Apparatus for removing dissolved metals from wastewater by electrocoagulation

An electrocoagulation system for removing contaminants from a flow of wastewater comprising:

• a closeable pressurized container for collecting the wastewater to be treated from a wastewater source;
• a reactor having at least one rectangular positive electrode plate made of iron and at least one rectangular negative electrode plate made of iron, the positive electrode plate being substantially parallel to the negative electrode plate, the reactor being located inside the container and in fluid communication with the container to receive the wastewater from the container, the positive and negative plates defining a flow path in the reactor through which the wastewater flows, a plurality of dummy plates interspersed between the positive and negative plates to increase the length of the flow path through which the wastewater travels through the reactor, the dummy plates creating intermediate voltages therebetween;
• a DC voltage source in electrical communication with the positive and negative plates for applying a voltage therebetween, the voltage causing the contaminants in the wastewater to react with the electrode plates to change from in-solution to in-suspension in the wastewater;
• a grooved ring cyclone filter for receiving the wastewater and contaminants from the reactor, the cyclone filter separating the contaminants contained in-suspension from the wastewater;
• a controller adapted to control the flow of wastewater from the wastewater source, through the reactor;
• and into the cyclone filter, the controller controlling the DC voltage source to control the amount of voltage supplied to the electrode plates;
• a rectifier in electrical communication with the DC voltage source to selectively reverse the polarity of the voltage supplied to the electrode plates thus changing the polarity of the electrode plates to allow the electrode plates to deteriorate substantially equally, the rectifier being controlled by the controller;
• a temperature sensor to measure the temperature of the wastewater exiting the reactor, the temperature sensor in communication with the controller, the controller adjusting the flow of wastewater and the DC voltage source to achieve a desired temperature of wastewater exiting the reactor;
• a first pH sensor being located at the wastewater source to measure the pH of the wastewater entering the container;
• and
• a second pH sensor located between the reactor and the cyclone filter to measure the pH of the wastewater exiting the reactor, the first and second pH sensors in communication with the controller, the controller adjusting the flow of wastewater and the DC voltage source to achieve a desired pH of wastewater exiting the reactor,
• the container having a pressure release valve to allow byproduct gases to be removed from the wastewater, the container having a first gas release having manual valves coupled to a first gas release valve on the container for venting gases from the container, and a second gas release valve coupled to the container by water outlet piping to release gases generated inside the electrocoagulation reactor.

An electrocoagulation method for treating wastewater containing contaminants in-solution comprising:

• collecting the wastewater in a container;
• passing the wastewater from the container to a reactor, the reactor having a plurality of positive and negative electrode plates and a plurality of dummy plates dispersed therebetween, the reactor being located inside the container;
• applying a voltage to the positive and negative electrode plates from a DC voltage source to form suspended particles in the wastewater;
• moving the wastewater with the suspended particles from the reactor in the container to a cyclone filter;
• removing the suspended particles from the wastewater by flowing the wastewater through the cyclone filter which causes the suspended particles to drop out of the wastewater;
• extracting from the cyclone filter the suspended particles removed from the wastewater;
• and
• extracting the treated wastewater.

A fluid treatment system adapted to remove contaminants from aqueous fluid by contacting said aqueous fluid with an electrical field and metal ions dissolved by said electrical field, comprising:

• an electrocoagulation reactor having an insulating enclosure, a support structure within said enclosure, a first plurality of planar electrodes with apertures at one end and having a positive electrical charge disposed on said support structure in spaced parallel relationship to one another and positioned parallel to the flow of said aqueous fluid, a second plurality of planar electrodes with apertures at one end and having a negative electrical charge disposed on said support structure in alternating spaced parallel relationship with said first plurality of planer electrodes and electrically insulated therefrom and positioned with said apertures at the opposite end of the apertures on said first plurality of planar electrodes, a first electrical coupling means for applying a positive electrical charge on said first plurality of planar electrodes, a second electrical coupling means for applying a negative electrical charge on said second plurality of planar electrodes, an inlet means for introducing untreated said aqueous fluid into said reactor to flow in sequence through the parallel spaces between said first and said second plurality of planar electrodes, an outlet means for allowing treated said aqueous fluid to exit said reactor;
• and,
• a DC electrical power supply having a means of adjusting the amount of current to be supplied at a preset level, a means of automatically adjusting the voltage to maintain said preset level of current, a means for automatically reversing the electrical polarity of the said current, a means coupled to said coupling means for applying a positive electrical charge on said first plurality of planer electrodes of said reactor, a means coupled to said coupling means for applying a negative electrical charge on said second plurality of planer electrodes of said reactor, and a means of housing said DC electrical power supply;
• and,
• a container for housing said electrocoagulation reactor having a means of opening and re-closing said container, a structure within said container to support said electrocoagulation reactor, an inlet means for allowing untreated said aqueous fluid into said container around the outside of said reactor, an outlet means for allowing untreated said aqueous fluid to exit said container, and inlet means coupled to said inlet means of reactor for allowing said aqueous fluid to enter said reactor, and outlet means coupled to said outlet means of reactor for allowing treated said aqueous fluid to exit said reactor, an outlet means for venting gases from said container, an outlet means for draining said aqueous fluid from said container, a first electrical port for an electrical connector for supplying a positive electrical charge to said reactor, a second electrical port for an electrical connector for supplying a negative electrical charge to said reactor;
• and,
• a first electrical connector assembly coupled to said first port of said container comprising a flange and threaded boss of non-conducting material and a threaded metal conductor extending out of said flange and said threaded boss, an explosion proof sealing hub, sealing compound, and an explosion proof housing for connecting the positive polarity of the DC electrical power supply;
• and,
• a second electrical connector assembly coupled to said second port of said container comprising a flange and threaded boss of non-conducting material and a threaded metal conductor extending out of said flange and said threaded boss, an explosion proof sealing hub, sealing compound, and an explosion proof housing for connecting the negative polarity of the DC electrical power supply;
• and,
• a system pump having the flowrate and pressure capacity required to operate said electrocoagulation system;
• and,
• a monitoring and control system having a programmable logic controller;
• sensors for monitoring said aqueous fluid flow, temperature, inlet and outlet pH, and pressure of said electrocoagulation system, a means for opening and closing valves during operation, interconnection wiring, and a means of housing said controller;
• and,
• a piping system having interconnecting piping, valves to direct and reverse the flow of water through said electrocoagulation system, valves coupled to said outlet means for draining said aqueous fluid from said container, a first gas release and manual valves coupled to said outlet means for venting gases from said container, a second gas release valve coupled to water outlet piping to release gases generated in said electrocoagulation reactor, and piping connections for said sensors of said monitoring and control system;
• and,
• a cyclone filter having a means of separating suspended solid particles from said aqueous fluid, a means of discharging said separated solid particles from the bottom of said cyclone filter housing, and a means of discharging remaining said aqueous fluid for the top of said cyclone filter housing.

A fluid treatment system for removing contaminants from a flow of aqueous fluid comprising:

• (1) an electrocoagulation reactor having
• an insulated enclosure for the reactor,
• a support structure within said enclosure,
• a first plurality of planar electrodes having a positive electrical charge, the first plurality of planar electrodes being disposed on said support structure and spaced parallel to one another and positioned parallel to the flow of said fluid,
• a second plurality of planar electrodes having a negative electrical charge, the second plurality of planar electrodes being disposed on said support structure in alternating spaced parallel relationship with said first plurality of planer electrodes, electrically insulated therefrom,
• a first electrical coupling means for applying a positive electrical charge on said first plurality of planar electrodes,
• a second electrical coupling means for applying a negative electrical charge on said second plurality of planar electrodes,
• an inlet means for introducing untreated said aqueous fluid into said reactor to flow in sequence through the parallel spaces between said first and said second plurality of planar electrodes, and
• an outlet means for allowing treated said aqueous fluid to exit said reactor;
• (2) a DC electrical power supply for adjusting the amount of current supplied at a desired level, the DC electrical power supply automatically adjusting the voltage to maintain said desired level of current, the DC electrical power supply having
• a rectifiers for automatically reversing the electrical polarity of the said current,
• a means coupled to said first electrical coupling means for applying a positive electrical charge on said first plurality of planer electrodes of said reactor,
• a means coupled to said second electrical coupling means for applying a negative electrical charge on said second plurality of planer electrodes of said reactor, and
• a housing for DC electrical power supply;
• (3) a closeable container for housing said electrocoagulation reactor having
• a structure within the container to support said electrocoagulation reactor,
• an inlet for allowing untreated said aqueous fluid into said container around the outside of said reactor,
• an outlet for allowing untreated said aqueous fluid to exit said container,
• a gas outlet for venting gases from said container,
• a drain outlet for draining said aqueous fluid from said container,
• a first electrical port for an electrical connector for supplying a positive electrical charge to said reactor,
• a second electrical port for an electrical connector for supplying a negative electrical charge to said reactor,
• a first electrical connector assembly coupled to said first electrical port of said container having a flange, a threaded boss of non-conducting material, and a threaded metal conductor extending out of said flange and said threaded boss, an explosion proof sealing hub, sealing compound, and an explosion proof housing for connecting the positive polarity of the DC electrical power supply;
• and,
• a second electrical connector assembly coupled to said second port of said container comprising a flange, threaded boss of non-conducting material, and a threaded metal conductor extending out of said flange and said threaded boss, an explosion proof sealing hub, sealing compound, and an explosion proof housing for connecting the negative polarity of the DC electrical power supply;
• (4) a system pump having a predetermined flowrate and pressure capacity to operate said electrocoagulation system;
• (5) a control system having a programmable logic controller, sensors for monitoring said aqueous fluid flow, temperature, inlet and outlet pH, and pressure of said electrocoagulation system, a means for opening and closing valves during operation, and controller housing;
• and,
• (6) a piping system having interconnecting piping, valves to direct and reverse the flow of water through said electrocoagulation system, valves coupled to said drain outlet, a first gas release and manual valves coupled to said gas outlet, a second gas release valve coupled to water outlet piping to release gases generated in said electrocoagulation reactor, and piping connections for said sensors of said monitoring and control system.