FIELD OF THE INVENTION

The present disclosure relates to a flow dis- tributor, to a method for manufacturing a flow distrib utor, to a tank for treating fluid, and to uses of the flow distributor.

BACKGROUND OF THE INVENTION

Different flow distributing structures are used in various liquid-liquid separating or extraction pro cesses, for example in sub-processes of hydrometallur- gical recovery of metals after leaching of ores, or in oil-water separating operations such as bilge water cleaning or waste-water treatment. Each particular pro cess utilising a flow distributor requires a specific design of flow conduits and barriers to enable efficient separation of a desired fraction or phase from an unde sired one.

Typically, irrespective of the process, a flow distributor comprises plates, which can be stacked ver tically, or arranged horizontally or in a slanting manner relative to the flow of fluid in the process, so that passages or conduits are formed between individual plates to enable desired flow of fluid through the flow distributor. The plates are fixed together by separate frames and attached to tanks or other vessels with sep arate fixing structures.

For example, a flow distributor may comprise a panel with vertical linearly-spaced barrier elements with flow channels defined between the barrier elements, the construction being held together with horizontal barrier elements forming a frame for the flow distribu tor. All of the different structures are fixed together to form a specific flow distributor, the arrangement of which may not be later on changed. This makes such an ensemble quite complex and cumbersome. Instead of hori zontal barrier elements as frames, completely separate horizontal and vertical support members are known to be used, to which each barrier or slat need to be individ ually attached either fixedly or releasably, which makes assembling and maintenance of the flow distributor time- consuming and complicated.

Typically, once assembled, such flow distributor structures may not be easily repaired or taken apart, and replacing damaged or worn parts such as individual plates is difficult and costly. A flow distributor de signed and assembled for a certain process cannot be re assembled to accommodate changes in the process. Due to the corrosive and high-temperature environments in many of the aforementioned processes, the flow distributors may need to be manufactured from costly steel or other such durable material, which make them cumbersome and heavy .

In order to improve the versatility of flow dis tributors, and to facilitate their assembly and mainte nance, as well as make the flow distributor lighter and easier to transport and handle, the flow distributor may be made from interchangeable modules that are releasably connected to each other to form a desired design of a flow distributor according to the needs posed by the end use. The modules may be made of a light and inexpensive material such as PE by known extrusion methods.

OBJECTIVE OF THE INVENTION

The objective of the invention is to alleviate or eliminate at least one of the disadvantages of prior art solutions as mentioned above.

In particular, it is the objective of the inven tion to provide a flow distributor, advantageously man ufactured as a modular structure without a separate frame, with which the above-mentioned problems related to prior art may be alleviated. According to the inven tion, the flow distributor is compiled from modules that can be combined into a desired functional structure de pending on the end use of the flow distributor.

The flow distributor may be configured according to specific needs of the end use, and may thus allow very careful and detailed controlling of the fluid treatment operation .

Further, maintenance of the flow distributor may be facilitated as individual modules, that is, individ ual plates may be changed according to their specific level of wear or breakage, as each plate is releasably connected to each other to form the flow distributor.

Since the flow distributor according to the in vention does not comprise any easily corrodible materi als, the plates and the flow distributor may also be durable in use, thus reducing the need for maintenance operations .

In addition, installing the flow distributor ac cording to the invention into a fluid treatment tank may be simplified, as no separate installation structures are needed, as the plates are connected directly to each other, and the flow distributor may be arranged directly into the sidewalls of the tank via the end parts of the plates .

A flow distributor according to the invention may also be significantly lighter and cheaper than the stacked fences known from prior art, as it does not comprise a separate support structure.

By eliminating a separate support structure, the overall cross-sectional area of the flow separator may also be increased within the dimensional range of a tank container. Thereby, the efficiency of the fluid treat ment process may be increased. SUMMARY OF THE INVENTION

The flow distributor according to the current disclosure is characterized by what is presented in claim

1.

The method of manufacturing a flow distributor according to the current disclosure is characterized by what is presented in claim 21.

The tank according to the current disclosure is characterized by what is presented in claim 22.

The use of a flow distributor according to the current disclosure is characterized by what is present in claims 26 and 27.

A flow distributor is disclosed, comprising a number of vertically stacked modules; openings defining a fluid flow conduit through the flow distributor, the openings formed between at least some of the modules stacked adjacent to each other; and at least one sup porter. The flow distributor is characterized in that a module comprises a connector for aligning and releasably connecting a module to an adjacent module so as to form a vertical stack of interchangeable modules held to gether by the supporter.

According to another aspect of the invention, a method of manufacturing a flow distributor according to the invention is disclosed. The method is characterized by providing a number of modules; stacking the modules vertically according to the desired end use of the flow distributor; aligning and releasably connecting each module to an adjacent module with a connector; providing at least one supporter to hold the stack of interchange able modules together; and releasably securing the sup porter onto a topmost module and a bottommost module.

According to another aspect of the invention, a tank for treating fluid is disclosed, the tank comprising at least one flow distributor according to the invention.

According to a further aspect of the invention, use a flow distributor according to the invention as a dispersion depletor gate in a solvent extraction settler is disclosed.

According to a further aspect of the invention, use a flow distributor according to the invention as a coalescing fence in a loaded organic tank or an after settler is disclosed.

The advantage of the invention is that a flow distributor according to the invention may be configured according to specific needs of the end use. Further, individual modules of the flow distributor may be changed and/or replaced according to their state of wear or func tionality. The modules are light, durable and both easy and cost-effective to manufacture.

In an embodiment of a flow distributor accord ing to the invention, a module comprises a first end part and a second end part opposite the first end part, and a centre part extending between the two end parts.

In an embodiment, a connector is arranged on both end parts.

In a further embodiment, the connector com prises a first connecting part arranged on a top side of an end part, and a second connecting part arranged on a bottom side of an end part.

In an embodiment, a connector is arranged on the centre part.

In a further embodiment, the connector com prises a first connecting part arranged on a top side of the centre part, and a second connecting part arranged on a bottom side of the centre part.

In an embodiment, a first connecting part or a second connecting part of a module is formed as a recess.

In a further embodiment, a first connecting part or a second connecting part of a module is formed as a projection fitting into the connecting part, formed as a recess, of an adjacent module. In an embodiment, a module comprises an open ing, through which the supporter is arranged to extend along the height of the stack of modules.

In an embodiment, the supporter is releasably securable to a topmost module and a bottommost module.

In an embodiment, the flow distributor com prises two or more supporters extending through openings arranged into the modules.

In an embodiment, a module comprises a first end part, a second end part opposite the first end part, and a centre part extending between the two end parts; the end parts having a width smaller than the width of the centre part.

In a further embodiment, the thickness of the first end part and the second end part is greater than the thickness of the centre part.

In an embodiment, at least one module is an open module comprising at least one horizontal passage defin ing a straight fluid flow conduit through the stack of modules .

In an embodiment, at least one module is a flow directing module for altering the direction of the fluid flow through the flow distributor.

In a further embodiment, a centre part of the flow-directing module is angled in relation to horizon tal, and the angled centre part is arranged to divert the fluid flow from horizontal.

In a further embodiment, the flow-directing module comprises a vertical passage or a passage diver gent from horizontal defining a fluid flow conduit for directing the fluid flow.

In an embodiment, at least one module is a closed module for blocking the fluid flow.

In an embodiment, a topmost module in the stack of modules and/or a bottommost module in the stack of modules is an interlocking module for assembling and stabilising the stack of modules. In an embodiment, the modules are made by in jection moulding or rotational moulding.

An embodiment of the method according to the invention is characterized by injection moulding or ro tational moulding a module in a desired module form.

In an embodiment of the tank according to the invention, the tank comprises sidewalls with slots for receiving the flow distributor.

In a further embodiment, the slots are arranged to receive end parts of the modules of the flow distrib utor to retain the flow distributor in place within a flow channel of the tank.

In an embodiment, the tank is one of: a solvent extraction settler, an after-settler tank, a loaded or ganic tank, an oil-water separator.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention and constitute a part of this specification, illustrate em bodiments of the invention and together with the de scription help to explain the principles of the inven tion. In the drawings:

Figure 1 shows a three-dimensional presentation a flow distributor according to an embodiment of the invention,

figure 2 depicts a view the flow distributor of figure 1 as seen from the direction of fluid flow,

figure 3 is a vertical cross-section of a flow distributor according to an embodiment of the invention, along a line A-A as shown in figure 2,

figure 4a depicts a flow distributor according to an embodiment of the invention, as seen from above, figure 4b is a simplified three-dimensional presentation of an exemplary embodiment of a module of a flow distributor according to the invention, figure 4c shows a detail of a module according to the invention, and

figure 5 is a schematic presentation of a tank according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

A flow distributor 1 is depicted in figures 1 to 3. It comprises a number of vertically stacked modules 10 and openings 12, formed between at least some of the modules 20 stacked adjacent to each other. The openings 12 define a fluid flow conduit 13 through the flow dis tributor 1, i.e. a fluid flow 3 may be conducted through the flow distributor 1 via the openings 12, as well as any openings arranged into the modules 10. Such openings, for example a passage 120, 121, arranged into the modules 10 thus also form a part of the fluid flow conduit 13 through the flow distributor 1, i.e. by fluid flow con duit 13 is meant herein the total open area within the flow distributor 1 available for fluid to pass through the flow distributor 1, comprising both the openings 12 between adjacent modules 10 and any openings arranged into the modules 10. The flow distributor further com prises at least one supporter 11. In an embodiment, the flow distributor may comprise two or more supporters 11.

Each module 10 is interchangeable, which means that it is 1) releasably connected so as to allow for changing a damaged module to a new or repaired module by simply disconnecting the stack of modules and removing the modules that need changing, and 2) replaceable with a similar module or a different type of module according to the requirements place on the flow distributor 1 by the process in which it is used. The flow distributor 1 may thus be modified as many times as necessary either because of maintenance work or because changes in the process .

Each module 10 comprises a connector 14 for aligning and releasably connecting a module 10a to an adjacent module 10b, 10c so that a vertical stack of interchangeable modules 10 held together by the sup porter 11 is formed.

A module comprises a first end part 16a and a second end part 16b opposite the first end part 16b, and a centre part 16c extending between the two end parts 16a, 16b (see figures 4a, 4b) . Further, the end parts 16a, 16b comprise a top side 161a, 161b, and a bottom side 162a, 162b, respectively. The centre part 16c com prises a top side 161c and a bottom side 162c.

A connector 14 may be arranged on both end parts 16a, 16b. In an embodiment, the connector 14 comprises a first connecting part 14a, arranged on a top side 161a, 161b of an end part 16a, 16b, and a second connecting part 14b, arranged on a bottom side 162a, 162b. Alter natively or additionally, a connector 14 may be arranged on the centre part 16c. In an embodiment, the connector 14 comprises a first connecting part 14a arranged on the top side 161c of the centre part 16c, and a second con necting part 14b arranged on the bottom side 162c of the centre part 16c.

The first and second connecting parts 14a of a module 10a may be formed as recesses. Further, a first connecting part 14a or a second connecting part 14b of a module 10b may be formed as projections fitting into the connecting part 14a, 14b formed as a recess, of the module 10a, adjacent to module 10b, and to be connected with module 10b to form a stack of modules.

Thus, there are several options in the way the connectors may be arranged:

- a module 10 may have a connector 14 comprising a first connecting part 14a formed as a recess arranged on the top side 161a of the first end part 16a, and a second connecting part 14a formed as a projection ar ranged on the bottom side 162a of the first end part 16a; and a connector 14 comprising a first connecting part 14a formed as a projection on the fop side 161b of the second end part 16b, and a second connecting part 14b formed as a recess on the bottom side 162b of the second end part 16b. As several such modules 10 are stacked, adjacent modules are aligned and connected by arranging each projection to a respective recess in the adjacent module .

- a module 10 may have connectors 14 comprising a first connecting part 14a formed as recesses arranged on the top sides 161a, 161b of both end parts 16a, 16b, and further comprising a second connecting part 14b formed as projections arranged on the bottom sides 162a, 162b of both end parts 16a, 16b; or vice versa (having projections on the top sides and recesses on the bottom sides of the end parts) . Similarly to the first example, several such modules become aligned and connected by the connectors 14 when stacked on top of each other and the recesses and projections of adjacent modules connecting. The idea however, is that each module 10 in a stack of modules forming the flow distributor 1 will have an iden tical connector arrangement to allow aligning and con necting of modules.

- in addition, or as an alternative, to connect ors 14 arranged on the end parts 16a, 16b of the modules 10 in the above-described alternatives, also the con nectors 14 arranged at the centre part 16c may be simi larly arranged. 1) A connector 14 may comprise a first part 14a formed as a recess on the top side 161c of the centre part 16c and a second part 14b formed as a pro jection on the bottom side 162c of the centre part 16c, or vice versa; 2) if there are more than one connectors 14 on the centre part 16c, all of the connectors 14 may comprise a first part 14a formed as a recess on the top side 161c and a second part 14b formed a projection on the bottom side 162, or vice versa; or 3) some of the connectors 14 may comprise first parts 14a formed as recesses on the top side 161c and projections on the bottom side 162c, while other connectors 14 may comprise first parts formed as projections on the top side 161c and second connecting parts 14b formed as recesses on the bottom side 162c.

The number of connectors 14 may be chosen ac cording to the dimensions (length) of the modules 10, and the specifications of the process for which the flow distributor 1 is intended. The connectors 14, i.e. the respective and corresponding first and second connecting parts 14a, 14b of adjacent modules 10 may form form- locks or friction-locks when connected, to further as sist in the stacking and connecting of the modules 10.

A module 10 may further comprise an opening 15, through which the supporter 11 is arranged to extend along the height (H) of the stack of modules (see figure 2) . There may be more than one supporters 11, and in that case, there are equal number of openings 15a, 15b, each accommodating a supporter 11a, lib. The opening 15 or openings 15a, 15b may be arranged on the centre part 16c of a module 10, so that the supporter or supporters 11 run through the stack of modules 10 at the centre parts 16c of the modules 10.

Alternatively or additionally, an opening 15a may be arranged on the first end part 16a and an opening 15b on the second end part 16b of a module 10, and the supporters 11 thus running through the stack of modules 10 at the end parts 16a, 16b of the modules 10 (not shown in the figures) .

The supporter 11 or supporters 11a, lib may be secured in a releasable manner to a top module 10' and to a bottom module 10' ' to finalize the stack of modules 10 into a flow distributor 1. The securing may be real ized for example by a nut-and-bolt type of fixture, wherein the bolt is formed by grooving arranged at each end of a supporter 11, into which the nut may be at tached. The topmost module 10' and the bottommost module 10' ' may comprise recesses for accommodating the nut- and-bolt fixture or other releasable securing structure so that it does not protrude from the flow distributor 1, which may then be arranged into a tank so that it is flush with the tank bottom and/or tank roof (see figure 1) .

In yet another embodiment, alternatively or ad ditionally, the supporter may be arranged to encompass or surround, or partially encompass or surround, the stack of modules 10 to hold the stack together. An ex ample of such an embodiment could be a supporter bracket or belt arranged to contact each module 10 at a groove or cut-out arranged on the end faces of the end parts 16a, 16b of each module 10. The number and form of sup porters 11, 11a, lib may depend on the type of modules predominant in the flow distributor 1 or the use of the flow distributor in a particular process. The supporter 11 or supporters 11a, lib may be made of for example polyethylene (PE), stainless steel, polypropylene (PP) . Preferably, PE may be used. The chosen material may de pend on the process for which the flow distributor 1 is intended .

A module 10 may be an open module lOd, as shown in more detail in figure 4b. An open module lOd comprises at least one horizontal passage 120 defining a straight fluid flow conduit 13 though the stack of modules 10 and the flow distributor 1. An open module may have more than one horizontal passages 120, i.e. the open part of the open module lOd may be divided into several horizontal passages 120, for example because of manufacturing spec ifications, so that vertical dividers between the hori zontal passages 120 act as supporting structures during the manufacturing process of the modules, and/or when assembling the flow distributor 1.

An open module lOd may have different heights and thus horizontal passages 120 of different height, depending on the end use of the flow distributor 1 in which the module is arranged. An embodiment two differ ently dimensioned open modules lOd may be seen in figure 3, wherein the higher open module 10d' has a height significantly greater than the lower open module 10d' ' . A higher open module 10d' may have a height 2 to 10 times, for example 2,25; 4; 4,75; 5,5; 6; or 7,3 times, greater than a lower open module 10d' ' . Thus, also the horizontal passage 120 or horizontal passages 120 of the higher open module 10d' is equally greater than those of the lower open module 10d' ' , thereby enabling a greater fluid flow 3 through the module 10 and flow distributor 1.

The form of a module 10 is essentially an elon gated rectangle (see figures 4a, 4b) . However, in order to facilitate the installation/mounting of a finished flow distributor 1 into a tank 2, the first end part 16a and the second end part 16b have a width W _e smaller than the width W _c of the centre part 16c of the module 10. That way, when the modules 10 are arranged into a ver tical stack of modules 10, the finished flow distributor 1 will have readily formed integral structures with which the flow distributor 1 may be arranged and retained in the tank by the tank side walls, or specific receiving structures arranged at the tank side walls, and no ex ternal fixtures or other connectors are needed. Further, the centre part of the flow distributor can be made as wide as possible to allow efficient processes, without interference of any external structures.

Further, the thickness T _e of the first end part 16a and the second end part 16b is greater than the thickness T _c of the centre part 16c. The two end parts 16a, 16b may be identical in thickness and in width dimensions (see figures 4a, 4c) . In this kind of embod iment, fluid flow conduits 13 may be arranged both be tween two adjacent modules 10 (as stacking the modules so that the end parts 16a, 16b are connected via a con nector or connectors 14 will result in the less thick centre part to settle between the thickness of the end parts thus creating an opening for fluid flow conduit 13 both above and below the centre part 16c, in relation to a centre part 16c of any neighbouring or adjacent module 10), as well as within one single module (depending on its form as described in the following) . This way, the total area of the fluid flow conduit 13 may be in creased/maximized, which in turn may increase the sepa ration efficiency, for example in a loaded organic tank.

A module 10 may be a flow-directing module lOe, lOf. A flow-directing module is used for altering the direction of the fluid flow 3 through the flow distrib utor 1. In an embodiment, the centre part 16c of the flow-directing module lOe is angled in relation to hor izontal (see figure 3), and the angled centre part 16c is arranged to divert the fluid flow 3 from horizontal as it passes the flow distributor 1. In an alternative embodiment, a flow-directing module lOf comprises a ver tical passage 121 or a passage 121 divergent from hori zontal, the passage 121 defining a fluid flow conduit for directing the fluid flow 3 (see figure 3) .

A module 10 may be a closed module lOg. By closed herein is meant that, in the direction of fluid flow 3, the module has a solid front wall and/or back wall, which inhibits the fluid flow 3 from entering the module lOg. At the same time, either the front wall or the back wall may also be open while the other is closed to allow intake of fluid flow 3 into and/or output of fluid flow 3 out of the flow distributor 1.

Alternatively or additionally, a closed module lOg may have an open internal structure, that is, its centre part 16c may have a top side 161c and/or bottom side 162c that is open (a closed module lOg with an open top side is shown in figure 3) , so that for example by stacking several such closed modules lOg, a vertical passage for fluid may be formed within the flow distrib utor 1. The top side 161c or bottom side 162c of the centre part 16c a closed module lOg may be open so that the fluid flow may be directed via another type of module 10 out of the flow distributor 1.

Alternatively, a closed module lOg may be formed so that it is entirely closed, i.e. there are no open sides or walls, but a flow-directing form such as an angled, cambered or concave side is formed to enable the directing of fluid flow 3 into a desired direction/into an adjacent module 10. This kind of construction for a flow distributor 1 may be used as a DDG fence. An exem plary construction for a coalescing fence can be seen in figure 1. It is self-evident that a person skilled in the art may, based on this disclosure and his/her general knowledge, form a suitable flow distributor for any given end purpose by utilising the different modules described herein in a certain arrangement. The examples described and shown herein are only meant as general examples of possible flow distributor constructions/assemblies.

A module 10 may be an interlocking module 10', 10''. The topmost, interlocking module 10' in the stack of modules 10, and/or the bottommost, interlocking mod ule 10' ' in the stack of modules 10 is used for assem bling and stabilising the stack of modules. Further, a supporter 11 may be releasably secured to the topmost module 10' and/or bottommost module 10' ' to finalize the stack of modules 10 into a flow distributor 1.

The modules 10, lOa-g may be made by injection moulding or rotational moulding from polyethylene (PE) . Also other such light-weight and inexpensive materials suitable for the aforementioned moulding techniques are possible. By injection moulding or rotational moulding, a module may be formed in a desired module form of the above embodiments.

In an embodiment, a preform length of module may be formed by injection moulding or rotational moulding, and the preform then cut into a number of individual modules. For example, the open modules lOd may be manu factured easily and cost-effectively in such a manner. The modules may comprise auxiliary structures such as vertical support structures (as can be seen from figure 2) due to the manufacturing process, for example to prevent the preform length from buckling, collapsing, fracturing or breaking during the cutting of the modules. Such structures, however, do not affect the functional ity of the modules 10 in use in a flow distributor 1.

The modules 10 may be arranged in a vertical stack forming a functional flow distributor 1 according to end use requirements of the particular process for which the flow distributor 1 is intended.

A flow distributor 1 according to the invention may be manufactured and assembled as follows.

First, a number of desired modules 10 are pro vided, the form of individual modules and their arrange ment in the stack to be formed depending on the intended end use of the flow distributor 1. The modules 10 are stacked vertically according to the desired end use of the flow distributor 1, and aligned during the stacking as well as releasably connected to an adjacent modules or an adjacent module with a connector 14.

Next, at least one supporter 11 is provided to hold the stack of interchangeable modules 10 together, for example by arranging the supporter 11 through the stack of modules 10 via openings 15 arranged into each module 10, as described above.

Finally, the supporter 11 is releasably secured onto a topmost module 10' and a bottommost module 10' ' by a mechanical connection, for example by fixing a nut into grooving arranged at the ends of the supporter 11, or by a locking pin; or by a material forming connection such as by plastic welding.

A tank 2 for treating fluid may comprise at least one flow distributor 1 according to the present disclo sure, and as described above. The tank 2 may comprise sidewalls 21, into which slots 22 are arranged for re ceiving the flow distributor 1 (see figure 5) . The slots 22 may be arranged to receive the first end parts 16a and the second end parts 16b of the modules 10 of the flow distributor 1, so that the flow distributor 1 may be retained in place within a flow channel 23 of the tank 2. Thereby no external or additional retainers or fixing structures are needed to arrange the flow distributor 1 into the tank 2. The tank 2 may be for example a solvent extraction settler, an after-settler tank, a loaded or ganic tank, or an oil-water separator.

The flow distributor 1 according to the invention may be used as a dispersion depletor gate (DDG) in a solvent extraction settler, or as a coalescing fence in a loaded organic tank or in an after-settler.

For example, a flow distributor 1 for use as a dispersion depletor gate (DDG) in a solvent extraction settler, for separating an organic phase from an aqueous phase, may be formed of a stack of modules 10 so that an open module lOd is arranged as the top module right below a topmost module 10', to allow passage of fluid flow 3 comprising an organic phase. Below the open module lOd, a closed module lOg having an open front wall (open in the direction of the fluid flow 3) , or alternatively, a form allowing the direction of fluid flow 3 downwards, as explained above, is arranged. This topmost closed module lOg also has a centre part 16c with an open bottom side 162c but a closed top side 161c and a closed back wall so that fluid entering through the open front wall is directed downwards to an adjacent closed module lOg, which has closed front and back walls and an open bottom side 162c, directly below the topmost closed module lOg. A number of such latter-mentioned closed modules lOg are arranged in a stack until a lowermost closed module lOg, which has a closed front wall and an open top side 161c, as well as an open back wall for directing the fluid flow 3 out of the stack of modules and the passage formed by the internal open space of the stacked closed modules lOg, or, alternatively a form allowing the fluid flow 3 having a vertical direction to alter its direction back into horizontal. The stack is aligned and releasably connected by connectors 14, and finalized by a bottommost module 10''. The flow distributor 1 is assembled by ar- ranging at least one supporter 11 to hold the modules together. The supporter may be releasably secured to the topmost module 10' and the bottommost module 10''.

It is obvious to a person skilled in the art that with the advancement of technology, the basic idea of the invention may be implemented in various ways. The invention and its embodiments are thus not limited to the examples described above; instead, they may vary within the scope of the claims.