaminant/brine reprocessing or disposal tanks can either be fit into the
transportable container, or transported separately and connected to the inlet
and
outlet ports as needed. Thus, the entire system 10 of the present invention
can
be easily transported in an ISO container, or the like, via ship, semi-tractor
trailer, or the like. Thus, the system 10 of the present invention can be
taken to
where needed to address natural disasters, military operations, etc., even at
remote locations. Such an arrangement results in a high level of mobility and
rapid deployment and startup of the system 10 of the present invention.
[Para 1091 FIGURE 29 schematically illustrates the processes occurring at
various points, i.e., sub-chambers, throughout the vessel 12. The inner
chamber
14 of the vessel 12 is effectively divided into a series of sub-chambers as
illustrated. The vessel 12 contains five sub-chambers that perform the
functions
of an axial flow pump, an axial flow compressor, a centrifugal flow
compressor,
an unlighted gas turbine and/or a hydraulic/water turbine. In operation, the
system 10 has the capability to vaporize the water through a mechanical
process,
thereby enabling efficient and effective desalination, decontamination and
vaporization of a variety of impaired fluids. Before entering the vessel 12,
the
fluid may be subject to a pretreatment step 120 wherein the fluid is passed
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through filters and various other processes to separate contaminants that are
more easily removed or that may damage or degrade the integrity of the system
10. Upon passing through the inlets 18, the fluid enters an intake chamber 122
which has an effect on the fluid similar to an axial flow pump once the system
10
reaches its operating rotation speed. An external initiating pump (not shown)
may be shut off such that the system 10 draws the contaminated water through
the inlet, i.e., the intake chamber functions as an axial flow pump, without
the
continued operation of the initiating pump. A significant reduction in intake
chamber pressure causes vacuum distillation or vaporization to occur at
temperatures below 212 F. Following the intake chamber 122, the fluid
encounters the first tray 22 where it enters the first processing chamber 124.
This first processing chamber acts as both a centrifugal flow compressor and
as
an axial flow compressor through the combined action of the rotating tray 22
and the adjacent baffle 24. A high percentage of the intake water is vaporized
through cavitation upon impact with the high speed rotating tray 22 in the
first
processing chamber 124. A centrifugal flow compression process occurs within
the first processing chamber 124 and each subsequent processing chamber. The
centrifugal flow compression process casts the non-vaporized dissolved solids
and at least some of the liquid water to the outer wall of the processing
chamber
124. This action separates the dissolved solids and most of the remaining
liquid
from the vapor. An axial flow compression process also occurs within the first
processing chamber 124 and each subsequent chamber. This axial flow
compression process compresses the vapor and liquid which also increases the
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pressure and temperature within the processing chamber. The second
processing chamber 126 and the third processing chamber 128 both function
similarly by compounding the action of the centrifugal flow compressor and
axial
flow compressor features of the first processing chamber 124.
[Para 110] By the time the fluid reaches the fourth processing chamber 130 it
has been subjected to centrifugal flow and axial flow compression processes
such that the nature of the fluid and its flow through the vessel 12 has
changed.
In the fourth processing chamber the fluid behaves as if it is passing through
an
unlighted gas turbine or an hydraulic/water turbine by causing rotation of the
shaft 36. The fifth processing chamber 132 compounds this unlighted gas
turbine or hydraulic/water turbine process. The turbine processes of the
fourth
and fifth processing chambers 130, 132 supply a measure of force to drive
rotation of the shaft 36 such that power on the motor 32 may be throttled back
without a loss of functionality in the system 10. After exiting the fifth
processing
chamber 132 the fluid has been separated to a high degree such that nearly all
of
the contaminants in the form of brine pass through the annular passageway 47
to the outlet 46 and the purified vapor passes through the central portion of
the
inner chamber 14 to the vapor outlet 48. The turbine operations of the fourth
and fifth processing chambers 130, 132 allow for continued operation of the
system 10 with a reduced energy input (by as much as 25%) as compared to a
startup phase once an equilibrium in the operation is reached.
[Para 1111 After the fifth processing chamber 132, the system includes a
discharge chamber. The discharge chamber 134, which is larger than any of the
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preceding processing chambers, contains the two discharge outlets 46, 48. The
large increase in volume results in a dramatic reduction in pressure and a
physical separation of the dissolved solids and the remaining water from the
vapor.
[Para 112] The dimensions of the vessel 12 are preferably configured such that
the combined processing chambers, 124-132 occupy about one-half of the total
length. The discharge chamber 134 occupies about one-third of the total
length.
The remainder of the length of the vessel, about one-sixth of the total
length, is
occupied by the intake chamber 122. The processing chambers 1 24-1 32 are
divided into approximately three-fifths compressor functionality and two-
fifths
turbine functionality. Once the fluid exits the last processing chamber 132,
it
has achieved about eighty percent vaporization as it enters the discharge
chamber 134 and is directed to the respective outlets 46, 48.
[Para 11 3] FIGS. 33 and 34 illustrate an embodiment of the system 10 that
includes a system to capture water from a body of water 150. In this
embodiment, the body of water 150 is preferably a sea or ocean containing salt
water, but could be any body of water. The capture system 152 includes a
capture vessel 1 54 that is disposed in the body of water 150 such that an
open
top or sides 156 of the vessel 154 are at least partially above a median water
level for the body of water 150. The system 10 may function with an open top
156 on the vessel 154 as shown in FIG. 33, but the vessel preferably has open
sides 156 facing the seaward and landward sides of the vessel 154 to take
advantage of both the incoming and receding waves/tide. For this system to
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work, the water level of the body of water 150 must vary sufficiently to allow
a
portion of the body of water to enter the open sides 156 but not completely
submerge the vessel 154. Ideally, this would occur with the rise and fall of a
tide
in a sea or ocean, as well as, waves that may occur in such a body of water.
The
distance that the open sides 156 of the vessel 154 extend above the median
water level depends upon the variability in the water level for a particular
body of
water 150. The open sides 156 are preferably covered by a filter screen 158 to
reduce the occurrence of living organisms and other large objects in the body
of
water 150 from entering the vessel 154. The open sides 156 preferably also
include pivoting louvers 157 disposed over the screens 158 that can be opened
or closed so as to control the amount of water and/or sand entering the vessel
154.
[Para 114] Inside the vessel 154 is a capture funnel 160 or similar structure
configured to direct most of the water that enters the vessel 154 into a feed
pipe
162. The capture funnel 160 is preferably positioned below the median water
level for the body of water. Although the vessel 154 and capture funnel 160
are
illustrated as generally square shaped, they may be configured in other forms.
It
has been found that the square shape, with a corner thereof oriented into the
a
wave or tide that is preferably present in the body of water 150 facilitates
the rise
of the wave or tide over the vessel 154 such that water enters the open sides
156. The vessel 154 may also be configured whereby the open sides 156 angled
other than vertical on a side that faces the incoming waves or tides so as to
facilitate entry of water thought the open side 156. The open sides 156 are
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preferably disposed with most of their surface area above the median water
level
so that there is less likelihood of sand or other sediment being in the higher
portion of the wave or tide when it reaches the open side 156.
[Para 115] The feed pipe 162 preferably passes to the shore and into a storage
vessel 1 64. The system 10 may include multiple storage vessels 1 64 to
accommodate and store a sufficient quantity of captured seawater. The feed
pipe 162 may be underground as it passes to shore, but realizing that any
changes in elevation to an above ground facility would require appropriate
piping
and pumps. The storage vessel 1 64 may be located near the body of water 150
or located some distance from the body of water 150 depending upon the need
of the user. Once a sufficient quantity of water is stored in the vessel 164,
a
pump 166 attached to an outlet 168 on the vessel 164 directs the stored water
through an inlet pipe 170 to the inlet 18 on the processing system 10. The
inlet
pipe 170 preferably includes a filtration system 172 to remove and large
sediment or particles that may have made it through the storage vessel 164 and
pump 166. The system 10 can then be used to desalinate the water as described
elsewhere.
[Para 1 1 6] FIGURE 35 illustrates another embodiment of the inventive system
10, wherein the system 10 is used to generate electricity from the water vapor
produced from the vapor outlet 48 as described elsewhere. In this embodiment,
the system 10 further includes a condenser 174 disposed a first distance 1 76
above the vessel 12. A vapor pipe 178 directs the water vapor from the vapor
outlet 48 to the condenser 174. Since the water vapor is lighter than air and
rises
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under its own power, no mechanical means are necessary to raise the water
vapor through the first distance 176 to the condenser 174. Preferably, the
vapor
pipe 178 has a generally vertical section 178a that extends at least the first
distance 176, if not slightly more than the first distance 176. A generally
horizontal section 178b of the vapor pipe 178 extends from the end of this
vertical section 178a to an inlet 180 on the condenser 174. This generally
horizontal section 178b may have a slight decline from the end of the vertical
section 178a to the inlet 180 on the condenser 174. This allows for the
possibility that any incidental condensing that occurs in the vapor pipe 178
runs
down the slope of the generally horizontal section 178b into the condenser
174.
The vapor pipe 178 and all sections thereof is preferably insulated to prevent
the
premature loss of heat and minimize the occurrence of condensation during the
rise to the condenser.
[Para 117] Although FIG. 35A illustrate the condenser 174 in a particular
generally diamond-shape, the condenser 174 may be constructed in other
shapes as known by those skilled in the art of processing vapor or steam. The
purpose of the condenser is to fully condense vapor that is produced by the
system 10. The preferably includes sufficient structures inside as are known
to
those skilled in the art to facilitate condensation of the vapor. As the vapor
condenses, it flows through an outlet 182 on the condenser 174 and into a
condensate holding tank 184.
[Para 118] The holding tank 184 is preferably disposed a second distance 186
above a hydro-electric generator 188. Once a sufficient quantity of condensed
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processed fluid is stored in the holding tank 184, the condensed processed
fluid
is released from an outlet 190 on the holding tank 184. The condensed
processed fluid falls under the force of gravity across the second distance
186
into the hydro-electric generator 188. The hydro-electric generator 188
converts
the kinetic energy of the falling condensed processed fluid into electrical
energy
for storage or immediate use. The electrical energy may be stored in a
rechargeable chemical battery, a capacitor, or similar known means of
electrical
storage 192. The condensed processes fluid that falls into the hydroelectric
generator 188 is released through a generator outlet 189 to be used for
subsequent processing (not shown), as would typically be done with such
treated
water.
[Para 119] Although the first distance 176 and the second distance 186 are
depicted in FIG. 35 as apparently "stacking" one on top of the other, that is
not a
requirement of these distances. The only requirement on either of these
distances is that the second distance 186 be sufficiently above the hydro-
electric
generator 188 so as to allow for the efficient conversion of kinetic energy of
the
falling processed fluid into electrical energy. Preferably, this second
distance 186
is at least ten feet, but may be twenty feet or more, depending upon the
quantity
of condensed processed fluid and the capabilities of the hydro-electric
generator. The first distance 176 needs to be of sufficient distance to place
the
condenser 174 and holding tank 184 above the second distance 186.
Necessarily, the first distance 176 depends upon the sizes of the condenser
174,
the holding tank 184, and the second distance 186.
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[Para 120] FIG. 36 illustrates another embodiment of the inventive system 10,
wherein the brine outlet 46 and vapor outlet 48 are both used for further
processing. Specifically, a brine reprocessing tank 194 receives the brine
from
the brine outlet 46 through a reprocessing inlet 196. The brine reprocessing
tank
194 also includes a reprocessing outlet 198 and a recirculating outlet 200. A
first
portion of the brine in the brine reprocessing tank 194 is passed to the
recirculating outlet 200 where it is directed by a recirculating pipe 202 back
to
the inlet 18 of the system 10 for re-processing. In this way, the brine is
reprocessed to recover additional water vapor from the processing fluid.
[Para 121] A second portion of the brine in the brine reprocessing tank 194 is
passed to the reprocessing outlet 198 for storage in a brine holding tank 204.
This reprocessing outlet 198 may include a valve 206 for restricting or
completely closing off the flow of the second portion of the brine to the
brine
holding tank 204. The brine holding tank 204 is connected to a brine drying
system 208 which includes a heat exchanger 210 with circulating heat pipes
212.
The circulating heat pipes 212 pass back and forth as is typical of heat
exchangers 210. Being part of the inventive system 10, the heat exchanger 210
receives its heat source from the water vapor from the vapor outlet 48.
Specifically, a vapor diverting pipe 214 extracts a portion of the water vapor
from
vapor out 48 and communicates to the circulating heat pipes 212 of the heat
exchanger 210. The stored brine from the brine holding tank 204 passes over
the heat exchanger 210 and any residual water is dried from the heat of the
water vapor.
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[Para 1221 The dried brine is then transported to a dried brine holding tank
216
for subsequent use or processing. Such dried brine could be used to produce
salt or other compounds found in salt water. In addition, any useful
contaminants, i.e., metals, elements, or other valuable compounds, found in
the
water processed in the inventive system 10 may be recovered from the dried
brine for resale or other subsequent processing.
[Para 123] As shown in FIGS. 37 and 38, the system 10 may be controlled by a
control system 218 that measures various operating parameters of the system
10. The control system 218 includes a graphical display 220 that is touch
screen
sensitive. The graphical display 220 can be used to adjust the power, torque,
and
rpms of the motor and shaft, as well as, the flow rate of fluid entering the
system
10. This graphical display 220 is similar to the graphical display depicted in
FIG.
28. The graphical display 220 includes a schematic graphical depiction of the
system 10 corresponding to various components thereof. The control system 218
and graphical display 220 described herein is an updated from the version of
FIG.
28. The graphical display 220 includes indicator lights 238 around its border
that
indicate power, CPU activity, and operating modes, corresponding to the fluid
being processed in the system 10, i.e., (1) brackish water, (2) sea water, (3)
produced water, and (4) pasteurizing water.
[Para 124] The updated graphical display provides measurement data captured
by a plurality of operating sensors 222 connected to the system 10, as well
as, an
internal clock to measure operating time and determine a rate for any of the
data
measured by the operating sensors 222.
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[Para 125] The operating sensors 222 include temperature and pressure
sensors 224 associated with each of a plurality of processing stages 226
within
the system 10. The processing stages may include an inlet stage 226a, an
outlet
stage 226b, and tray/baffle stages 226c associated with each operating pair of
a
tray 22 followed by a baffle 24. The operating sensors 222 also include
rotational
sensors 228 associated with the shaft 36 and the motor 32, 32a. The rotational
sensors 228 are configured to measure revolutions per minute, torque,
horsepower, runtime, and total revolutions. The operating sensors 222 may also
include bearing sensors 230 associated with the bearings 38, 40 on either end
of
the shaft 36. The bearing sensors 230 are configured to measure temperature
and flow rate of a lubricant passing through the bearings 38, 40, as well as,
vibration of the shaft 36. The operating sensors 222 may also include flow
sensors 232 associated with the fluid inlet 18 and contaminant outlet 46. The
flow sensors 232 are configured to measure an opened or closed state of a
valve
on the fluid inlet 18, flow rate in the fluid inlet 18 and concentrate outlet
46, and
total fluid flow in the fluid inlet 18 and concentrate outlet 46.
[Para 126] The graphical display 220 has several display modes. The main
screen is shown in FIG. 38 and displays the values measured by the operational
sensors 222 in the schematic illustration of the system 10. A graphs screen,
shown in FIG. 39 displays the values measured by the temperature and pressure
sensors 224 in a bar graph format 234 configured to represent the orientation
of
the plurality of operational stages 226. The graphs screen also displays
numerical measurement values for the rotational sensors 228, the bearing
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sensors 230, and the flow sensors 232. A trends screen, shown in FIG. 40,
displays a line graph 236 of the values measured by the temperature and
pressure sensors 224 against time. On this line graph, each operational stage
226 associated with one of the temperature and pressure sensors 224 is
depicted as a separate line. The line graphs may show present operational
conditions or may be reviewed to show historical operational temperature and
pressure data. The trends screen may also display data measured by the other
sensors, including at least revolutions per minute of the rotor from the
rotational
sensors 228. The display screen 220 also has functionality to capture an image
of the graphical display, as well as, to regulate whether data logging is on
or off.
[Para 127] FIGS. 41 and 42 illustrate schematic flowcharts of alternative
systems
for purifying a contaminated or impaired water supply. Specifically, FIG. 41
depicts an embodiment of a system 250 for recovering desalinated water from an
impaired water source. FIG. 42 depicts an embodiment of a system 264 for
generating steam from an impaired water source.
[Para 128] In the desalination system 250, impaired water source may be
introduced from an impaired water pipeline or tank 252. A tank is preferred
insofar as a tank is likely to contain a more consistent supply of water to
maintain the system 250 in a continuous operational state for a longer period
of
time. A pipeline is more likely to suffer from interruptions in supply.
[Para 129] The outflow from the impaired water tank 252 is preferably directed
into a macro filtration or strainer device 254 intended to remove large
undissolved particles from the impaired water flow that may damage of clog
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downstream equipment, particularly a vaporization-desalination unit 10. A
particularly preferred embodiment of the filtration-strainer device 254
preferably
includes two or more stacked screens having apertures of various and/or
adjustable sizes. The filtration-strainer device 254 may include multiple sets
of
stacked screens so that the water flow may be diverted from one to another
when
cleaning is required. The outflow from the filtration or strainer device 254
is
then directed into a feed tank 256 for the filtered impaired water, which is
intended to provide a more consistent supply of water to maintain the system
250 in a continuous operational state. The outflow from the feed tank 256 is
then directed into a vaporization-desalination unit 10 as described above.
[Para 130] The vaporization-desalination unit 10 is constructed and operates
as
described above to separate the impaired water flow into a contaminant flow
and
clean water vapor flow. The contaminant flow is directed to a brine tank 258
for
later disposal. As described above, the unit 10 operates, in part, by heating
the
impaired water flow to convert part of the impaired water flow into the clean
water vapor. The clean water vapor flow is directed to a vapor recovery
pipeline
260, which in turn leads through a heat exchanger 256a on the impaired water
feed tank 256. Because the impaired water contained in the feed tank 256 is at
or below ambient temperature, the clean water vapor flow passing through the
heat exchanger 256a condenses into liquid water. This condensed liquid water
is
directed into a desalinated water recovery tank 262. Having been desalinated,
the condensed liquid water can be utilized for any purpose.
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[Para 131] The steam generation system 264 starts with similar components as
the desalination system 250. An impaired water source may be introduced from
an impaired water pipeline or tank 252, with the preferred source being a tank
so
as to provide a more consistent supply of water to maintain the system 264 in
a
continuous operational state for a longer period of time. The outflow from the
impaired water tank 252 is preferably directed into a macro filtration or
strainer
device 254 intended to remove large undissolved particles from the impaired
water flow.
[Para 132] The outflow from the filtration or strainer device 254 is then
directed
into a feed tank 256 for the filtered impaired water, which is intended to
provide
a more consistent supply of water to maintain the system 264 in a continuous
operational state. The outflow from the feed tank 256 is then directed into a
vaporization-desalination unit 10 as described above, which is constructed and
operates as described above to separate the impaired water flow into a
contaminant flow and clean water vapor flow. The contaminant flow is directed
to a brine tank 258 for later disposal.
[Para 133] It is at this point that the steam generating system 264 differs
from
the desalination system 250. The clean water vapor flow from the unit 10 is
preferably directed to a steam generator 266, which converts the clean water
vapor flow into a steam flow. The steam flow is then introduced to a steam
turbine 268 for generating electricity. Alternatively, the system 264 may omit
the steam generator 266, such that the turbine 268 is driven by the clean
water
vapor flow direct from unit 10. Having driven the steam turbine 268, the flow
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exiting the steam turbine 268 is cooled and condensed such that the outflow
can
be directed back into the system, as into the impaired water feed tank 256 so
as
to continue the vaporization and steam generating steps. The electricity
generated from the steam turbine may be stored in batteries, added directly to
an electrical grid, or otherwise utilized to provide power to equipment.
[Para 134] FIG. 43 schematically illustrates a system 270 for generating steam
and recycling produced water from an oilfield steam process. A prior art
oilfield
steam process uses a steam generator to convert an external supply of water,
e.g., municipal water supply, into steam for injection into an oil zone to
stimulate
and increase oil production. Generation of steam from an external water supply
comes with high costs, both in the cost of the water and the cost of heating
the
water. After the steam is injected into the oil zone, the oil released thereby
is
drawn out of the oil zone in a combined oil-water flow, which after processing
produces crude oil for commercialization and a contaminated water flow. This
contaminated water flow is not useable for any purpose and can only be
disposed
of. Due to its bulk and weight, transportation and disposal and this
contaminated water flow is expensive and takes a lot of space.
[Para 135] The inventive system 270 provides for purification of this
contaminated water flow and recycling of the same into steam for use in the
oilfield steam process. As the oilfield steam process system 270 is a
recycling
loop, the following discussion will start with the steam generator 266. When
the
system 270 is first started up, the steam generator 266 is primed with an
external supply of water 272. This external supply of water 272 can be
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municipal water or any other available source of water, often available at
significant cost. Depending on the temperature of the water supply 272 it may
need to be pre-heated and possibly converted into vapor - also are significant
cost - prior to introduction to the steam generator 266.
[Para 136] The output from the steam generator 266 is injected into an oil
zone
274. Such injection occurs through an injector 276a associated with a
traditional
oil wellhead 276b. Once injected, the steam combines with the crude oil in the
oil zone 274 to form a combined crude oil-water flow. This combined crude oil-
water flow stimulates production and facilitates removal of the crude oil from
the
oil zone 274, increasing the rate of oil production. The oil wellhead 276b
utilizes
traditional wellhead equipment to remove the combined crude oil-water flow
from the subsurface oil zone 274 where it is sent to a gas separator 278. The
gas separator 278 removes any gas bubbles entrained in the combined crude oil-
water flow.
[Para 137] The degassed combined crude oil-water flow output from the gas
separator 278 is introduced into an oil-water separation tank 280. The oil-
water
separation tank 280 produces a first output that is a crude oil flow directed
to a
crude oil storage tank 282, where it is subsequently processed and/or
transported for later commercial distribution. The oil-water separation tank
280
also produces a second output that is a contaminated water flow directed to a
contaminated water storage tank 252.
[Para 138] As in earlier systems, the produced water from this contaminated
water storage tank 252 is preferably passed through a macro filtration-
strainer
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254 to remove large, undissolved particles from the produced water. Ideally,
the
filtration-strainer 254 preferably operates at a flow rate of between 660
gallons
per minute and 1 760 gallons per minute. Such minimal filtration lowers the
overall cost of operating the system by eliminating most of the macro
particles
from the produced water flow prior to the purification-desalination, as well
as,
increasing the efficiency of such purification-desalination. The output from
the
filter-strainer 254 is then introduced into the vaporizer-desalination unit
10.
[Para 139] As described above, the vaporizer-desalination unit 10 produces a
contaminant or brine output 46 and a clean water vapor output 48. This clean
water vapor output 48 is essentially desalinated, with nearly all of the
contaminants being in the separated contaminant-brine output 46. The
contaminant-brine output 46 is directed to an oilfield disposal well 284 for
storage. Because the contaminant-brine output 46 has been separated from the
remainder of the contaminated water flow, it has a greatly reduced weight and
volume, facilitating transportation and storage of the same - resulting in
reduced
costs associated with disposal. The process 270 reduces the volume of
contaminated water requiring disposal by approximately 70%.
[Para 1401 Completing the recycled loop, the vapor output 48 from the unit 10
is directed into the steam generator 266 so as to replace the external water
supply 272 once the system 270 is fully primed. Because the process 270
provides significant quantities of vapor, which is in-turn converted to steam,
it is
possible to perform continuous steam injections into the oil zone 274. The
process 270 provides clean water vapor for steam injection such that the
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57
procurement of fresh water is not needed. Low impurity vapor
reduces/eliminates the need for treatment of other fresh water sources used in
steam generation. Because the clean water vapor output 48 is already at an
elevated temperature there is no need for pre-heating and the associated
expense as with the use of an external water supply 272, i.e., municipal
water.
The recycling of the clean water vapor separated from the produced water
eliminates the need for continuous use of the external water supply 272 beyond
priming the system and periodic replenishment of any portion that remains
entrained in the contaminant-bring output 46.
[Para 141] Utilizing this inventive oilfield steam process 270, the industry
for
the steam recovery oil from oil zones can be greatly improved and expanded.
The continuous injections of steam into the oil zone 274 result in an increase
in
oil production by up the 600% in heavy oil reservoirs. Oil can be removed from
a
well at greatly reduced expense - saving on water supply costs, pre-heating
costs, and disposal costs. In addition, the continual introduction of steam
into
the oil zone stimulates the oil well so as to increase the rate of oil
production.
Thus, the inventive process 270 can recover more oil, at a faster rate, at a
greatly
reduced cost.
[Para 1421 Although several embodiments have been described in detail for
purposes of illustration, various modifications may be made without departing
from the scope and spirit of the invention. Accordingly, the invention is not
to
be limited, except as by the appended claims.
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