Thermal Treatment System
The present invention relates to a heat treatment system and in particular such a system used for heat treatment of waste material, particularly human waste material.
It is known to provide thermal treatment apparatus to treat waste such as human waste by evaporating off the moisture content. Such apparatus is known to use a fuel burner directing heat/flames into a thermal treatment chamber. Gas/vapour evolved escapes via an outlet flue.
Such apparatus can be used, for example, in remote locations for example mining camps for treatment of human waste material.
An improved arrangement has now been devised.
According to the present invention, there is provided a thermal treatment system comprising: a thermal treatment chamber a heater device a material infeed arrangement for delivering material to be thermally treated into the chamber sensor means providing an output indication of presence, or condition of material in the chamber; a control system configured to receive and process the output from the sensor means to control the operation of the material infeed and/or operation of the heater (preferably both).
The sensor means may be a thermal sensor such as a thermocouple device.
The control system is configured to receive and process the output from the sensor means to control the material infeed operation and/or operation of the heater, according to a computer program in which the sensor output temperature is a control variable.
In one embodiment it may be preferred that the material to be treated is fed into an overflow receptacle positioned in an upper portion of the chamber and overflows into an overflow zone of the chamber spaced from the overflow receptacle; wherein the presence or condition of material at the overflow zone is determined by the sensor means and that determination is used to control operation of either the heater or whether further material should be fed into the chamber.
In one embodiment, it may be preferred that the thermal sensor output is used to ascertain the temperature within an upper and lower threshold range and the system is operated to alter parameters (for example on or off of in-feed or burner) dependent upon the sensor output compared with the threshold range.
In a preferred arrangement a macerator pump is arranged to macerate the material before the material is pumped to the chamber. Beneficially, the material is pumped from a first location in a holding tank to a second location in the holding tank via the macerator pump,
It may be preferred that the thermal treatment chamber and the holding tank are mounted in a common unit, the treatment chamber preferably being mounted on top of the holding tank.
In a system according to the invention it may be beneficial that material is fed into a receptacle positioned in an upper portion of the thermal treatment chamber and the sensor means is positioned below the level of the receptacle.
It may be preferred that the material is deposited into the receptacle proximate one end of the receptacle and overflows at a predefined location spaced from the one end. To this
end, the receptacle may be provided with an inclined flow surface promoting flow to overflow the receptacle at a defined location.
In certain embodiments the receptacle may be provided with an overflow weir lip for overflow of the material.
Beneficially the heater comprises a directional burner, the burner being directed to heat the underside of the receptacle. This most beneficially effects evaporation of the moisture content of the material contained in the receptacle, before overflow.
The underside of the receptacle may be provided with heat transfer enhancement formations (such as turbulators or fins).
According to a further aspect, the invention provides a method of thermally treating material fed into a thermal treatment chamber, in which material is fed into an overflow receptacle positioned in an upper portion of a treatment chamber for treatment and a heater/burner is operated to treat the material in the chamber, wherein material to be treated overflows the overflow receptacle into an overflow zone of the chamber spaced below the overflow receptacle; wherein overflow of material is determined and used to control operation of either the heater and/or whether material should be fed into the chamber .
Typically it is the pump and/or the burner (but most preferably the in feed pump) that is operated by the control system in response to the sensor output. The operation is controlled to ensure that the burner (either constantly or in periodical bursts) is operated until the temperature at the overflow zone of the chamber reaches a predetermined critical/threshold value. At the predetermined value it is known that the liquid waste is no longer present /overflowing at the relevant location. When this condition is reached the in feed pump can be operated to deposit more of the waste material into the overflow receptacle in the chamber. The measured temperature is maintained between set upper and lower threshold values.
In an alternative embodiment to the first system described it may be preferred that the sensor means comprises separate sensors provided at different locations.
In such an arrangement the control system may be configured to receive and process the output from both of the separate sensors to control the operation of the material infeed operation and/or operation of the heater. The output from both of the separate sensors may be compared to a datum value and/or each other in order to control the operation of the material in feed operation and/or operation of the heater. It may be preferred that material is fed into a receptacle (for example an overflow receptacle) positioned in an upper portion of the thermal treatment chamber and the sensor means includes a sensor (such as a thermal sensor) positioned in the receptacle.
In such an arrangement it may be preferred that the sensor means comprises a second sensor, the second sensor being positioned away from the receptacle. Beneficially the second sensor is positioned below the level of the receptacle, for example in an overflow zone positioned below an overflow receptacle.
Different thermal readings or output values will be obtained depending upon whether 'wet' material is present in the relevant zone, or whether all the material has been evaporated. Hence it can be determined from the sensors output whether material is present.
The sensor means may comprise one or more thermocouple devices. The heater typically comprises a fuel burner.
The material infeed arrangement may have a pump which operates to transfer the material to be treated into the chamber. Typically, in this dual sensor realisation of the invention it is the pump and/or the burner that is operated by the control system in response to the sensor(s) output. The operation is controlled to ensure that the burner (either constantly or in periodical bursts) is operated
until the temperature tagged to the overflow receptacle and the overflow zone of the chamber below reaches a predetermined critical value. At the predetermined value it is known that the liquid waste is no longer present (ie it has all evaporated) at the relevant location - i.e. the overflow receptacle and the overflow zone of the chamber below. When this condition is reached for both locations, all the waste has been evaporated and the pump can be operated to deposit more of the waste material into the overflow receptacle in the chamber.
If either of the sensors does not reach the critical value than the burner operation continues.
According to an alternative aspect, the invention provides a method of thermally treating material fed into a thermal treatment chamber, in which material is fed into the chamber for treatment and a heater/burner is operated to treat the material in the chamber, wherein temperature is measured at different zones and the different zone temperature
measurements are used to determine operation of either the heater or whether material should be fed into the chamber.
Sensor output is used to control the material infeed operation and/or operation of the heater, according to a computer program.
The different zone sensor outputs (e.g. thermal measurements) are used to determine operation of both the heater and whether material should be fed into the chamber.
According to a further aspect, the invention provides a method of thermally treating material fed into a thermal treatment chamber, in which material is fed into the chamber for treatment and a heater/burner is operated to treat the material in the chamber; wherein material to be treated is fed into an overflow receptacle positioned in an upper portion of the chamber and overflows into an overflow zone of the chamber spaced from the overflow receptacle; wherein the presence of material at both the overflow receptacle and the overflow zone is determined and that determination is used to control operation of either the heater or whether further material should be fed into the chamber.
According to an alternative aspect, the invention provides thermal treatment apparatus comprising a thermal treatment chamber having an overflow receptacle to be positioned in an upper portion of the chamber and an overflow zone spaced from the overflow receptacle, wherein the overflow receptacle is slidably received in the chamber to be slidable to a home position for use and locking means is provided to lock the overflow receptacle in the home position.
It is preferred that the thermal treatment chamber is provided with an opening through which the overflow receptacle can pass to be inserted into, or removed from the chamber. Beneficially, the opening is closed by a panel, which is preferably provided with a burner port to which the burner can be mounted.
Preferably, the chamber is provided with guide rails or runners permitting sliding of the receptacle to the home position.
Beneficially, the locking means abuts against a rear portion of the overflow receptacle inhibiting sliding retraction of the overflow receptacle from the home position.
It is preferred that the locking means is actuatable from the exterior of the chamber.
The locking means preferably extends through the chamber wall and preferably comprises a bolt actuatable from the exterior of the chamber.
It is preferred that the overflow receptacle is provided below an inlet for material to be treated. The overflow receptacle is preferably suspended above the overflow zone in the chamber.
According to a further aspect, the invention provides a thermal insulation jacket for a thermal treatment chamber, the jacket comprising a plurality of flexible panels to fold about the chamber, the jacket having at least one side provided with a waterproof or water resistant surface layer, and an internal filler of a thermally insulating layer, certain of the panels being provided with hook pads of a hook and loop fastening system, and other of
the panels being provided with loop panels of a hook and loop type fastening system and arranged to overlap/overlie with the hook pads, the jacket having one or more openings or fold back flaps for accommodating a flue and inlet pipe of the treatment chamber. According to a further aspect, the invention provides a tubular support frame system for a thermal treatment chamber, the support frame defining an outer perimeter spaced above and below and fore and aft of the chamber and including a chamber supporting mount positioned above the base portion of the frame and upon which the chamber sits. The support frame preferably includes a pair of side rail tubes for mounting the chamber which extend from one side to the other of the frame and are spaced above the base portion of the frame.
The side rail tubes for mounting the chamber are preferably positioned inwardly of the perimeter defined by the frame system, preferably wherein the end sections of the tubes have outwardly configured elbow portions.
It is preferred that closure panels are fitted to the sides and ends of the frame to shield the chamber from the environment.
The invention will now be further described by way of example only and with reference to the accompanying drawings in which:-
Figure 1 is a side view of a treatment chamber for a thermal treatment system in accordance for the invention;
Figure 2 is a plan view of the treatment chamber of figure 1 ;
Figure 3 is a perspective view of the treatment chamber of figures 1 & 2;
Figure 4 is a side view of the treatment chamber with the system burner fitted;
Figure 5 is a view of the front end of the chamber; Figure 6 is a perspective view of the support frame for the chamber; Figure 7 is a side view of the chamber support frame;
Figure 8 is a plan view of the support frame system;
Figure 9 is a perspective view of the system with cladding fitted to the support frame;
Figure 10 is a plan view of the insulation system for the chamber;
Figure 11 is a side view of an alternative embodiment of a treatment chamber for a thermal treatment system in accordance for the invention;
Figure 12 is a perspective view of the overflow receptacle included in the treatment chamber of figure 11; Figure 13 is a schematic view of a thermal treatment system in accordance with the invention.
Referring to the drawings and initially to figures 1 to 5 a thermal treatment system includes, as a core component, a thermal treatment chamber (1) fabricated of welded steel plate and shown in perspective view in figure 3. The thermal treatment chamber (1) has a fuel burner heater (2) fitted to a burner port (18) at a forward end of the chamber (1). The fuel burner heater (2) is only shown fitted to the chamber (1) in figure 4. Fuel burners for use for such purposes are well known in the prior art and the burner can be an off the shelf component and may be used burning any desired fuel (petrol, paraffin, gas etc). The burner directs heat energy and flames through the burner port (2) and into the interior of the thermal treatment chamber (1). This location for the burner is preferred rather than through a side wall or particularly through the base or top wall of the container. Gaseous
products resulting from the thermal treatment exit the thermal treatment chamber via a flue (4) provided in the roof of the thermal treatment chamber (1).
The material to be treated, which is typically 'wet' waste material in fluid form (such as for example human effluent) enters the thermal treatment chamber (1) via the inlet duct (5). This deposits the product to be treated into an overflow receptacle (6) which is typically in the form of a tray suspended internally of the thermal transfer chamber (1). The overflow receptacle (6) is suspended on side guide rails or runners (7) which extend from the front end of the treatment chamber towards the rear end where the tray is suspended in a 'home' position. The fascia panel (8) at the front end of the treatment chamber (1) can be removed and the overflow receptacle (6) slid in through the open front end of the chamber to the 'home' position as shown in figure 1. When in the 'home' position a securing bolt (9) is screwed home through the external roof of the treatment chamber (1) and abuts against the rear end of the overflow receptacle (6) in order to hold it securely in position. This is an important feature as accurate positioning and maintenance of accurate positioning of the overflow receptacle (6) within the interior of a thermal treatment chamber is important. The overflow receptacle (6) can also then easily be removed for maintenance and checking. The overflow receptacle (6) receives the waste material flowing into the chamber via the inlet duct (5) and when full overflows such that the overflowing material spills to land on the internal floor surface of the treatment chamber (1).
A first thermocouple is positioned in thermocouple tube (10) via the inlet duct (5) to provide thermal readings for the system representative of the temperature as shown in figure 1 positioned in the overflow receptacle (6). The end of the thermocouple tube (10) is positioned in the receptacle (6) such that if 'wet' material is present in the receptacle, then the end of the thermocouple tube will be 'wet' also. A second thermocouple is positioned in thermocouple tube (11) on the exterior of the thermal treatment chamber approximate the base of the chamber. This provides thermal sensor readings representative of the temperature of the chamber at its base. If 'wet' material is present on the base of the chamber, then the end of the thermocouple tube (11) will be 'wet' also.
The chamber (1) is provided with fixing plates or brackets (12) enabling the treatment chamber to be mounted internally of a support frame assembly (13) as shown in figures 6 & 7 and as will be described. It is important that, in use, the thermal treatment chamber (1) is insulated and held in an environment where there is sufficient airflow around the chamber. The chamber also needs to be well shielded from the environment as the systems are typically used in harsh environments.
Accordingly the thermal treatment chamber (1) is mounted in a support frame assembly (13) the support frame assembly is of a generally tubular frame component in order to enhance the rigidity and support function of the assembly. The support frame assembly includes upper and lower tube members (13j, 13k) and spaced above the lower tube member (13k) a support section comprising side rail tube members (13a). The side rail tube members (13a) are positioned inwardly of the perimeter defined by the frame system, and the end sections of the side rail tubes have outwardly configured elbow portions 13b. the side rail tubes (13a) are provided with lateral mounting sections (13c) and (13d) to which the chamber (1) is bolted by means of the securing brackets (12) provided on the thermal treatment chamber (1). In this way it is ensured that the chamber (1) is held in a fully supported and secure position above the lower frame lengths. The support frame assembly includes bracing struts (13e), (13f), (13g) & (13h) in order to enhance the support function. The tubular support frame assembly provides a sub-structure to which weather proofing panels can be fixed as shown clearly in figure 7.
Prior to mounting in the support frame assembly (13) the thermal treatment chamber (1) is fitted within a bespoke thermal insulation jacket (21). This is shown most clearly in figure 10 in flattened out form. The outer skin surface or layer of the product is a waterproof layer and for example can be fabricated from grey silicon coated with woven glass fibre fabric. The inner skin of the jacket may comprise for example silicon fabric. The insulating filler material of the jacket can for example be glass fibre needle mat 50mm thickness 130kg per meter cube density. The jacket is fabricated to have fold over panels (21 a, 21 b, 21 c, 21 d, 21 e) to lie contiguous with different side top and bottom portions of the thermal treatment chamber and is provided with Velcro fastenings provided on the
underside of tabs (21g) to secure with complementary Velcro patches (21h) on the panels (21a, 21b, 21c) in order to secure the jacket in position on the thermal treatment chamber.
The arrangement is effectively a thermal insulation jacket for a thermal treatment chamber, the jacket comprising a plurality of flexible panels (21a, 21b, 21c, 21d, 21e) to fold about the chamber, the jacket having at least one side provided with a waterproof or water resistant surface layer, and an internal filler of a thermally insulating layer, certain of the panels being provided with hook pads or patches of a hook and loop fastening system, and other of the panels being provided with loop pads or patches of a hook and loop type fastening system and arranged to overlap/overlie with the hook pads. The jacket has an opening (22) and a fold back flap (23) for accommodating a flue (4) and inlet pipe (5) of the treatment chamber. A separate insulating collar (25) is provided for fitting about the flue opening (22). The support brackets (12) of the chamber are arranged to be accessible with the thermal insulation jacket in position. Additionally the flue duct (4) and the inlet duct (5) extend through gaps (22) or fold back portions (23) in the foldable jacket. In use the thermal treatment chamber, pre jacketed, is mounted in the support frame and the shielding panels are fitted as shown in figure 9.
The burner (3) is mounted to the fascia panel (8) of the thermal treatment chamber and supplied with the relevant fuel for burning in order to thermally treat the material in the chamber. It has been found that the operational control of the burner and the temperature regime within the interior of the chamber is extremely important in order to ensure adequate heat treatment and also to ensure maximisation of the operational life of the system. The temperature control regime relies upon thermal feedback from the first and second thermocouples located in thermocouple tubes (10) and (11). Thermocouple output is fed into the controller to ensure appropriate operation of the burner and also feed of the material to be treated into the chamber via the inlet duct (5). In non optimal scenarios, the software logic control has been timer controlled, such that the burner would operate for a predetermined time and once this time had elapsed more waste would be pumped into the chamber. The problem caused by this was that if the flame or burn did not reach the
correct temperature, burning and clearing of the waste material within the chamber did not occur or at least did not occur to a sufficient degree. Then the chamber (1) would overfill and flood causing spillage of waste. The present invention solves this problem by making use of the thermocouples in tubes (10 and 11) .Software has been developed to control the burn and delivery of the waste material by way of sensor feedback and has resolved this problem. Two thermocouples are placed within the chamber (thermocouple tubes 10 and 1 1). The thermocouple in tube 1 reads the temperature at the top of the chamber internally of the overflow receptacle (6) and the thermocouple in tube (11) reads the temperature representative at the internal base overflow zone of the chamber. When the two thermocouples have reached and maintained a prescribed temperature this is indicative that the waste within the chamber has been evaporated. Following this further waste can then be delivered by way of pump into the chamber via the inlet duct (5). By monitoring the thermocouple in tube 10 (representative of the temperature in the tray) it can be ascertained when there is no longer any liquid material in the tray (6) (the thermocouple temperature rises to the required degree).
Furthermore the temperature representative of thermocouple in tube (11) rises when there is no longer any liquid waste in the interior of the chamber and this is indicative of the waste in the chamber having been evaporated. The pump which pumps waste in through the inlet (5) and/or the burner (2) is operated by the control system in response to the sensor (s) output. The operation is controlled to ensure that the burner (either constantly or in periodical bursts) is operated until the temperature tagged to the overflow receptacle and the overflow zone of the chamber below reaches a predetermined critical value. At the predetermined value it is known that the liquid waste is no longer present (ie it has all evaporated) at the relevant location - i.e. the overflow receptacle and the overflow zone of the chamber below. When this condition is reached for both locations, all the waste has been evaporated and the pump can be operated to deposit more of the waste material into the overflow receptacle in the chamber. If either of the sensors does not reach the critical value then the burner operation continues.
The following operational sequence is exemplary:
The chamber temperature is required to reach a set temperature (critical temperature) in the overflow receptacle (6) - thermocouple tube 10, and the overflow zone (thermocouple tube 11) prior to waste being pumped into the tray via the inlet duct (5).
The burner is then initiated and the burn cycle commences. Following the burn cycle there is a defined wait period (88 seconds) in which the temperature is observed. If the temperature falls below the critical temperature the burner is recommenced and then stopped again. Once the chamber reaches the critical temperature on both thermocouples the system initiates the pumping of further waste into the chamber. The pumping cycle is recommenced when operational parameters determine this to be permitted and this continues until the waste tank is empty and the waste signal is removed from the display. This shut down cycle runs for 60 seconds. The programme will then revert to the standby mode.
Referring now to the embodiment of figures 11 to 13, this is similar in many respects to the embodiment of figures 1 to 5 but differs in certain respects. A single thermocouple (111) is provided internally of the chamber (101) to sense temperature at the overflow zone at the base of the chamber immediately below a forward weir lip of the overflow receptacle (106) and there is no thermocouple provided in/at the overflow receptacle (106). This provides an enhancement over the arrangement of the earlier embodiment in that more efficient operation can be achieved. In the earlier described embodiment, the delay in waiting for the overflow receptacle thermocouple (10) to reach again the critical value for
recommencement of operation was found to be unnecessarily long. It was found that using a single thermocouple (111) provided internally of the chamber (101) to sense temperature at the overflow zone at the base of the chamber immediately below a forward weir lip (106a) of the overflow receptacle (106) could provide sufficient control.
When the overflow receptacle (106) is full of waste and starts to overflow, the
thermocouple (111) provided internally of the chamber (101) at the base of the chamber immediately below the forward weir lip (106a) of the overflow receptacle (106) becomes wet and the decrease in temperature is sensed. The tray 106 is inclined to promote flow
towards the weir lip and the material overflows the weir lip when the film thickness in the receptacle is at an optimum depth.
The burner (103) is mounted to the fascia panel (108) of the thermal treatment chamber (101) and supplied with the relevant fuel for burning in order to thermally treat the material in the chamber. The burner flame is directed below the overflow receptacle (106) and in this embodiment the underside of the overflow receptacle is provided with turbulence inducing formations in the form of fins (106b). This improves the heat transfer to the receptacle (106). The underside of the receptacle 106 is heated and this provides the heat to evaporate the moisture content of the waste material present in the container.
The receptacle (106) slides forwardly into position via the fascia panel (108) when removed to be received in a reception duct (129). The rear wall (106c) of the receptacle (106) seals against the forward upper shoulder of the reception duct (129). This ensures that exhaust gases must exit via the flue (104). A locking bolt (109) secures the receptacle (106) in the home position.
The thermocouple (111) is positioned into the chamber (101) via the thermocouple tube (110) passing through the gap (106e) in the forward weir lip (106a) of the overflow receptacle (106).
The material to be treated enters the chamber (101) via the inlet duct (105). In this embodiment and as shown most clearly in figure 13, the material is pumped from a separate storage tank (130) to a holding tank (140) on board a processing unit which also incorporates the chamber. Typically the chamber (101) is mounted on top of the holding tank (140). It should be realised that this arrangement could be utilized for the first embodiment described also. The control system checks the status of the separate storage tank (130) at timed intervals and if waste material is present operates delivery pump (145) to pump material from the separate storage tank (130) to the on-board holding tank (140). In order to control the particle size of the waste material for optimum treatment a macerator pump (150) is used to pump the material from a first location in the holding tank (140) to another zone. When demanded a peristaltic pump (160) is operated to pump the
macerated waste from the holding tank, via the inlet duct (105) into the chamber above the rear end of the inclined overflow receptacle (106).
By monitoring the thermocouple (111) it can be ascertained when there is material overflowing the tray 9106) at the weir lip (106a). For example the burner activation and in-feed peristaltic pump (160) operation to pump waste material into the chamber (101) can be controlled based upon an upper set threshold thermocouple measurement and a lower set threshold thermocouple measurement. The operation is controlled to ensure that the burner (either constantly or in periodical bursts) is operated until the temperature at the overflow zone of the chamber reaches a predetermined critical/threshold value. At the predetermined value it is known that the liquid waste is no longer present /overflowing at the relevant location. When this condition is reached the pump (160) can be operated to deposit more of the waste material into the overflow receptacle in the chamber. The thermocouple measured temperature is maintained between set upper and lower threshold values.
The following operational sequence is exemplary: The thermocouple (111) monitored temperature is maintained between a lower threshold of 105 Celsius and an upper threshold of 1 10 Celsius, by means of controlling operation of the peristaltic in-feed pump (160). If the temperature falls to 105 Celsius the peristaltic in- feed pump (160) feed is turned off, because this is representative of the thermocouple (111) being wet and the overflow receptacle (106) is overflowing. Once the temperature has risen to 110 Celsius the peristaltic in-feed pump (160) feed is turned back on and , material is pumped into the overflow receptacle (106). The burner can be kept operational during the entire cycle which is more efficient. The burner is operated to be switched off if there is no demand to draw material from the tanks (130,140). Controlling the overflow characteristics for the overflow receptacle (106) can ensure that the depth of waste in the receptacle is optimised and consequently that evaporation is optimised. Directing the burner heat/flame output below the receptacle so as to heat the underside of the receptacle
also provides improved operation than directing the burner directly into the waste in the receptacle.
The system according to the invention is particularly suited to the efficient disposal of 'wet' waste in situations where storage and disposal of such waste is otherwise inconvenient or expensive.