WO1997048421A2 - Apparatus and methods for the disinfection of fluids - Google Patents
Apparatus and methods for the disinfection of fluids Download PDFInfo
- Publication number
- WO1997048421A2 WO1997048421A2 PCT/US1997/011428 US9711428W WO9748421A2 WO 1997048421 A2 WO1997048421 A2 WO 1997048421A2 US 9711428 W US9711428 W US 9711428W WO 9748421 A2 WO9748421 A2 WO 9748421A2
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- WO
- WIPO (PCT)
- Prior art keywords
- fluid
- contaminated fluid
- fluids
- ultraviolet
- contaminants
- Prior art date
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Classifications
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- A—HUMAN NECESSITIES
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- A23L3/00—Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs
- A23L3/26—Preservation of foods or foodstuffs, in general, e.g. pasteurising, sterilising, specially adapted for foods or foodstuffs by irradiation without heating
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- A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
- A61L2/02—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor using physical phenomena
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- A61L2/10—Ultra-violet radiation
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- C02F1/32—Treatment of water, waste water, or sewage by irradiation with ultraviolet light
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/30—Treatment of water, waste water, or sewage by irradiation
- C02F1/32—Treatment of water, waste water, or sewage by irradiation with ultraviolet light
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/34—Treatment of water, waste water, or sewage with mechanical oscillations
- C02F1/36—Treatment of water, waste water, or sewage with mechanical oscillations ultrasonic vibrations
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/40—Devices for separating or removing fatty or oily substances or similar floating material
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2101/00—Nature of the contaminant
- C02F2101/30—Organic compounds
- C02F2101/32—Hydrocarbons, e.g. oil
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
- C02F2103/02—Non-contaminated water, e.g. for industrial water supply
- C02F2103/023—Water in cooling circuits
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
- C02F2103/34—Nature of the water, waste water, sewage or sludge to be treated from industrial activities not provided for in groups C02F2103/12 - C02F2103/32
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2301/00—General aspects of water treatment
- C02F2301/02—Fluid flow conditions
- C02F2301/024—Turbulent
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2303/00—Specific treatment goals
- C02F2303/04—Disinfection
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2303/00—Specific treatment goals
- C02F2303/24—Separation of coarse particles, e.g. by using sieves or screens
Definitions
- This invention relates to apparatus and methods for the disinfection of fluids and, in particular, to the disinfection of opaque industrial fluids with ultraviolet radiation
- Coolant use in America's heavy industries has been a story of significant successes and failures
- the efficacy of coolants in prolonging the life of various tools used in manufacturing has been high. This is due, in part, to the inclusion of specific organic and surfactant compounds that lubricate the materials and minimize oxidation damage and surface buildup of constituent substances on the tools.
- These compounds, as well as contaminating tramp oils that leak into the coolant from multiple sources, provide a very suitable nutrient base for microbial growth.
- Coolants as well as other industrial fluids, have traditionally possessed a fairly short useful life and need to be replenished often or even completely replaced
- biocidai chemicals can be added to inhibit microbial growth
- the biocidai effect eventually fails and supplementation with further biocides becomes impractical Consequently, useful coolant life is only slightly extended.
- there are considerable environmental problems associated with disposal of used coolant due in large part to the presence of these additives and other contaminants.
- machine coolant has been disposed of by dumping in drains, sewers and rivers, causing extensive and prolonged environmental ground pollution.
- the EPA ruled that all oil-based coolants were contaminated waste and must be treated or a new way of disposal found (Public Law 94-580; October 21, 1976).
- centrifugation or filtration were considered as primary alternatives. Although filtration could remove some contaminant, filters often clogged or broke requiring more overall costs than would have been incurred by simply replacing the coolant In addition, a successful filtration process only prolonged the life of the coolant by about two or three weeks making overall savings minimal Centrifugation has been the p ⁇ nc ⁇ al mechanism for removing contaminated oils in larger machine tool plants While centrifugation as an oil removal technique has a limited treatment rate, it has been used to reduce concentrations of contaminants, usually to about two percent However, this partial removal does not prevent bacterial regrowth or breakdown of coolant and oil components
- UV treatment has been used to disinfect clear waters and some wastewater as shown in United States patent numbers 3,634,025, 3,700,406, 3,837,800, 3,889, 123, 3,894,236, 4,471,225 and 4,602, 162
- U S patents describes a method advocated to be designed to sterilize water-based fluids
- the p ⁇ ncipal idea behind this technique was that UV radiation would penetrate the clear liquid to kill offending microorganisms
- the conventional technology of UV treatment is limited because total quartz systems have a tendency to foul easily and maintenance costs were high UV treatment proved to be unsuccessful for indust ⁇ al fluids such as coolants, as coolants are opaque, or substantially so, and often contain significant levels of contaminants such as hydraulic and way oils which are highly occlusive to ultraviolet light Under these constraints, ultraviolet radiation cannot pass more than a very small distance, if at all, into the fluid stream (e.g.
- One embodiment of the invention is directed to methods for disinfecting a fluid.
- V is the flow rate of the fluid being exposed to ultraviolet radiation
- the method is useful for the treatment of opaque and substantially opaque fluids such as industrial fluids including coolants, machine fluids, bath fluids, process fluids and washing solutions.
- Another embodiment of the invention is directed to methods for disinfecting a contaminated fluid in a flow path. Fluid is pumped through the portion of the flow path exposed to a disinfecting amount of ultraviolet radiation at a rate sufficient to prevent adhesion of contaminants to UV transmissible surfaces within that portion.
- Another embodiment of the invention is directed to methods for disinfecting a contaminated fluid in a flow path. These methods comprise passing the fluid through a portion of the flow path and generating turbulence within that portion. Turbulent fluid is exposed to a disinfecting amount of ultraviolet radiation.
- Turbulence can be generated by pumping pressurized fluids such as a gas or a liquid through the flow path.
- turbulence can be generated by placing obstacles within the flow path. Such obstacles include ribbon, beads, cones, vanes and combinations of these structures.
- Another embodiment of the invention is directed to apparatus for disinfecting an industrial fluid.
- the apparatus is comprised of a tubing system for guiding the passage of the industrial fluid at a flow rate (V) through the apparatus.
- the tubing system comprises an ultraviolet -transmissible portion having a flattened to rounded cross section.
- the contaminated fluid is then exposed to an ultraviolet radiation system
- the ultraviolet radiation system comprises a plurality of ultraviolet lamps and, optionally, reflectors to direct UV radiation in close proximity to the fluid flow as a dry modular apparatus
- the apparatus comprises a tubing system for guiding the indust ⁇ al fluid through the apparatus at a flow rate (V) through the apparatus
- the tubing system is comp ⁇ sed of ultraviolet-transmissible tubing having a flattened to rounded cross section
- the apparatus further comprises a turbulence-generating system for creating turbulence with a Reynolds number or turbulence characteristic above that defining laminar flow, within the fluid during irradiation
- Turbulence generating means include techniques such as placing intra-tubular paddles, beads, cones or vanes within the tubing, or creating a pressure differential or aeration within the tubing Turbulence moves target microorganisms from UV-free zones within the interior of the tube to the surface of the fluid at the tube where they are killed upon exposure to UV radiation
- Turbulence also serves as a scouring force to prevent contaminants from adhering to tube and/or lamp surfaces Turbulent fluid is than irradiated from ultraviolet radiation system comprised of a plurality of
- Figure 4 (A) Single bead and (B) beads on a string turbulence-generating mechanisms (C) Cross-sectional view of a UV transmissible tube Figure 5 The L02C filtration and germicidal system
- Figure 7 Bacteriocidal effectiveness during UV treatment at 40 gallons per minute.
- Figure 8 Expression for percent of oil removal for UV effectiveness as a function of percent maximum fluid velocity in the system and viscosity of the oil
- the present invention is directed to apparatus and methods for the disinfection of fluids with ultraviolet radiation
- Substantially reduced means that microbial contamination is reduced such that useful life of the coolant is extended or the concentration of biocide needed to prevent microbial growth is lowered
- MPC minimum percentage of contaminants
- One embodiment of the invention is directed to a method for the disinfection of a fluid with an ultraviolet radiation treatment system
- a successful process is dependent on maintaining at least a minimum flow of fluid in the system
- This flow rate is required, in part, to prevent occlusion that interferes with the transmission of UV energy to the microorganisms Interference can be in the form of occlusion on the inner walls of the tubing of a dry disinfection system or the outer walls of quartz-jacketed ultraviolet lamps in a submerged disinfection system
- occlusion can be controlled by removing at least a minimum percentage of contaminants from the fluid
- a desired fluid flow rate can be established that allows for successful treatment with a disinfecting amount of ultraviolet radiation
- Flow rates are typically from less than about 1 to about 150 GPM or more, and preferably from about 10 to about 60 GPM
- the disinfection process can be tailored to the working parameters of most any configuration of machines Using this simple formula, fluid disinfection by ultraviolet radiation can be successfully predicted and accomplished at almost any flow rate
- the principal contaminants in a contaminated fluid such as, for example, an industrial fluid, are heavy oils including way oils Although solid particles may be present, MPC
- Fluids that can be disinfected according to the invention include, for example, liquids such as water and flavored water, carbonated beverages and other fluids under pressure, flavored drinks, fruit juices, soft drinks, beers, wines, liquors and industrial fluids
- Industrial fluids are fluids typically used in assembly lines and other manufacturing configurations, to cool, clean and lubricate as appropriate to the specific operation being performed Typical industrial fluids accumulate about 1 % to 7% hydrophobic hydrocarbon contaminants, with the remainder of contaminants being silicon oils and soluble lubricants, all usually in an aqueous medium (e.g.
- non-aqueous fluids such as electro-discharge machine fluid (EDM)
- EDM electro-discharge machine fluid
- fluids to be disinfected are substantially opaque
- substantially opaque fluids are fluids that do not allow lethal ultraviolet radiation energy to pass more than about 1.5 mm into the fluid.
- manufacturing lines can be quite long and contain huge volumes of fluid such as in the manufacture of automobiles, aircraft and automobile and aircraft parts.
- These lines comprise one or a plurality of machines in series (i.e. a working line), a fluid reservoir or tank, a plumbing system interconnecting the various machines and often a fluid sump with a pumping mechanism.
- the sizes of the tubes that guide the flow of the fluids in such system vary tremendously depending on the location in the system ranging from small to large. Smaller tubes may have a diameter of greater than about 4 mm, greater than about 6 mm, or greater than about 10 mm or more. Larger tube sizes, greater than two inches, greater than three inches and even greater than four inches, are typical in most industrial settings.
- the invention is not limited by the ability of UV radiation to penetrate a fluid, most all fluids used in industrial systems can be treated according to the methods of the invention.
- fluids typically found within these manufacturing lines include metal-working fluids, machine-tool coolants, machine-tool lubricants, electro-discharge machine fluid, Zyglo, electro-coating fluid, chassis- washing fluid, top-coating fluids, sonic-bath fluids, spot- and steam-welding coolants, electron- beam and laser-welding coolants, test-cell waters for metal processing, plastic molding and forming coolants, quenching fluids, recycled and recirculation fluids, and combinations thereof.
- prefilters or particle filters are typically used to remove heavy particles such as metallic or plastic chips and filings. With industrial coolants, this step removes metallic particles which, in combination with way oils, lead to sludge formation and subsequent occlusion of UV transmissible tubing or UV lamps in the system.
- Prefilters are preferably comprised of metal or plastic strainers that remove the larger and coarser particles present in the fluid (e.g. metallic or plastic particles, chips and shavings).
- Additional filters that can be used include composite fiber-mesh filters and the like.
- Mesh filters contain fibers of, for example, polyester, polypropylene, nylon, Teflon, Nomex, Viscose or combinations of these materials.
- Fibers have a wide variety of pore sizes (e.g. 2, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 75, 100, 125, 150, 175, 200, 300, 400, 500 micron) and are commercially available.
- a second stage filter such as, for example, a coalescent filter to remove additional contaminants.
- Coalescent filters contain fibers, structured with various pore sizes, that are adherent to the contaminant. Coalescent filters are commercially available that are adherent, for example, to the heavy way and hydraulic oils, such as tramp oils, common in industrial fluids.
- the combination of a particle filter and a separator removes sufficient amounts of contaminant particles and oils present in the coolant to allow for successful disinfection with ultraviolet radiation.
- An important advantage of this combination is that both live and dead bacteria are removed from the fluid which thereby reduces the requirement for the ultraviolet system to conduct all of the killing and at the same time.
- dead bacteria are an important nutrient source for bacterial growth
- removal of dead microbes is an important and previously unrecognized advantage.
- fluid flows from the separation system to the disinfection system.
- fluid is disinfected by treatment with ultraviolet radiation.
- Radiation may be applied from ultraviolet lamps submerged within the fluid or kept separated from the fluid.
- Submerged lamps generally require protection from the fluid such as a quartz jacket or coating that allows for a high transfer of UV radiation while preventing damage to the UV lamps.
- the disinfection system is a dry system where the UV lamps are placed in close proximity to, but not within the fluid. This allows for easy UV lamp replacement and heat generated from the UV lamps can be disseminated without damaging the fluid.
- ultraviolet treatment is applied at greater than about 12,000 microwatt seconds per cm 2 of radiation, preferably greater than about 20,000 microwatt seconds per cm 2 , and more preferably greater than about 40,000 microwatt seconds per cm 2 . In the absence of a minimum amount of contaminants, as determined by flow speeds, fluid can be successfully exposed to the killing effects of ultraviolet radiation.
- the invention possess many advantages. As ultraviolet radiation neither adds to nor detracts anything from the fluid, the process has no effect on the integrity of the fluid. A need for chemicals such as germicides and biocides, presently used in the disinfectant of fluids, is greatly reduced or completely eliminated. As biocides are themselves expensive and pose serious health risks to workers, the savings can be considerable. In addition, many chemicals are detrimental to the efficiency and integrity of the fluid. Consequently, use of the methods and apparatus of the invention greatly extends the useful life and/or shelf- life of the fluid. In addition, odors from contaminated fluid and some biocides can be fairly unpleasant. Use of the invention also reduces or eliminates such odors providing an improved air quality and working environment.
- bacteria counts acceptable to federal (e.g. EPA or FDA), state or local regulations and various other health fields can be set for a particular fluid.
- This process allows for the possibility of multiple passes with resident time in the UV system of exposure for seconds or minutes.
- EPA or FDA federal
- state or local regulations and various other health fields can be set for a particular fluid.
- This process allows for the possibility of multiple passes with resident time in the UV system of exposure for seconds or minutes.
- a bacteria count before coolant was processed through the oil separator and UV unit was approximately 10 3 to 10 6 microorganisms per ml. After a 24 hour cycle, the microorganisms count was almost zero.
- costs for the disposal of contaminated coolants and for coolant replacement are substantially reduced.
- chemical pollution to the environment is minimized or can be avoided where processes are available for recycling used fluids.
- coolants are heat transfer mediums or thermofors and may be in liquid or a gaseous form having the property of absorbing heat from the environment and transferring that heat effectively away from the source
- coolants are used in the transportation industry, the tool manufacture industry and in most every small to large manufacturing plant Coolants, as do most industrial fluids, come in a variety of colors such as gray, red, yellow, white, green and blue, and may be fairly thick in composition as compared to plain water
- Types of coolants include propylene and ethylene glycol and Dowtherm
- some coolants are anti-freezes such as, for example, propylene glycol
- coolants pick up a substantial amount of contaminants
- Substantial means that the level of contaminants are increased so as to shorten the normal useful life of the fluid due to their concentration and interference with coolant function and to the presence of an enhanced environment for microbial growth
- Particles such as metallic or plastic filings or iron or steel chips, typically accumulate on and in the machines being cooled. Particles such as microorganisms, insects, insect parts and other debris also collect in the reservoir and in the lines. These particles are all swept-up in the fluid flow
- Other contaminants include lubricating oils, pretreating oils, hydraulic fluids and way oils Lubricating oils have a low viscosity and, compared to way oils which are quite viscous, and fairly thin (i.e.
- Tramp oils i.e. renegade contaminant oil that gets into machine operations
- oils typically considered a type of way oil also accumulate in the fluid, as well as water which accumulates from condensation in the lines
- contaminant substances are sticky, adhere to the walls of pipes and the UV system components, and further encourage microbial growth, especially bacterial growth in the line and in the fluid reservoir.
- Such substances also bind bacteria to their molecular interface surfaces.
- these bacteria are removed during a physical separation step thereby reducing the requirement of the ultraviolet to be the sole bacterial control mechanism.
- coolant is subjected to filtration by passing the coolant through a prefilter to remove larger particles and debris.
- the prefiltered fluid is passed through a first stage filter that removes finer particulate matter.
- filters remove particles of greater than about 100 microns, preferably greater than about 50 microns, more preferably greater than about 25 microns and still more preferably greater than about 10 microns
- Other contaminants, such as way and other tramp oils are removed using one or more oil separators which are, preferably, dedicated to the removal of such contaminants.
- Coalescent filters comprise fibers with predefined pore sizes wherein the fibers are adherent to the contaminants. Such filters are commercially available (U.F.
- the pretreatment steps include a strainer step to remove particles of greater than about 100 microns, a centrifugation step to remove a large portion of the heavy oil contaminants, a prefilter step to remove contaminants of greater than about 25 microns, and a coalescent filter for removal of oil and small contaminants.
- the contaminant-reduced fluid can be successfully irradiating with a disinfecting amount of ultraviolet radiation such that any contaminants that remain do not interfere with disinfection of the coolant.
- the disinfecting amount of radiation depends on the flow rate and volume of the fluid being treated at any one moment
- radiation is administered at from at least about 15,000 microwatt seconds/cm 2 or more, depending also on the type of ultraviolet lamps, the ultraviolet transmissibility of the tubing, the orientation of lamps around the fluid- filled tubes and the structure of the tubing (e.g. flat verses rounded)
- the method is preferably a dry disinfecting system.
- the oil separator and the ultraviolet radiation generating system can be designed as modular units to further increase convenience and to reduce overall costs As such, the system can be operated continuously, subject to periodic maintenance for UV lamp changes or removal of accumulated contaminants, for a period of greater than one week, greater that one month, greater than one year or even longer
- All types of conventional radiation treatment can be administered to the contaminant-reduced fluid including treatment methods described in United States patent 4,798,702, for use of corrugated ultraviolet-transmissible tubing, United States patent number 4,971,687 and 4,968,891, for use of thin films, United States patent number 5,494,585 for use of a cavitation process, and United States patent numbers 3,527,940 and 4,766,312, for maximizing radiation treatment by passing fluids through a helical path.
- such radiation can include ionizing radiation, such as gamma radiation or x-rays in place of ultraviolet Thin films may be shaped by the structure of a portion of the ultraviolet transmissible tube
- the fluid may be guided into a thin film with a thickness of less than about 5 mm, preferably less than about 4 mm, and more preferably less than about 2 mm
- ionizing radiation such as gamma radiation or x-rays in place of ultraviolet Thin films
- substantially opaque fluids can disinfect about 1 mm to about 1.5 mm of fluid
- radiation transmitted from all sides of a 2 mm to 3 mm fluid flow can be disinfected
- thin films may be useful
- a wide variety of ultraviolet sterilization devices or self-contained units can be used with one or a plurality of ultraviolet lamps both within, between and surrounding the tubing Tubing and thus fluid exposure to the radiation can be optimized by creating an orientation pattern of UV lamps around the tubing with ultraviolet reflective surfaces directing the radiation toward the fluid ( Figure 1).
- Disinfection units placed within containers can be coated on the interior surfaces of housing 101 with reflective substances
- One or more UV lamps 103 and reflectors 102 can be positioned so as to maximize exposure of the fluid in tube 104 to the available radiation
- Reflectors can be coated with an ultraviolet reflective material such as, for example, an aluminum, a titanium or titanium nitrate based material, or a combination thereof
- the reflector is coated by a sputtering process whereby the coating material is deposited in a vacuum onto a solid support such as an aluminum or teflon surface
- UV lamps may be partially coated with UV reflector substances or UV blocking substances to direct energy output and/or prevent exposure of other surfaces to UV radiation
- Two types of reflection techniques are shown in Figure 2 In Figure 2, reflectors 201 and 202 are position in close proximity to UV lamp 207
- the reflector of Figure 2A comprises UV and heat resistant plastic reflector 203 to which is applied an aluminum coating by sputtering and retainer bump 204 at each end of the
- reflectors are known to those of ordinary skill including polished aluminum reflectors, described in United States patent number 4,534,282, reflectors mounted to the frame, described in United States patent number 3,634,025, elongated curved reflectors, described in United States patent number 4,766,321 and outward reflecting reflectors
- ultraviolet radiation can be directed to kill eukaryotic cells, bacterial cells, fungi and spores, virus particles and almost any living microorganism
- one of ordinary skill can choose to disinfect or completely sterilize the fluid. Sterilization is usually unnecessary for industrial fluids, but is often required to meet EPA or FDA guidelines for products regulated by government guidelines such as pharmaceuticals and animal products
- Industrial fluids typically contain between about 10 5 to about 10 9 bacterial per ml. Reduction of bacterial levels to at or less than about 10 3 is generally required to provide a safe and risk-free working environment as well as to extend coolant life.
- Treatment of contaminated fluid kills greater than 90% of the microorganisms in the contaminated fluid, preferably greater than 95%, and more preferably greater than 99% This reduces the bacterial load of the fluid at least about one log, preferably at least about 2 logs, more preferably at least about 3 logs
- Increased disinfection is possible to decrease the bacterial load of the fluid at least about 4 logs, preferably at least about 5 logs, and more preferably at least about 6 logs or more when necessary
- Treatment times vary depending on the volume of fluid being treated and the amount of contamination and the rate of fluid flow Therefore, treatment may be performed, for example, in a continuous system operated for months, weeks, days or hours to reduce the bacterial load to desired levels and to maintain such levels.
- Another embodiment of the invention is directed to a method for disinfecting a contaminated fluid flowing through a tubing system
- a minimum flow rate MFR
- MFR minimum flow rate
- the fluid is irradiated with a disinfecting amount of ultraviolet radiation
- contaminants included in the calculation of PC are those contaminants which are in a liquid state and not solids such as particulate matter
- a contaminated industrial fluid will typically contain a variable percentage of contaminating oil and an amount of solid particles. Only the volume percentage of oil would be used to determine the value for PC. From this value, the minimum flow rate that would prevent occlusion can be determined. However, as the percentage of contaminants in the contaminated fluid can be adjusted, the flow rate needed to prevent occlusion can also be adjusted. This would be useful in those instances wherein the level of contaminants would be so high so as to require a flow rate that would be impractical for the particular system. In such cases, some percentage of the contaminants can be removed and the flow rate reduced according to the equation.
- Another embodiment of the invention is directed to a method for disinfecting a fluid comprising establishing a turbulence in a fluid stream during irradiation.
- a turbulence As ultraviolet radiation cannot pass more than about 1 mm to about 2 mm into most opaque fluids, it is important to maximize exposure of the microorganisms in the fluid to ultraviolet radiation.
- Turbulence should be sufficient to provide a Reynolds number greater than that defining a laminar flow or greater than about 4,000.
- microbes By encouraging microorganisms to move transversely, microbes are brought to the surface of the fluid at the inner surface of UV-transmissible tubing 104 and not hidden within mid- sections of the tube. Passage of fluid and microorganisms within the fluid are moved from zones of no or low UV radiation to surface zones of high UV radiation. In this manner not only is killing effect magnified, but the turbulence creates a scouring effect within the tubing. Radiation can also induce oxidation of certain chemicals that may be present in the fluid which may add to both the scouring and killing effects.
- Tube sizes that guide the flow of turbulent fluid are not limited by the ability of UV radiation to penetrate the fluid.
- Tube diameters which can be utilized for this method may have a diameter of greater than about 4 mm, preferably greater than about 6 mm, and more preferably greater than about 10 mm or more.
- Tube sizes of greater than two inches, greater than three inches and even greater than four inches, typical in most industrial settings, are also applicable to this method.
- Turbulence-generating systems that encourage transverse motion include aeration systems that create gaseous bubbles within the tube
- air pump 301 pumps air into inner tube 302 which contains a large number of small holes 303 These holes allow the pressurized gas to escape from tube and generate fluid turbulence, transverse to fluid flow direction 304, within the lumen of the tube 305
- the gas does not interact with the fluid components
- Typical gasses that can be used for most fluids include, for example, air, carbon dioxide, oxygen, hydrogen helium, nitrogen, argon and combinations of gasses, any of which may be pressurized. In addition, this technique is not limited to gas.
- Liquids may be forced into the inner tube as well creating turbulence in the fluid as the liquid exits holes within the inner tubing walls.
- Liquids which can be used include the liquid itself, which may be the contaminated liquid or liquid that has been treated according to the invention, an inert liquid or another liquid that does not negatively interact with the fluid being treated
- the tube within a tube configuration preferably has a controllable pressure differential within the tubing.
- Turbulence can also be generated by suspending articles within the fluid stream such as, for example, ridges, helical vanes, impellers, baffles, projections, vanes, paddles, wheels, beads, cones or slotted cones, or almost any geometric structure.
- Such structures or turbulators or agitators may be on a string, free in the fluid or free, but confined in a section of the tubing
- bead 401 can be attached to string 402, which may be constructed of a metal such as steel or a composite polymer, and is shown both longitudinally and in cross-section. The beaded string is placed into the lumen of a tube along the direction of fluid flow.
- bead 401 is slightly smaller than the lumen of the tube. However, a variety of sizes may be utilized the only requirement being that they fit within the lumen and not cause an impractical or high head pressure in the system Combinations of these techniques may also be utilized.
- Another embodiment of the invention is directed to combinations of fluid disinfection treatments such as those described above Fluids may be treated with a combination of contaminant removal and turbulence generation followed by radiation treatments Such treatments may be further supplemented with conventional treatments such as, for example, filtration, centrifugation and the addition of biocides including anti-bacterial and anti-fungal agents.
- conventional treatments such as, for example, filtration, centrifugation and the addition of biocides including anti-bacterial and anti-fungal agents.
- biocides including anti-bacterial and anti-fungal agents.
- the combination is highly effective, the amount of biocidai agents that are added can be greatly reduced as compared to conventional methods
- the working environment would be improved due, in part, to the lack of noxious fumes caused by microbe- induced decaying fluid, and the lack of biocides and/or microorganisms, greatly improving air quality Health risks to workers are also greatly reduced
- Another embodiment of the invention is directed to an apparatus for disinfecting an industrial fluid
- the apparatus comprises a tubing system, an ultraviolet radiation-treatment system, a turbulence-generating system and/or a contaminant-separation system which, for example, may be specific for particles, microbes, oil or a combination of these contaminants
- the tubing system guides the passage of the industrial fluid at a determinable flow rate through the apparatus with the UV lamps separated from the fluid Tubing of the system is composed of ultraviolet- transmissible material such as, for example, a fluoropolymer, as described in United States patent number 4,798,702 Tubing which is useful for the tubing system should preferably be capable of withstanding pressures of greater than about 70 psi, and preferably greater than 150 psi, have a thickness of between about 20 to about 80, and more preferably 60, thousandths of an inch, and be transmissible to greater than 90%o of the ultraviolet radiation being applied
- a preferred type of tubing has been identified and is composed of tetrafluoroethylene-perfluoro (propyl vinyl ether) copolymer or, alternatively, perfluoroalkoxy polymer (Zeus Industrial Products, Inc , Orangeburg, SC) and fluo ⁇ nated ethylene propylene (FEP) (Product No 3E 750 SW 0, Zeus Industrial
- the tubing system may also comprise one or more inlet and outlet ports attached to opposite ends of a coiled tube
- the inlet ports allow for the flow of fluid from the line or the reservoir into the disinfection unit
- the outlet port allows for the flow of disinfected fluid back to the line such as a manufacturing or assembly line
- Tube surfaces may be smooth, furrowed, wrinkled, indented, transverse ridged or corrugated, and the tubing may be coiled, parallel, twisted, serpentine or in a helix at the point of radiation treatment
- Ultraviolet lamps can be positioned outside and inside the tubing configuration as well as between the tubes Tubing has a flattened to rounded cross section (e.g. oval)
- the system may be configured to create a thin film of fluid (flattened) at the point of radiation treatment to maximize radiation exposure
- the contaminant separation system should be designed to remove particulate and other contaminants from the fluid Particulate matter can be removed with filters having pore sizes designed to remove particles of greater than 100 micron, preferably greater than 50 micron, and more preferably greater than about 10 micron
- the contaminant separation system contains an oil separator which is designed to remove at least most of the oil from the fluid Examples of suitable types of oil separators include skimmers, centrifuges and coalescent separators Other unwanted liquids can be removed by a separation means particular to the type of liquid Such separation means are known to those of ordinary skill in the art.
- the apparatus also includes an ultraviolet radiation system
- the radiation system is comprised of one or more ultraviolet lamps in close proximity to the tubing system As the lamps do not come into direct contact with the fluid, the apparatus may be described as a dry system (i.e.
- the lamp does not come into direct contact with the fluid contained within the UV-transmissible tube
- fluid components are not subjected to unwanted heating from the UV lamps
- the UV lamps are not cooled by circulating fluid and, therefore, maintain a temperature high enough for optimum generation of UV radiation
- maintenance of lamps is minimized due to the separation of dirty or contaminated fluid from the lamp surfaces
- the energy imparted to the target fluid is proportional to the square of the distance of the UV lamps to the fluid, that distance should be minimized to maximize the amount of energy transmitted to the fluid
- the unit can be ventilated or air conditioned to prevent heat build-up as necessary to prolong the life of the UV lamps and so as not to damage the fluid
- the apparatus may also contain a turbulence-generating system to maximize exposure of the fluid to the radiation
- the turbulence-generating system should preferably be placed into the tubing wherein the fluid is exposed to the radiation
- turbulence-generating systems include structures attached to the walls of the tube or otherwise free-floating in specified areas of the lumen of the tube. Such structures include nearly any shaped article such as paddles, beads, cones, vanes, ribbons and the like, any of which may be slotted, and which may be fixed to tubing walls, attached to each other or attached to a string and suspended in the fluid.
- Fixed structures may be placed at set angles to the laminar flow of the fluid, preferably up to about 90°, such as, for example, about 20°, about 30°, about 45°, about 60° or about 75°.
- Other turbulence-generating systems include tube within a tube configurations that allow for a pressure differential, ultrasonic vibrations, split-flow systems or aeration within the fluid
- the apparatus may also contain circuitry appropriate for proper monitoring and control of all aspects of the apparatus The additional of computer control can also be utilized to create units that are completely or partially automated An example of one embodiment of the apparatus is shown in Figure
- the apparatus is contained within housing 501 which is on casters 502 and, consequently, quite mobile
- the basic unit contains pump and oil separator module 503, ultraviolet module 504 and electronics module 505 which may contain a fan, gauges reporting on the condition of the unit and/or the status of the fluid flow, indicator lamps and switches UV lamps 506 are positioned around a helical portion of tubing 507 to maximize UV exposure
- Reflectors 508 are positioned around UV lamps 506 Fluid enters through inlet port 509, travels through oil separator 510, tubing 507 and, disinfected, exits through outlet port 511
- the unit is dry modular in design, it can be used to disinfect many different types of fluids
- coolant to be disinfected is first treated by passing through a screen to remove metallic particles and other debris Coolant is next run through an on site commercial centrifuge to reduce contaminant concentrations to approximately two percent Coolant to be treated is drawn into the system by a pump mechanism
- the pump forces coolant into a filter vessel under pressure which contains a filter cartridge
- the cartridge will normally contain a 10 to 20 micrometer pore size which facilitates separation of the oil and binding of the oil to the fiber structure of the cartridge
- Such filtration performs the important role of removing large amounts of both living and dead bacteria Removal of the dead bacteria reduces nutrient loading in the fluid
- the differential pressure between the input and the output of the filter vessel is used to monitor the condition of the filter cartridge and can be read at the electronic module When the pressure reaches the specified differential, in most cases the greatest differential, the filter cartridge has filled with contaminant oil and must be replaced Rate of oil accumulation will vary depending upon the amount of oil in the coolant and the viscosity of the oil as well as the type of coolant.
- the fluid
- Another embodiment of the invention is directed to fluids treated according to the methods of the invention.
- Such fluids includes liquid which, after treatment, are substantially free of microbial contamination and, optionally, other contaminants as well as way and tramp oils, microbial particles and other particulate materials.
- Substantially free means that the population level of microbes has been reduced to a level that does not pose a risk to workers, resulting in an improved quality to the working environment
- Such fluids include machine tool coolants, machine tool lubricants, electro-discharge machine fluid, Zyglo, electro-coating fluid, chassis- washing fluid, top-coating fluids, sonic-bath fluids, spot- and steam- welding coolants, electron-beam and laser-welding coolants, test-cell waters for metal processing, plastic molding and forming coolants, quenching fluids, recycled and recirculation fluids and combinations thereof
- Other fluids including water such as potable water, water to be consumed in areas of suspected contamination, water supplies from natural or man-made emergencies, water used during military operations, third-world water supplies, livestock water and beverages such as, for example, flavored and plain water, flavored drinks and drink blends, vegetable, fruit and other juices, soft drinks, beer, wine and other liquors.
- Example 1 The Prototype Filtration/Germicidal System.
- a novel process has been discovered to treat coolant fluids with a combination of filtration and ultraviolet (UV) light exposure. This process has the ability to disinfect both opaque and transparent industrial coolant fluids and may eliminate or reduce the need of biocide treatments for microbial control.
- This technology uses ultraviolet irradiation, a technique proven for the treatment of waste water effluent, which is effective against a wide range of microorganisms The ability of the treatment to kill or control microorganisms under various operating conditions was determined
- the prototype filtration and germicidal system ( Figure 5) comprises two major operational modules, a variable-speed pump and filtering module (filter unit of module is a UF1 Filtration System, U F Strainrite, Inc , Lewiston, ME) and a germicidal module
- filter unit of module is a UF1 Filtration System, U F Strainrite, Inc , Lewiston, ME
- a germicidal module In operation, about 15 to about 20 gallons of fluids are required to fill the filtration module, and the filtering module has a minimum capacity or flow rate of about six gallons per minute
- the pump and filte ⁇ ng module and the germicidal module are controlled from a separate control panel (the electronics module), attached to the side of the germicidal module
- the ultraviolet output of the germicidal module can be adjusted by changing the number of ultraviolet generating lamps utilized For these experiments, a maximum of 8 lamps were used although the module was also capable of lower UV output settings by using 2, 4, 6 or 8 lamps
- the filtration module is capable not only of separating and removing tramp oil, but also of reducing the number of microorganisms present in used coolant Tramp oil contains high concentration of dirt and contaminants.
- Example 3 Testing of Model Unit LOl Using a Highly-Contaminated Coolant was performed at BioCheck Laboratories, Inc. (Toledo Ohio). Bacterial populations were monitored using membrane-filter and direct-plating technology as per Standard Methods (Standards Methods for the Evaluation of Water and Waste Water Vol. 19, published by American Public Health Assoc, 1994), and/or SaniCheck BF paddles (Biosan Laboratories, Inc.; Warren, Ml). Trypticase soy agar (TSA) plates were used to monitor bacterial growth.
- TSA Trypticase soy agar
- Results from the temperature monitoring and from membrane filtration/plate counting analysis of the coolant are shown in Tables 2 and 3, and Figure 6.
- the number of bacteria cultured from the coolant in the recycling reservoir decreased over 100,000-fold during the 24 hour course of the treatment. While the most effective killing rate occurred within the first hour of treatment, continued treatment was effective in further reducing culturable bacterial numbers.
- Coolant was sampled and analyzed before it returned to the reservoir. The results indicated that approximately 90% of the bacteria in the coolant fluid were eliminated by a single passage through the coalescer filter and UV chamber
- Run LI focused on bacterial survival in used coolant during cycling through the apparatus at a flow rate of 40 gallons per minute. This run was designed to determine if the high level of bacterial killing observed in Run I could be maintained at the maximum flow rate obtainable with the LOl unit.
- Temperature of the coolant in the reservoir and the temperature of the UV chamber were monitored during Run II.
- the temperature of the coolant increased during the course of the treatment (Table 4); however, throughout the test period, temperatures remained within operating parameters of the coolant.
- Fluid flow velocities that prevent occlusion of ultraviolet radiation transmissible tubing have been determined from empirical testing Increasing velocity of the fluid as a scouring force prevents occlusion as a function of viscosity of the components within the fluid
- the amount of oil that would need to be removed from an oil-contaminated fluid to avoid occlusion can be represented as a function of percent maximum fluid velocity in the UV system at a given tube diameter (Table 6)
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- General Health & Medical Sciences (AREA)
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- Hydrology & Water Resources (AREA)
- Environmental & Geological Engineering (AREA)
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- Food Science & Technology (AREA)
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Abstract
Description
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Priority Applications (1)
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AU37936/97A AU3793697A (en) | 1996-06-20 | 1997-06-20 | Apparatus and methods for the disinfection of fluids |
Applications Claiming Priority (2)
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US08/667,028 US6083387A (en) | 1996-06-20 | 1996-06-20 | Apparatus for the disinfection of fluids |
US08/667,028 | 1996-06-20 |
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WO1997048421A2 true WO1997048421A2 (en) | 1997-12-24 |
WO1997048421A3 WO1997048421A3 (en) | 2001-09-13 |
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US (1) | US6083387A (en) |
AU (1) | AU3793697A (en) |
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Also Published As
Publication number | Publication date |
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US6083387A (en) | 2000-07-04 |
AU3793697A (en) | 1998-01-07 |
CA2258865A1 (en) | 1997-12-24 |
WO1997048421A3 (en) | 2001-09-13 |
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