RELATED APPLICATIONS

[0001] This application claims priority from US provisional patent application

62/302,988 filed on March 3, 2016 and US provisional patent application 62/305,625 filed on March 9, 2016, both of which are incorporated herein by reference.

FIELD

[0002] This specification relates to grey water recycling.

BACKGROUND

[0003] US Patent 8,377,291 describes a water recycling system that can be used for reclaiming and recycling grey water to provide water for landscaping or sanitary facilities such as a toilet. The water recycling system includes a tank, an influx pipe with a filter screen, and a pump. The filter screen covers an opening in the bottom of the influx pipe. The part of the influx pipe containing the filter screen is sloped. At least some influent water passing through the influx pipe falls through the filter screen to be collected in the tank. Any excess influent water continues past the filter screen and flows through the influx pipe to an external sanitary drain. When filtered water is drawn from the tank for use, a portion of it is sprayed against the bottom of the screen to force material off the filter screen and into the influx pipe.

[0004] NSF/ANSI Standard 350 establishes effluent quality criteria for, among other things, onsite residential (single residence, up to 1 ,500 gallons (5700 L) per day) grey water treatment systems used to provide non-potable (i.e. toilet flushing) water. The influent test water has a TSS of 80-160 mg/L and CBOD ₅ of 130-180 mg/L, among other parameters. The effluent requirements include TSS of 10 mg/L or less and CBOD ₅ of 10 mg/L or less. The required BOD reduction is a difficult challenge, in part because the synthetic challenge water used for the test includes organics from shampoo, hair conditioner and soap as well as suspended solids and a small amount of residential wastewater.

INTRODUCTION

[0005] This specification describes a grey water collection and recycling system and process. The system and process are useful, for example, in collecting grey water from baths or showers or both (bathing water) for re-use in toilet flushing in a single-family residence. The following paragraphs describe various features of the system and process. However, a claimed invention may involve only a subset of the features in this summary, or a subset of features in this summary combined with one or more features in the detailed description to follow.

[0006] In a typical day, a household generates an excess of bathing water in the morning but uses a similar volume of water for toilet flushing throughout the day. The system described herein has two holding tanks to, at least in part, separate in time the collection of bathing water from the provision of toilet flushing water. This allows a relatively small membrane filtration unit to operate at low flux while still operating in a cycle of about 24 hours (i.e. up to 27 hours) or less. For example, the membrane unit may process grey water at a rate of 10-80 L/hr. However, the total volume of both tanks may be 500 L or less, preferably 400 L or less. The entire system can be provided in an integrated appliance sized package, preferably a packaged unit that is no more than two feet (610 mm) wide and no more than six feet (1830 mm) high. One exemplary system tested met NSF 350 standards for suspended solids and BOD removal.

[0007] In a process, influent bathing water is collected, optionally pre-filtered, and stored in a collection tank. Collected influent water is filtered through a membrane unit. The membrane filtration is not instantaneous, but the typical daily volume of bathing water generated in a single-family residence (for example 240 L or more, optionally 325 L, or more) is filtered through the membrane unit in about 24 hours (i.e. up to 27 hours) or less. The membrane permeate is stored in a permeate tank for delivery on demand for toilet flushing. Optionally, permeate is also treated with a sorbent and disinfected, i.e. oxidized.

[0008] A system described in this specification has an optional prefilter, a greywater collection tank, a microfiltration or ultrafiltration membrane, a sorbent media column, a permeate tank, a chemical dosing system and a control system. Optionally, the prefilter has an automated backwash cycle. Optionally, the membrane is located in the bottom of the collection tank, which may have a reduced cross section in an area surrounding the membrane unit. Optionally, the chemical dosing system may communicate with the permeate tank or the collection tank or both.

BRIEF DESCRIPTION OF THE FIGURES

[0009] Figure 1 is a schematic overview of a grey water recycling system in a house. [0010] Figure 2 is a schematic drawing showing an example of a grey water recycling system.

[0011] Figures 3A, 3B and 3C are front, side and isometric views of a membrane unit of the grey water recycling system of Figure 2.

DETAILED DESCRIPTION

[0012] Figure 1 shows a house 10 with a grey water recycling system 12. Grey water collected from a bathtub or shower 20 flows down grey water drain 22 to the grey water recycling system 12. The grey water recycling system 12 delivers treated water under pressure to a toilet 24 through a pressurized supply line 28. A waste drain line 30 connects the grey water system to a sanitary drain stack 32. Sanitary drain stack 32 is connected to a sewer, septic system or other wastewater treatment system in or outside of the house 10.

[0013] Figure 2 shows an example of a grey water recycling system 12. When installed, grey water inlet 40 is connected to the grey water drain 22 of the house 10.

Treated water outlet 42 is connected to pressurized supply line 28. Waste outlet 44 is connected to waste drain line 30.

[0014] As mentioned above, reclaimed bathing water from showers and baths enters the grey water recycling system 12 through a grey water inlet 40. Influent grey water passes through a pre-filter unit 46. The pre-filter unit 46 has a filter screen 48, which separates solids such as hair, soap pieces and other debris from the grey water. An integrated bypass tank 50 is connected to the grey water inlet and provides a volume in communication with and above the filter screen 48. If the filter screen 48 begins to clog, the bypass tank 50 will temporarily retain a volume of grey water. The bypass tank 50 thereby acts as a buffer to allow more time for the incoming grey water to pass through the filter screen 48. If the filter screen 48 becomes significantly clogged, grey water rises up to the top of the bypass tank 50 and may overflow to the waste outlet 44. As, or shortly before, the grey water overflows to the waste outlet 44, a water proximity sensor 50 sends a signal indicating that influent grey water is near the top of the bypass tank 50. After receiving the signal, the controller implements a filter screen 48 cleaning process. The controller is not shown in Figure 2 to simplify the figure. However, the controller is connected to all of the sensors and controlled devices (i.e. pumps and valves) of the grey water recycling system 12 as well as to an operator interface. [0015] Under normal operation, a flapper valve 54 is open. This allows incoming grey water to flow through the filter screen 48 and flow out of a pre-filtered outlet 56 of the pre-filter unit 46 to a grey water collection tank 60. When water is detected at the water proximity sensor 50, the controller waits for a predetermined period of time, for example 5 or 10 minutes, and then opens a backwash valve 58, (i.e. a solenoid valve). Backwash valve 58 is connected to the outlet of a main pump 62. Main pump 62 draws treated water from a permeate tank 64. Main pump 62 has an integrated pressure sensor on its outlet. Main pump 62 turns on whenever the outlet pressure drops below a preselected minimum, for example 30 psi, and turns off whenever outlet pressure exceeds a preselected maximum, for example 50 psi. Opening backwash valve 58 thereby causes a flow of pressurized water in backwash line 66. The pressurized water impinges against flapper valve 54 and causes flapper valve 54 to cover the pre-filtered outlet 56. Water then flows in a reverse direction through the filter screen 48 and overflows through the by-pass tank 50 to the waste outlet 44. Solids attached to the filter screen 48 are thereby removed from the pre-filter unit 46. After a predetermined time, the controller closes the backwash valve 58 to end the cleaning process. Optionally, a backwash waste connector 66 can be opened during the cleaning process to allow backwash water to flow to the waste outlet 44 without passing through the by-pass tank 50. Optionally, an air pump (for example air pump 82 described below) can be turned on and used to add air to the flow of pressurized water in backwash line 66. Optionally, the pre-filter unit 46 may be as described in US provisional application 62/302,988 filed on March 3, 2016, entitled Intake Filter for Water Collection System with Pressure Activated Backwash Valve, or a PCT application claiming priority to that application filed on the same date as the present application, both of which are incorporated herein by reference.

[0016] The pre-filtered water is stored temporarily in the collection tank 60. The grey water recycling system 12 may be designed for a typical single-family residence, for example with up to five inhabitants. Although water use varies, one frequent pattern is for bathing to peak in the morning, sometimes with a minor amount of bathing in the evening. Toilet flushing also has a morning peak, but is typically more evenly dispersed throughout the day compared to bathing. The permeate tank 64 is sized to hold at least enough treated water for a morning toilet flushing peak. The collection tank 60 is sized to hold the water generated during a morning bathing peak. This holding volume of the collection tank 60 is provided to reduce stress on a membrane unit 70 by allowing the membrane unit 70 at least a few hours, for example 3-8 hours or more, to process enough water to re-fill the permeate tank 64. In this way, the membrane unit 70 operates at a lower flux, which reduces fouling.

[0017] The membrane unit 70 may have, for example, ultrafiltration or microfiltration membranes. The membrane unit may be located in its own tank or immersed in the collection tank 60, preferably on or near the bottom of the collection tank 60. The collection tank 60 shown is shaped with a reduced horizontal cross sectional area around the membrane unit 70. This reduces a minimum holding volume required to ensure that the membranes are submerged in water at most times, or at least while permeating an otherwise frequently enough to avoid drying the membranes out.

[0018] Figures 3A, 3B and 3C show an example of a membrane unit 70. In this example, several flat sheet membranes 72 are oriented vertically in a membrane housing 74. Permeate collectors 76 separate the individual membranes 72, connect them to the membrane housing 74, and provide ports in communication with the inside of the membranes 72 for permeate removal. Aerators 78 are attached to the membrane housing 74 below the membranes 72 for use in cleaning the membranes 72. Optionally, the membranes may be made of PVDF for chlorine resistance.

[0019] Referring back to Figure 2, filtered water (permeate) is drawn through the membrane unit 70 by suction from a membrane pump 80, for example a peristaltic pump. Flux through the membranes may be in the range of 1-5 gfd (1.7 -8.5 L/m ² /hour). The membrane unit 70 can be cleaned physically cleaned periodically by one or more of relaxation, backwashing and bubble scouring. Preferably, relaxation or backwashing and bubble scouring are conducted simultaneously or at least overlapping in time, or with the bubble scouring directly follows backwashing. To provide relaxation, the membrane pump 80 is stopped. To provide backwashing, the membrane pump 80 can be reversed. Alternatively, backwashing can be provided by opening a valve, for example a solenoid valve, in a conduit connecting the outlet of the main pump 62 to the outlet of the membrane unit 70, which backwashes membrane unit 70 with fully treated water. Backwashing may be provided, for example, for 5-120 seconds every 15 to 240 minutes. To provide bubble scouring, the air pump 82 is turned on to deliver air to the aerators 78. Bubbles from the aerators 78 circulate grey water through the membrane unit 70 and scour the membranes 72. The bubbles may also break up a concentration polarization layer on the membranes 72.

[0020] A pressure sensor 84 at the bottom of collection tank 60 allows the controller to calculate the volume of water in the collection tank 60. The pressure sensor 84 also detects the addition of any new incoming water. A typical shower produces about 65 L of water. In a typical single-family residence, there are often three or more showers in a morning. The collection tank 60 is sized to hold at least a significant portion of morning shower water for processing later. For example, the collection tank 60 may have a volume of 150 L or more.

[0021] A purge pump 86 is installed at the bottom of the collection tank 60. As permeate is removed from the collection tank 60, water in the collection tank becomes concentrated. The collection tank 60 is purged from time to time to avoid over-concentrating the waster in the collection tank 60. The controller may determine that over-concentration has occurred, or is likely to occur, based on the cumulative amount of grey water collected since the last purge. When a new purge is indicated, the controller waits for a new input of grey water to be detected entering the collection tank 60, as indicated by an increase in pressure (and therefore the tank water level) detected by the pressure sensor 84. The controller then causes the purge pump 86 to pump water from the collection tank 60 to the waste outlet 44. The purge pump 86 may remove a predetermined volume of water or reduce the pressure (water level) in the collection tank to a predetermined amount. Purging water from the collection tank 60 prevents operation of the membrane unit 70 in overly concentrated greywater and thereby reduces fouling.

[0022] If no new grey water has entered the collection tank 60 for more than 48 hours, the controller turns on the purge pump 60 and empties the collection tank 60. Then, the transfer solenoid 90 opens to add the minimum volume of water required to submerge the membrane unit 70 within the collection tank 60, for example 20 L.

[0023] When new water is entering the collection tank 60, or water has remained stagnant in the collection tank 60 for more than 6 hours, the controller opens a collection tank chlorination valve 90 (i.e. a solenoid valve). Pressurized water delivered from the main pump 62 flows through a collection tank venturi 92. Reduced pressure in the collection tank venturi 92 draws chlorine (i.e. liquid laundry bleach) from a chlorine tank 94. The chlorine tank 94 is located below the collection tank venturi 92. The chlorine mixes with the flowing water and chlorine is transferred from the chlorine tank 94 to the collection tank 60. Alternatively, a dedicated chlorine pump can transfer chlorine from chlorine tank 94 to the collection tank 60 directly or indirectly. To provide an indirect transfer, chlorine can first be pumped from chlorine tank 94 and through a T-connection that is located in a line downstream of main pump 62, optionally replacing collection tank venturi 92. Following that step, the chlorination valve 90 is opened, which causes pressurized water from the main pump 62 to carry chlorine that was pumped through the T-connection to the collection tank 60. Adding chlorine to the collection tank 60 reduces the risk of biofilm formation in the collection tank 60 and on the surfaces of the membranes 72.

[0024] Periodically, for example once every 4 to 8 days, the collection tank 60 is hyper-chlorinated to clean the membrane unit 70. A hyper-chlorination cycle is preferably started when the water level in the collection tank 60 is low, for example than 40 L or less. The controller stops the permeate pump 80 and turns on the purge pump 86 to reduce the volume of water in the collection tank 60 to the minimum required to submerge the membrane unit 70, for example 20L. The controller then transfers sufficient chlorine to the collection tank 60 (using any method described above) to bring the chlorine concentration in the collection tank to 200 ppm or more, for example 300 ppm. The membrane unit 70 is soaked in the concentrated chlorine solution. The membrane pump 80 is then activated to draw chlorinated water through the membrane unit 70. Permeate produced during this time is directed to the waste outlet 44 by opening a waste permeate valve 96 (i.e. a solenoid valve). In an alternative method of hyper-chlorination, chlorine is transferred to the collection tank 60 and backwashed through the membrane unit 70 simultaneously, or partially simultaneously or sequentially. First, chlorine is injected into a line or manifold downstream of the main pump 62. Thereafter, opening a valve in a conduit connecting the outlet of the main pump 62 downstream of the chlorine injection to the outlet of the membrane unit 70 backwashes membrane unit 70. Opening chlorination valve 90 provides an indirect transfer of chlorine to collection tank 60 as described above. After cleaning the membrane unit 70 with the concentrated chlorine solution, the purge pump 86 is turned on to empty the collection tank 60. A transfer solenoid 90 is then opened to add enough water to the collection tank 60 to keep the membrane unit 70 submerged. Membrane pump 80 is then activated, optionally with the permeate valve 96 open, to flush water through the membrane unit 70 and permeate tubing. The permeate valve 96 is then closed if it was open and the grey water system 12 resumes the normal processing of incoming water. Particularly in the hyper-chlorination method in which the membrane unit 70 is backwashed rather than permeating, the permeate valve 96 may be deleted. In this case, after the membrane unit 70 is soaked in chlorine solution for the required period of time and the collection tank 60 is purged, the membrane pump 80 can be re-activated. A small amount of chlorinated water will be pumped into the next stage (adsorption unit 100 discussed below). [0025] The permeate flows from the permeate pump 80 to an adsorption unit 100.

Optionally, the adsorption unit 100 may have multiple adsorption columns in series. The adsorption columns may be U-shaped or otherwise configured to provide more contact time in a compact area. In an example, the surface loading in an adsorption column is 0.66 m/hr, and the total empty bed contact time is 156 min. Dissolved surfactants and other organics are adsorbed into the adsorbing media of the adsorption unit 100, for example activated carbon. Optionally, or if necessary, a vent with a valve such as a solenoid valve operable by the controller can be used to vent air from the adsorption unit. Air can be vented on a predetermined schedule, for example once every 15 to 120 minutes.

[0026] Treated water is collected in the permeate tank 64 after passing through the adsorption unit 100. When there is demand for water after a toilet 24 flushes, the main pump 62 senses reduced pressure at its outlet and turns on to send water from permeate tank 64 to the toilet 24. A second pressure sensor 102 reads the water level in the permeate tank 64. The permeate pump 80 turns on to deliver more water to the permeate tank 64 whenever the permeate tank 64 is below full capacity the water level in the collection tank 60 is above the membrane unit 70.

[0027] A permeation tank chlorination valve 106 (i.e. a solenoid valve) is opened periodically, for example once every 1-4 hours. This causes main pump 62 to circulate water from permeate tank 64, through a permeate tank venturi 104, and back to permeate tank 64. Water flowing in permeate tank venturi 104 draws chlorine from chlorine tank 94. Alternatively, a chlorine pump can be used to pump chorine from chlorine tank 94 into permeate tank 64 directly, or indirectly through a T-fitting replacing permeate tank 104 followed by opening permeation tank chlorination valve 106. Chlorine is thereby transferred from chlorine tank 94 to permeate tank 64 to disinfect the water in the permeate tank 64. The amount of chlorine added to the permeate tank 64 is determined by the controller considering, for example, the volume of new and stagnant water in the permeate tank 64.

[0028] A typical toilet uses 6-13 L per flush. The permeate tank 64 is preferably sized to hold enough water for a morning peak, for example 4 or more flushes. For example, the permeate tank 64 may have a volume of 25 L. However, a larger volume, for example 50 L or more, is preferable to reduce the chance of emptying the permeate tank 64. Further, permeate tank volume in excess of that required for a morning peak, for example 80 L or more, allows the membrane unit 70 to operate for a longer period of time overnight, which in turn reduces the required flux or membrane area. [0029] If the water level in the permeate tank 64 is less than a predetermined minimum, for example 10% of the permeate tank 64 volume or 8 L, a make up water valve 110 (i.e. a solenoid valve) opens. The make up water valve 1 10 is connected to a fresh water supply (not shown) for example a supply of municipal drinking water to the house 10. The make up water valve 1 10 is kept open until enough fresh water is added to bring the water level in the permeate tank back to a predetermined amount, for example 25% of the permeate tank 64 volume or 15 L. As discussed previously, the transfer valve 90 may open from time to time, for example to add water to submerge the membrane unit 70 after the collection tank 60 is purged after a membrane cleaning (hyper-chlorination) cycle. In some cases, this may cause the make up valve 110 to open and some make up water may flow into the collection tank 60.

[0030] In the example shown in Figure 2, a control system includes a controller (not shown), pressure sensors 84, 102 in the permeate and collection tanks, optionally one or more leak detection sensors, a plurality of solenoid valves such as 106, 58, 90, 110, and optionally 96 that can be opened/closed by the controller and pumps (main pump 62, membrane pump 80, purge pump 86, air pump 82 and optionally a chlorine pump) that can be turned on and off by the controller. The controller is programmed to perform various calculations. For example, the controller can calculate the volume of water in each tank 60, 64. The controller activates and ends chlorination, purging, and hyperchlorination (membrane cleaning) processes, optionally considering the volume of water in a tank 60, 64 and time passed from the previous cycle. The controller can detect clogging of the pre-filter and activate and end a process to clean the pre-filter. Optionally, the controller can also detect failures in the system (for example failures of a valve or a pump) and inform the homeowner to seek service.

Example

[0031] The effectiveness of a prototype grey water recycling system 12 as shown in

Figure 2 in meeting NSF 350 requirements was evaluated. The prototype included a submerged ultrafiltration membrane and a carbon adsorption column. The results suggested that NSF 350 requirements for CBOD5, TSS and turbidity were met using a combination of ultrafiltration and activated carbon adsorption. [0032] Synthetic NSF350 challenge water was prepared as per the requirements of

NSF 350 (ANSI/NSF 2014). Table 1 shows the ingredients of the challenge water. This challenge water is suitable for testing systems treating bathing water only.

Table 1

[0033] The challenge water was added to the collection tank. The treatment process included two steps: (1) membrane ultra-filtration and (2) carbon adsorption. The membrane unit included 10 flat sheet membranes with a combined surface area of 13 ft ² (1.2 m ² ). The sheets were made of PVDF membrane coated on a non-woven substrate. The membranes had a molecular weight cut-off (MWCO) of 75 kDa. The membrane unit was operated at a flux of 3 gfd (5 L/m ² /hour) and was immersed in the collection tank. A peristaltic pump (MasterFlex L/S, Cole Parmer) draws permeate through the membrane unit. The membrane permeate was passed through a 2-inch (51 mm) adsorption (activated carbon) column with an empty bed contact time of 13.5 min. The granular activated carbon was HydroDarco 3000 (Cabot Carbon) with a mesh size of 8x30 (falls through as screen with openings of US screen size 8 (2.4 mm) but remains on a screen with openings of US screen size 30 (0.6mm)).

[0034] Raw water samples were collected immediately after mixing the NSF350 challenge water and kept refrigerated before transporting to an analytical lab. Membrane permeate and adsorption column effluent was collected in pre-labeled sampling bottles, and instantly refrigerated. Triplicate samples were taken from the membrane permeate and the adsorption column effluent.

[0035] The water quality results in Table 2 show that combination of ultra-filter (UF) membrane and carbon adsorption can meet NSF 350 requirements. The membrane alone can reduce turbidity and TSS to the required values for NSF 350. In addition, the membrane removes 53% of CBOD5, but this is not enough to reach the standard requirements. The addition of an adsorption column reduces CBOD5 to less than 5 mg/L as well as providing further reduction in turbidity.

Table 2