WO2024258901A1

WO2024258901A1 - Filtration apparatus and method

Info

Publication number: WO2024258901A1
Application number: PCT/US2024/033499
Authority: WO
Inventors: Steve C. Benesi
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-06-14
Filing date: 2024-06-12
Publication date: 2024-12-19
Anticipated expiration: 2025-12-14
Also published as: DK202570145A1; AU2024302824A1; FI20265010A1

Abstract

A filtration apparatus that can include a filtering device can include slurry bath agitation to provide a desired distribution of slurry on a filter element for improved filtration and drying. Embodiments can utilization one or more filter cake flapping mechanisms to fracture and/or reposition filter cake formed on filter elements during drying to enhance drying of the filter cake. A scraper and disc sector arrangement can also be utilized (or alternatively be utilized) to facilitate improved scraping that can reduce wear on the filter elements and improve scraping of filter cake off the filter elements as well.

Description

FILTRATION APPARATUS AND METHOD

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application No. 63/508,084, which was filed on June 14, 2023.

FIELD

The present innovation is directed to filtration systems, filter devices, processes for filtering particulate material from a slurry, and methods of making and using filter devices.

BACKGROUND

Filter devices are often used in mineral processing, processing of starch or chemical products, processing of agglomerated material, power generation applications, and other industries to remove solid materials from a slurry (e.g. a liquid having solid particulates entrained therein or a gas having solid particulates entrained therein). Examples of such devices can be appreciated from U.S. Pat. Nos. 6,409,929, 6,006,554, 4,330,405, 4,207,190, 4,152,267, 3,869,389, 3,471,026, 3,291,312, 3,250,396, and 1,538,980 and U.S. Patent Application Publication Nos. 2018/0326357, 2018/0071667, 2017/0341004, 2016/0121245, 2016/0074784, 2015/0266780, 2015/0184099, 2014/0346104, 2013/0161252, 2013/0008006, 2011/0131873, 2011/0011785, 2010/0115899, 2009/0139193, 2008/0314012, 2007/0017196, 2005/0067342, and 2004/0177471. Other examples of filter devices and mechanisms that can be used in such devices can be appreciated from my International Publication No. WO 2020/185484, my U.S. Pat. Nos. 7,011,741, 6,521,135, 6,491,817, 6,159,359, 5,477,891, 5,292,434, 5,059,318, and U.S. Patent Application Publication Nos. 2006/0102545, 2006/0027509, 2006/0283785, 2007/0256984, and 2022/0143536.

SUMMARY

A filter apparatus, filtering method, filtering device, and methods of making and using the same are provided to provide improved filtering operation to separate particulate material from a liquid that is within a slurry. Embodiments can be configured to provide improved operational efficiency in filtration of particulate material that also can provide improved drying and discharge functionality. Embodiments can be configured to provide greater output of filtration operation throughput as well as reducing maintenance downtime.

In some embodiments, a filtration device can be provided that includes a first disc that is rotatable about a shaft. The first disc can be positioned adjacent a slurry bath such that disc sectors of the first disc are insertable into slurry retained in the slurry bath. The disc sectors can each be configured to form one or more filter cakes comprised of solid particulate material of the slurry via rotation of the first disc about the shaft.

The filtration device can include multiple discs or a single first disc. Each of the disc sectors of a disc (e.g. the first disc) can include filter elements on opposite sides of the body of the disc sector so that opposite sides of each disc has a plurality of filter elements. Each filter element can include a membrane material, filter cloth material, or other filter media for retaining solid particulates within the slurry while allowing liquid of the slurry to pass through the filter element so that a filter cake can be formed on the filter element as the disc is rotated. In each revolution of rotation, each disc sector may be inserted into the slurry as the disc is rotated retained in the slurry bath and subsequently be rotated about an axis of rotation to move out of the slurry for dewatering, or drying and subsequent filter cake discharge (e.g. via a scraper, etc.).

The filtration device can also include at least one of: (i) a slurry agitation mechanism positioned in the slurry bath adjacent to at least one slurry shaping structure positioned to direct the slurry onto the disc sectors of the first rotatable disc such that the slurry from the slurry bath is directed onto each of the disc sectors when the disc sector is a lowest disc sector within the slurry bath during a revolution of the first disc; (ii) at least one nozzle positioned to inject at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is a lowest disc sector within the slurry bath during a revolution of the first disc; and/or (iii) at least one cake flapping mechanism positioned to contact the filter cakes during rotation of the first disc to fracture the filter cakes formed on the disc sectors of the first disc to aid drying of the filter cakes during rotation of the first disc.

In some embodiments that utilize at least one nozzle, the at least one nozzle can be positioned to pulse the at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc. In other embodiments that utilize the at least one nozzle, the at least one nozzle can be positioned to continuously inject the at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc. One or more conduits (e.g. tubes, pipe, etc.) can be positioned adjacent at least one nozzle to help provide a gas injection flow within the slurry of the slurry bath in some embodiments as well.

In some embodiments, the disc sectors can be pinwheel structured disc sectors. In some embodiments that utilize at least one cake flapping mechanism, the at least one flapping mechanism can be positioned between the first disc and a second disc to contact filter cakes formed on disc sectors of the second disc to consolidate, reposition interstices, and/or fracture the filter cakes as well as contact the filter cakes during rotation of the first disc to consolidate, reposition interstices, and/or fracture the filter cakes formed on the disc sectors to aid drying of the filter cakes during rotation of the first disc.

A process for filtering particulate material in a slurry is also provided. Embodiments of the process can include use and/or operation of an embodiment of the filtration device.

In some embodiments, the process can include rotating a first disc such that disc sectors of the first disc are insertable into slurry retained in a slurry bath and distributing slurry from the slurry bath onto filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in a tent distribution when the disc sector is a lowest disc sector within the slurry bath during a revolution of the first disc. The first disc can be rotated so that particulate material of the slurry is retained on the filter elements of the disc sectors to form filter cakes thereon for filtration of the slurry after the distributing of the slurry from the slurry bath onto the filter elements occurs.

Embodiments of the process can also include other steps. For example, some embodiments can include scraping the filter cakes off the filter elements of each of the disc sectors to discharge the filter cakes during the revolution before the filter elements are rotated into the slurry bath. The discharged filter cakes can be passed through a discharge chute, for example.

In some embodiments of the process, the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc can include (i) agitating slurry positioned in the slurry bath adjacent to at least one slurry shaping structure positioned to direct the slurry onto the disc sectors of the first rotatable disc such that the slurry from the slurry bath is directed onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc; and/or (ii) injecting at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc.

Embodiments of the process can also be performed to include fracturing the filter cakes during rotation of the first disc to fracture the filter cakes formed on the disc sectors of the first disc to aid drying of the filter cakes during rotation of the first disc. For example, the fracturing can be performed via at least one cake flapping mechanism positioned adjacent to the first disc to contact the filter cakes while the first disc is rotated and before the filter cakes are scraped off the filter elements. The contacting of the filter cakes can result in consolidation, repositioning of interstices, and/or fracturing of the filter cake while it is on the filter media to aid in drying of the filter cake. In some embodiments, fracturing of other filter cakes can also occur. For example, the process can also include consolidating, repositioning of interstices, and/or fracturing of the filter cakes during rotation of the first disc to fracture the filter cakes formed on the disc sectors of the first disc to aid drying of the filter cakes during rotation of the first disc and also consolidating, repositioning of interstices, and/or fracturing filter cakes during rotation of a second disc to fracture the filter cakes formed on disc sectors of the second disc to aid drying of the filter cakes during rotation of the second disc. The consolidating, repositioning of interstices, and/or fracturing can be performed via at least one cake flapping mechanism positioned between the first disc and second first disc, for instance.

In some embodiments, the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc can include injecting pulses of at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc.

In some other embodiments, the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc can include injecting of at least one continuous gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc.

These and other objects, aspects and advantages of the present invention will be better appreciated in view of the drawings and following detailed description of certain exemplary embodiments thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of filtering devices, filtration apparatuses, and embodiments of methods for making and using the same are shown in the accompanying drawings. It should be understood that like reference numbers used in the drawings may identify like components. Figure 1 is a schematic diagram of a first exemplary embodiment of a filtration system 1 having at least one filter apparatus.

Figure 2 is perspective view of a first exemplary embodiment of a filter apparatus.

Figure 3 is a schematic view of the first exemplary embodiment of the filter apparatus.

Figure 4 is another schematic view of the first exemplary embodiment of the filter apparatus.

Figure 5 is a schematic view of a second exemplary embodiment of the filter apparatus.

Figure 6 is a schematic illustration of an exemplary embodiment of a cake flapping mechanism CF that can be utilized in embodiments of the filter apparatus.

Figure 7 is another schematic view of an exemplary embodiment of the filter apparatus.

Figure 8 is another schematic view of an exemplary embodiment of the filter apparatus.

Figure 9 is a flow chart illustrating a first exemplary process for filtering particulates from a slurry.

Figure 10 is a schematic top view illustration of an exemplary embodiment of a cake flapping mechanism CF that can be utilized in embodiments of the filter apparatus.

Figure 11 is a schematic top view illustration of another exemplary embodiment of a cake flapping mechanism CF that can be utilized in embodiments of the filter apparatus.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Referring to Figures 1-8 and 10-11 a processing facility can include a filtration system 1 that has one or more filtering devices 10, which can also be referred to as filtration devices 10. The filtration system 1 can utilize a slurry-based system for recovering minerals or other desired solid particulates (e.g. particular type of rock or ore or a collection of different solid particulates, recovery of filtrate as valuable product, tailings, etc.). For example, the solid particulates within the slurry can have base metal concentrates, iron ore, chromite, copper, gold, cobalt, nickel, zinc, lead, pyrite, silver, or and/or other solid material. As another example, the solid particulates can include starch, food product additives, precipitates formed from a chemical process, or be another type of solid material entrained within a fluid that is desired to be removed from the fluid.

In some embodiments, the filtration system 1 can utilize a tank 3 that is positioned to form a slurry or adjust a concentration of solid particulates within the slurry so the slurry has a concentration of solid particulates that is within a pre-scribed range (e.g. a preselected range). In some embodiments, the tank 3 can be configured a process slurry control tank or a slurry control vessel. The slurry from within the tank 3 can be fed via a slurry feed conduit 5 so the slurry is transported from the tank 3 to a mixer unit 7 or a slurry filter tank, which can have at least one mixer unit (e.g. at least one mixer, agitator, stirrer, etc.). The slurry feed conduit 5 can be structured as piping, tubing, or other type of conduit and can include one or more valves or other flow control mechanisms.

The mixer unit 7 can have at least one agitator 7a that is moved to stir or otherwise agitate the slurry within the mixer unit 7 for subsequently feeding the slurry to one or more filtration devices 10. The mixer unit 7 can be configured as a mixer or other type of slurry collection and agitation mechanism. In some embodiments, the mixer 7 can have agitators 7a that are configured as impellers for stirring the slurry and driving output of the slurry to one or more filtration devices 10. A filtration device feed conduit 9 can be a pipe, tube, or other type of conduit that extends from the mixer unit 7 to the filtration devices for transporting the slurry from the mixer 7 to the filtration device(s) 10. It should be appreciated that the filtration device feed conduit 9 can include valves and have sensors attached thereto or positioned therein. One or more of the devices of the filtration system 1 can have sensors connected to at least one controller (e.g. a programmable logic controller (“PLC”), etc.) as well as other process control elements. For instance, the slurry feed conduit 5 can have a control valve 5a that can be opened and closed to control a rate at which slurry from the tank 3 is fed to the filtration devices 10 via the mixer 7. The control valve 5a can be fully opened, partially opened, or closed to adjust the rate at which slurry is fed to a slurry bath 14 and/or a density of the slurry that is to be within the slurry bath 14 being fed via the slurry feed conduit 5. The filtration system 1 can also include a specific gravity sensor 5b and a flow sensor 5c connected to the slurry intake conduit 5 for measuring the flow rate and specific gravity of the slurry to monitor those process variables and control them so the flow rate and specific gravity of the slurry are within a pre-selected specific gravity range and a pre-selected flow rate range. These parameters can be adjusted or otherwise controlled for controlling the slurry level and slurry density within the slurry bath 14. For instance, the pre-selected ranges for flow rate and the slurry specific gravity can be defined by user selected set-points that account for a particular filtration system design, the material to be filtered, and other design criteria and operational criteria. An automated process control system can be connected to the control valve 5a, specific gravity sensor 5b, and flow sensor 5c to monitor and control operations of the filtration system 1. Other filtration system mechanism (e.g. mixer 7, filtration devices 10, mixer output conduit 9, tank 3) can also have one or more sensors and/or valves included therein connected to at least one controller of an automated process control system of the filtration system.

In some embodiments, the filtration system 1 can be configured so it does not utilize a mixer unit 7. For example, some embodiments of the filtration system 1 can connect the tank 3 to a single filtration device or a plurality of filtration devices via a slurry feed conduit 5 that extends from the tank 3 to the filtration device(s) 10. The slurry feed conduit (as well as tank 3 and the filtration device(s) 10) can include at least one valve and one or more sensors connected to at least one controller of an automated process control system of the filtration system 1.

The filtration device(s) 10 of the filtration system 1 can best be appreciated from Figures 2-5 and 7-8. For example, each filtration device 10 can be configured as a rotary filter having an array 20 of discs 20b supported by bearings on a frame 16. The discs 20b can be positioned to be rotated via rotation of the shaft 25 to which the discs 20b are connected so that disc sectors 20a of each disc pass through a reservoir of the slurry bath 14 during a full revolution of the disc 20b as that disc rotates. For instance, in some embodiments, the array 20 of discs 20b can be rotatable about a horizontally extending shaft 25 having a first end, a second end, and an intermediate portion between its first and second ends. A drive mechanism can be attached to a shaft 25 about which the array 20 of discs 20b rotates to drive rotation of the shaft to rotate the discs 20b. The drive mechanism can include an electric motor, a gear box, or other type of shaft rotating drive device.

The frame 16 of each filtration device 10 can be connected to a hood so that the array 20 of discs 20b is fully enclosed within a housing. The hood can permit the enclosed space in which the array 20 of discs 20b and slurry bath 14 are positioned. This can permit embodiments of the filtration device 10 to be operated at a desired pressure or temperature in the event operations can be improved by operating under a vacuum condition, operating at a pressure that is higher than atmospheric pressure, or operating at a controlled atmosphere. For example, inert gas steam or other gas can be passed into the space within the hood to define a desired atmosphere in which the slurry bath 14 and array of discs 20b are positioned. As another example, the temperature and pressure of the inner space defined by the hood can be maintained within pre-selected temperature and pressure ranges.

The hood can also help avoid contaminant material from a plant environment in which the filtration system 1 is positioned from entering the slurry bath 14 or discs 20b of the array 20. It should be appreciated that some embodiments of the filtration device 10 may not include a hood. Such embodiments may be configured as an open system that operates at atmospheric pressure and temperature conditions (though certain flows fed to the array 20 of discs 20b may be at different temperatures or pressures).

The frame 16 can also support a slurry overflow tank 12. The slurry overflow tank 12 can be positioned adjacent the slurry bath 14 (e.g. around a periphery of the bath) and can be in fluid communication with the slurry bath 14 to receive overflow of the slurry bath 14 (e g. a flow of slurry that may rise over the upper edges of the slurry bath 14).

The array 20 of discs 20b can be configured and positioned so that as the array 20 of discs 20b rotates, filter elements 2f of disc sectors 20a of the filter discs 20b are submerged within a slurry bath 14 adjacent a bottom of the array 20 of discs 20b as the discs 20b are rotated. Each revolution of a disk can result in each of the disc sectors being at least partially submerged in the slurry of the bath 14 and subsequently passed out of the slurry bath for undergoing drying and filter cake discharge. The filter elements 2f can be the filter media of each disc sector 20a.

Filter media can be attached to each disc sector 20a so that a first side of each disc sector 20a has filter media on an outer face of that first side and a second side of the disc sector 20a that is opposite the first side also has filter media on an outer face of that second side. The filter media of the first side can face away from the filter media of the second side and the filter media of the second side can face away from the filter media of the first side so the filter media of these sides are on opposite peripheral sides of the disc sector. Each disc sector can have a cavity defined therein between the first side and outer side (and between the filter media of the first side and filter media of the second side).

The array 20 of discs 20b can include a number of separate peripheral discs 20b that each have an array of disc sectors 20a that are attached to define the disc 20b. The disc sectors 20a can include frames that are sized and configured to attach filter elements to the disc 20b. Each filter element can include filter media, which can be structured as a mesh or web material that has an array of passageways a sized to permit the fluid of the slurry (e.g. liquid or gas) to pass through the filter element while also retaining solid particulate material entrained within the slurry on the filter element so that an accumulation of the solid particulates forms a filter cake on the filter element. The filter elements 20f can include ceramic material (e.g. a sintered alumina filter media), a cloth filter material, or a filter element that includes a metal wire mesh body that is at least partially coated on an outer surface with a layer of filtering material that includes particulate material cured onto the outer surface of the mesh body via a binder (e.g. a polymeric material, an epoxy, polyurethane, other type of binder as discussed herein, etc.). Examples of such filter elements and filter media can be appreciated from my U.S. Patent Application Publication No. 2022/0143536, the entirety of which is incorporated by reference herein.

Slurry that can include a liquid having solid particulates entrained therein can be fed from the filtration device feed conduit 9 into the slurry bath 14. An agitator 14a can be positioned in the slurry bath to stir or agitate the slurry within the bath to help keep the solid particulates within the slurry entrained therein to help avoid the solid particulates collecting on the bottom of the bath. The agitator 14a can be structured as an impeller, a sweep mixer, or other type of agitation mechanism. An injection of a gas (e.g. air) can be provided in combination with such agitation to help provide a directed flow of slurry onto disc sectors 20a during the insertion phase to help improve the distribution of slurry on the disc sector to facilitate improved fdter cake formation and more efficient drying of that filter cake as well by reducing an amount of the overall rotational path that is for the insertion phase so that the drying phase can be a larger extent of a revolution.

During operation, the array 20 of discs 20b can be rotated at a pre-selected rotational speed. The pre-selected rotational speed can be in the range of 0.5-10 revolutions per minute (RPM), 1-10 RPM, 0.5-8 RPM, or 1-8 RPM for some embodiments. Many embodiments can operate at a relatively high rotational speed of over 1 RPM, which can provide for a significant increase in operational capacity and efficiency.

The array 20 of discs 20b can be rotated so that the filter discs 20b of the array 20 that have disc sectors 20a are inserted into the liquid slurry of the slurry bath to collect the slurry. About 15°-180° of the 360° rotation of the array 20 of discs 20b can be the extent of the rotation path that involve a disc sector 20a being within the reservoir of the slurry bath 14 for collecting the slurry in a slurry insertion/collection zone or phase of the revolution. For example, some embodiments can be configured so that a disc sector 20a of each disc is within the slurry bath for 15°-45°, 30°-60°, 45°-90°, or 30°-120° of the 360° rotation of the disc sector 20a of the disc 20b for a single revolution of the disc sector 20a of the disc 20b.

It should be appreciated that the extent to which a disc sector 20a is within a reservoir of the slurry bath for the insertion phase can be affected by the height of slurry within the reservoir of the slurry bath 14. Some embodiments of the filtration device 10 can be configured so that the slurry bath has a low overflow position OL (e.g. the slurry is at a lower height and is relatively far away from the rotational axis AX of the discs 20b as compared to embodiments having a slurry bath at a higher overflow position OH). When the slurry bath has a lower height of slurry (e.g. a lower overflow position OL), the insertion phase may extend for a short duration of a single revolution as compared to when the slurry bath has a higher height, or a higher overflow position of slurry therein. This can also affect the extent to which a drying phase may be present in a single revolution (e.g. with a lower overflow position, the drying phase may make up a larger portion of a revolution as compared to embodiments utilizing a slurry bath with a higher overflow position).

As the array 20 of discs 20b continues to rotate in a single revolution after exiting the slurry bath 14, the disc sectors 20a of the discs 20b can pass through a spraying zone (or phase) in which at least one fluid is sprayed onto the disc sectors 20a to facilitate washing, treating, and/or separation of the solid particulates from the fluid of the slurry. The spraying zone or phase of a revolution of the array 20 of discs 20b can be an optional aspect and may not be necessary for operations due to the solid particulates being filtered and the composition of the fluid of the slurry.

After the optional spraying zone or phase of the revolution of the discs 20b (or immediately after the disc sector 20a passes out of the slurry bath 14 when the spraying is not needed or used), the disc sector 20a can undergo a drying zone or phase during a revolution of the discs 20b at which the liquid of the slurry drains from the disc sector and the solid particulates retained by the filter element are dried due to gas flow (e.g. air flow or gas flow within a controlled atmosphere surrounding the discs 20b within a space at least partially defined by a hood, etc.) from the speed at which the array 20 of discs 20b rotates (which can be further facilitated by application of a vacuum). The drying phase can range from 3O°-33O° of the 360° rotation of the discs 20b about the horizontal shaft 25 or a horizontal axis. During the drying phase, the cavities of the disc sectors may have a vacuum applied to help facilitate drying.

As discussed herein, fdter cake formed on the disc sectors 20a can also undergo cake flapping, or cake contacting via at least one cake flapper. Such cake flapping can help fracture formed filter cakes on the disc sectors 20a and/or reposition filtered and partially dewatered solids that form compressed filter cakes on the filter elements 20f to facilitate improved drying during the drying phase.

The final phase of the revolution that the disc sectors 20a can undergo during a single revolution of the array 20 of discs 20b is the scrape/discharge zone or phase that occurs in a revolution after the drying or dewatering phase. In this final phase, the dried (or mostly dried) filter cake formed on the filter elements 20f of the disc sector 20a is scraped off the filter element(s) and/or otherwise removed from the filter element(s) and distributed to a discharge chute 29 supported on the frame 16 to transport the solid particulates to another processing device that is downstream of the filtration device 10. The scrape/discharge zone or phase of the rotation of the disc sector 20a in a single revolution can be less than 1°, up to 1°, up to 5°, or between 0.25°-5° of the 360° rotation of the disc sector 20a of a disc 20b. In other embodiments, the scrape/discharge zone can be up to 10°, between l°-10°, up to 15°, up to 20°, or up to 30° of the 360° rotation of the disc sector 20a of a disc 20b that rotates about the horizontal shaft 25 or a horizontal axis. Each disc sector 20a can pass through these phases during a single revolution of the discs 20b of the array 20. A vacuum can be applied to the cavity of the disc sector while it passes through the discharge zone to facilitate the removal of filter cake off of the filter elements (e.g. off the filter media) for passing to the chute. A scraper 31 can also (or alternatively) be utilized to facilitate scraping off of the filter cakes from the outer surfaces of the filter elements of the disc sector 20a when the disc sector 20a passes through the scrape/discharge zone or phase of the rotation of the disc sector 20a during a full revolution of rotation of the disc sector 20a. The scraper and discs 20b can be arranged and configured so that a distal edge of the scraper is configured to first engage an inner end of a filter element 20f of the disc sector 20a during the scraping phase or contact an inner end of filter cake formed on the filter element 20f during the scraping phase. Rotation and configuration of the disc sector 20a can be configured so that the disc sector is moved along the scraper so that the distal edge of the scraper is the first part of the scraper to contact the filter cake at its inner edge 20i location and subsequently the scraper 31 can move along the filter element 20f outwardly to contact the entirety of the filter cake formed on the filter element in an inward position to outward position motion caused via the rotation of the disc 20b and disc sector 20a. The upper portion of the outer edge 20o of a filter element 20f can be the final portion of the filter element 20f that is scraped in such a motion and a part of another filter element’s inner edge 20i portion can be scraped at the same time the upper outer edge 20o portion of a lower filter element 20f is scraped. It has been surprisingly found that this scraping path can provide improved scraping performance that can also minimize vibration and wear on disc sectors 20a during the scraping operation.

After the scrape/discharge phase, the disc sectors 20a of the discs 20b return to the slurry insertion/collection phase and continue to repeat the cycle of phases as the discs 20b rotate about the shaft for further revolutions. It should be appreciated that for each revolution, a disc sector 20a can go through all of these phases (slurry insertion phase, optional spraying phase, drying phase, and scrape/discharge phase in sequence).

As may best be seen from Figures 3-5 and 7-8, embodiments of the filtration device 10 can include an agitator 14a that is positioned in the slurry bath below the top surface of the slurry n the slurry bath 14 to agitate the slurry. The slurry can be agitated via shaping of the blades of the agitator 14 and/or use of gas injection flows (IGP) to direct the slurry within the bath onto a filter element to provide a tent-like distribution 15 of slurry on a lowermost filter element 20f of a disc sector 20a. This type of distribution 15 (e.g. a triangular shaped distribution, a filter element shaped distribution that has a shape that is similar to and/or matches the shape of the filter element, etc.) can be referred to as a tent distribution 15. In some embodiments, the tent distribution 15 (which can also be called a tent-like distribution 15) can be formed by providing a directed wave of slurry so that adjacent filter elements are not in contact with slurry or have a minimal contact with the slurry while the lowest disc sector receives the distribution 15 of slurry thereon. Such a distribution effect can permit the drying phase to start sooner so that the insertion phase takes less time and involves less of the rotational path of a single revolution so that more moisture from the filter cake to be formed on the filter element 20f can be removed during the drying phase.

The tent-like distribution 15 of slurry can be provided by shaping of blades of the agitator, the rotational speed of the agitator, and injection of flows of gas IGP via one or more nozzles 14i positioned in the slurry bath for injection of gas therein. The injected gas can be air or other gas and can cause bubbling or turbulence within the slurry bath 14 to direct the slurry onto the filter elements in a tent-like distribution or wave-like pattern during rotation of the disc 20b to provide the tent-like distribution 15 of slurry on the filter element 20f during the insertion phase for each disc sector 20a. Slurry shaping structure SS can also be positioned in the bath 14 and/or adjacent to the bath 14 to help guide the slurry from the slurry bath into the tent-like distribution 15 on a filter element during its insertion phase of a revolution of the disc 20b. In some embodiments, the injection of air or other gas IGP via nozzle(s) 14i can be passed through conduits 37 positioned in the slurry bath 14 that are in communication with the slurry of the slurry bath so that the injected gas is passed through the conduits to propel the slurry along with the gas in desired directions for forming the tent-like distribution 15 of slurry on the filter element 20f during the insertion phase of a revolution of the disc for that disc sector 20a of the filter element 20f. The conduits 37 can be pipe segments, tubes, pipe, or other type of annular structure or shaped structure that can help define a path of travel for injected gas while also retaining slurry therein so the injected gas can directly affect the slurry and force the slurry into a desired position. The angular position of the conduits 37 and/or outlet of the nozzles 20i can be adjustable within the slurry bath 14 via their connection to the slurry bath 14 to permit such positions to be adjusted as may be needed for forming the desired tent-like distribution as well.

Embodiments can also include slurry shaping structure SS attached to the slurry bath 14 and/or positioned adjacent the bath 14 to facilitate the direction of slurry onto the lower-most disc sector during the insertion phase in the tent-like distribution 15. The slurry shaping structure SS can include one or more members (e.g. a pair of plate members, a pair of distributor members, at least two corresponding guide members positioned on opposite sides of the agitator 14 above the slurry bath or in an upper portion of the slurry bath 14, sloped guide members, guide members shaped for directing the slurry onto the fdter elements 20f when they are at their lowest position during the insertion phase to help provide the tent-like distribution 15, etc.) positioned adjacent the disc 20b and slurry bath 14 to direct the slurry being agitated via agitator 14 and/or gas injection flow(s) IGP to guide the slurry onto the lowermost filter element 20f in a tent-like distribution so the slurry is distributed over a substantial portion or entirety of the filter element 20f including an upper inner portion closest to the inner edge 20i of the fdter element that is narrower than a wider lower portion of the filter element at the outer edge 20o of the filter element 20f in a tent-like distribution 15. The members of the slurry shaping structure SS can include a plurality of members with a first set of members positioned on opposite sides of a disc 20b from a second set of members. The first and second set of members can include front side spaced apart members and rear side spaced apart members or left side spaced apart members and right side spaced apart members for example. The spaced apart members can be positioned along opposite sides of the disc and be opposite a corresponding opposing member to help define the slurry shaping structure SS and function as a guide to facilitate slurry distribution on the filter element 20f in a tent-like distribution. The agitation, slurry shaping structure SS, and/or the gas injection flow(s) IGP can be provided in a pre-selected region RG of the bath to provide a desired level of slurry shaping. In some embodiments, this pre-selected region RG can be a forward region adjacent a scraper 31 so that it is within an initial phase of insertion of a sector 20a within slurry to receive the tent-like distribution 1 of slurry (e.g. a tent distribution), for example.

The gas injection flow(s) IGP provided by one or more nozzles 14i can be provided continuously or be pulsed. If pulsing of the flows is utilized, the pulsing can be timed based on the revolving speed of the disc 20b so that the gas injection flows are injected to coincide with a filter element 20f being in a pre-selected position to facilitate formation of the tent-like distribution 15 of slurry on the filter element 20f when that filter element is in the insertion phase of a revolution of the disc 20b. The pulsing can be provided so that gas is only injected for a preselected pulse period of time and there is a pulse delay period of time between the next pulse of gas (e.g. the injected gas flow is not a continuous flow at a steady speed but is either only injected periodically every pulse period of time or is injected continuously but is injected at a higher flow rate at the pulse period of time and is injected at a lower flow rate between the pulses during the pulse delay period of time between pulses). For example, pulsing of the gas injection can occur so a pulse of gas is injected every second for a 12 sector disc 20b that is rotated at a speed of 5 RPM (e.g. 12 seconds per rotation). Such pulsing can help ensure that the pulse of gas is provided when each sector is at a lowest point in the slurry bath or near that lowest point in the slurry bath 14 for its insertion phase to help ensure a desired slurry distribution on the filter element 20f when the filter element is at its lowest position in the slurry bath during its insertion phase of the revolution. Of course, other embodiments can utilize other numbers of discs and rotational speeds that may result in a different pulsing arrangement to meet a pre-selected set of design criteria.

The formation of the tent-like distribution of slurry via the injection of gas, conduits 37, slurry shaping structure SS, and/or agitator 14 can permit the overflow height of the slurry within the slurry bath to be at a lower position (e.g. low overflow position OL) within the slurry bath. This can help further enhance the drying phase as noted above (see e.g. Figures 3, 4, 5, 7, and 8).

The filtration device 10 can also include a cake flapping mechanism CF. The cake flapping mechanism CF can include one or more flaps 42F that extend from a rotatable gear 42G or are attached to a rotatable gear 42G so that rotation of the gear 42G can drive motion of the flaps 42F for contacting the filter elements 20f or filter cakes formed thereon for fracturing the filter cakes and/or repositioning of the filtered and partially dewatered solids that form compressed filter cakes on the filter elements 20f. Repositioning of the solids and/or formation of cracks in the filter cakes during the drying phase can facilitate improved drying by enhancing moisture removal by at least 0.5% to 1% in some embodiments. The rotation of the gear 42G can be driven by a connection the gear 42G can have to the disc 20b so that rotation of the disc results in rotation of the gear 42G for contacting of the filter elements 20f and/or filter cake formed therein during the drying phase of a revolution of a disc 20b. The cake flapping mechanism CF can be arranged and configured so that each filter element 20f or filter cake formed on each filter element 20f can be contacted by a flap 42F at least one time during each revolution of the disc 20b when that filter element 20f passes through the drying phase of the revolution of the disc 20b. The timing and positioning of the flaps 42F for contacting the filter cakes can be pre-selected to provide a flat slap on the filter cake or filtered solids so that each contact of the filter cake and/or solids is a flat slapping of that material via the flap(s) 42F (e.g. flap member connected to rotatable gear 42G).

The rotatable gear 42G can be rotatable about a vertical axis so that the flaps can move horizontally for slapping the filter cake and/or solids on the filter elements. The flaps 42F can be moved via their connection to the rotating gear 42G for flatly contacting the filter cakes in via horizontal motion of the flaps 42F, for example.

Figures 6 illustrates a schematic view of an exemplary cake flapping mechanism CF that is positioned for contacting filter cakes formed on different disc sectors 20a of different discs 20b. An array of gears 42G can be positioned for rotating a vertical axle for driving motion of the flaps 42F for contacting the filter cake to fracture and/or reposition the filter cake and/or solids of the filter cake to improve the dewatering and drying of the filter cake during the drying phase of the revolution of the disc 20b. In the exemplary arrangement illustrated in Figure 6, a first gear 42G is positioned adjacent a first disc 20b so that rotation of the first disc causes the first gear 42G to rotate to help drive the central drive gear 42G’s rotation of the vertical axle having the flaps 42F. A second gear 42G is positioned adjacent a second disc 20b so that rotation of the second disc 20b causes the second gear 42G to rotate to help drive the central drive gear 42G’s rotation of the vertical axle having the flaps 42F. The outer diameter of each disc 20b can be wheeled, pulleyed, geared, or otherwise connected to the gear 42G to which it is adjacent to transfer rotation of the disc 20b to motion of the gear 42G.

The central drive gear 42G can be connected to a shaft and/or have a shaft that is rotatable about a vertical axis via the rotational motion provided by the first and second gears 42G. The transfer of this motion can be provided via a gearbox arrangement or other type of connection between the first and second gears 42G and the central drive gear 42G. The vertical axis that is rotated can have the flaps 42F thereon or can be attached to the flaps 42F so that the rotation of the shaft causes the flaps to move to contact the filter cake for flatly slapping, or contacting, the filter cake or particulate material on the filter element to fracture and/or reposition that material. Figures 10 and 11 illustrate different top views for different flap 42F configurations that can be utilized for embodiments of the cake flapping mechanism CF.

Embodiments of the filtration device 10 can also include (or alternatively include) a scraper 31 and disc sector 20a configuration in which the distal end 3 la of the scraper first contacts an inner diameter edge of each filter element during the scraping phase and subsequently moves along upper and outer portions of the filter element 20f until reaching a top upper outer edge portion of the outer edge 20o of the filter element 20f The scraping can occur so that the upper outer edge portion of a lower filter element 20f is scraped by an intermediate portion and/or proximate edge of the scraper while the inner edge and lower portion of the immediately adjacent and upper filter element 20f is also being scraped by the distal edge 3 la of the scraper 31. This type of scraping motion can be defined by the shape of the filter elements and disc sectors 20a and/or scraper 31 so that the scraper 31 moves along filter elements 20f in such a path via rotation of the disc 20b and non-motion of the scraper 31.

The scraper 31 can be positioned over a chute 29 so that filter cake that is scraped off the filter elements 20f can be passed into the chute 29 for removal from the filtration device 10.

In some embodiments, each disc sector can have angled sides that project outwardly from its inner edge 20i in a curved and/or angled manner to define a sector 20a of the disc 20b that facilitates the angled scraping path. This can help facilitate the positioning of the scraper 31 in a lower position to help provide a larger drying phase for each revolution and a shorter scraping/discharge phase for each revolution as well. The angled sides that project outwardly to the outer edge 20o can be linearly and/or curvedly extending to provide the shaping of the filter element 20f and disc sector 20a to facilitate the upward and outward scraping path for removal of the filter cake from the filter element 20f during the scraping/discharge phase. The defined sectors 20a can be defined in a pinwheel structure or pinwheel segment structure for example. Figure 5 illustrates an example of such a pinwheel segment structure shaping for the disc sectors 20a.

Alternatively, the disc sectors can have sides the extend outwardly from their inner edges 20i that extend in a more linear or polygonal manner to their outer edges 20o to have a rhombuslike shape to define each sector 20a of the disc 20b to provide a non-curved or minimally curved pinwheel-like segment structure. In such a configuration, only the inner edge 20i may be curved for being positioned around the shaft 25 and/or the inner edge 20i can be curved and the sides that extend between the inner edge 20i and outer edge 20o can have a relatively small amount of curvature for defining the shape of the disc sector 20a. Referring to Figure 9, a process for filtering particulate material from a liquid slurry containing the particulate material therein can include a first step SI in which slurry is directed onto a filter element during the insertion phase of a rotation of a disc 20b via injection of gas and/or agitation via an agitator 14. As noted above, the slurry can be agitated and/or mixed via shaping of the blades of the agitator 14, one or more guides (e.g. one or more slurry shaping structure SS), and/or use of gas injection flows IGP to direct the slurry within the bath onto a filter element to provide a tent-like distribution 15 of slurry on a lowermost filter element 20f of a disc sector 20a in the first step SI. When utilized, the one or more gas flows can be pulsed gas flows or continuous gas flows that can be output via at least one nozzle 14i as discussed above.

This type of distribution 15 can provide a directed wave of slurry so that adjacent filter elements are not in contact with slurry or have a minimal contact with the slurry while the lowest disc sector receives the distribution 15 of slurry thereon. Such a distribution effect can permit the drying phase to start sooner so that the insertion phase takes less time and involves less of the rotational path of a single revolution so that more moisture from the filter cake to be formed on the filter element 20f can be removed during the drying phase. In some embodiments, the slurry direction can be performed so that there is a 1 : 10 sector submerged within the slurry to sector out of the slurry ratio that occurs during a revolution of the disc 20b having the disc sectors 20a (e.g. in a disc 20b having eleven disc sectors 20a, there is one disc sector 20a in the slurry while ten disc sectors 20a are not in the slurry retained in the bath, etc.). Embodiments can be performed so that a low level of slurry is within a bath (e.g. slurry can be in a low overflow position OL).

In a second step S2, the filter cake formed on the filter element can be contacted by at least one flap during a drying phase of the revolution of the disc 20b to fracture and/or reposition the filter cake (e.g. consolidate and/or form cracks in the filter cake) to facilitate drying of the filter cake. This contacting can be slapping the face of the filter element 20f via horizontal motion of at least one flap 42F as discussed above, for example.

In a third step S3, the filter cake can be scraped off the filter element in a discharge phase of the revolution of the disc 20b. The scraping can be provided so that a lower inner edge of the filter element is scraped via a distal edge of the scraper first and the filter element is moved such that the scraper’s intermediate and opposite proximal edge subsequently scrapes an upper outer edge portion of the filter element 20f while the distal edge 31a scrapes the inner lower portion of the immediately adjacent upper filter element 3 If. The disc sectors 20a can have a pinwheel segment structure to help facilitate such scraping and a lower scraper position, as discussed above.

Embodiments of the process can be implemented in embodiments of the system 1 and operation of embodiments of the filtration device 10.

It should also be understood that the foregoing is provided for illustrative and exemplary purposes; the present invention is not necessarily limited thereto. Rather, those skilled in the art will appreciate that various modifications, as well as adaptations to particular circumstances, are possible within the scope of the invention as herein shown and described. For instance, different embodiments may be designed to meet a particular set of design criteria. As another example, the size and configuration of different elements and the material for those elements can be designed for a particular operational objective (e.g. filtration of a particular type of mineral from a liquid slurry, filtration of a particular set of solid particulates from a slurry, a size and layout of the facility in which at least one filtration device is to be incorporated, operational parameters at which the facility that will include one or more filtration devices is to operate, etc.). As yet another example, it should be appreciated that some components, features, and/or configurations may be described in connection with only one particular embodiment, but these same components, features, and/or configurations can be applied or used with many other embodiments and should be considered applicable to the other embodiments, unless stated otherwise or unless such a component, feature, and/or configuration is technically impossible to use with the other embodiment. Thus, the components, features, and/or configurations of the various embodiments can be combined together in any manner and such combinations are expressly contemplated and disclosed by this statement. Therefore, while certain exemplary embodiments of filter devices, filtration apparatuses used to remove solid particulates from a slurry, and methods of making and using the same have been shown and described above, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.

Claims

What is claimed is:

1. A filtration device comprising: a first disc that is rotatable about a shaft, the first disc positioned adjacent a slurry bath such that disc sectors of the first disc are insertable into slurry retained in the slurry bath, the disc sectors configured to form filter cakes comprised of solid particulate material of the slurry via rotation of the first disc about the shaft; and at least one of:

(i) a slurry agitation mechanism positioned in the slurry bath adjacent to at least one slurry shaping structure positioned to direct the slurry onto the disc sectors of the first rotatable disc such that the slurry from the slurry bath is directed onto each of the disc sectors when the disc sector is a lowest disc sector within the slurry bath during a revolution of the first disc;

(ii) at least one nozzle positioned to inject at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is a lowest disc sector within the slurry bath during a revolution of the first disc;

(iii) at least one cake flapping mechanism positioned to contact the filter cakes during rotation of the first disc to consolidate, reposition interstices and/or fracture the filter cakes formed on the disc sectors of the first disc to aid drying of the filter cakes during rotation of the first disc.

2. The filtration device of claim 1, wherein the filtration device includes (i) the slurry agitation mechanism.

3. The filtration device of claim 2, wherein the filtration device also includes (ii) the at least one nozzle.

4. The filtration device of claim 3, wherein the filtration device also includes (iii) the at least one cake flapping mechanism.

5. The filtration device of claim 2, wherein the filtration device also includes (iii) the at least one cake flapping mechanism.

6. The filtration device of claim 1, wherein the filtration device includes (ii) the at least one nozzle.

7. The filtration device of claim 6, wherein the filtration device also includes (iii) the at least one cake flapping mechanism.

8. The filtration device of claim 1, wherein the filtration device includes (iii) the at least one cake flapping mechanism.

9. The filtration device of claim 1, wherein the filtration device includes (ii) the at least one nozzle, the at least one nozzle positioned to pulse the at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc.

10. The filtration device of claim 1, wherein the filtration device includes (ii) the at least one nozzle, the at least one nozzle positioned to continuously inject the at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc.

11. The filtration device of claim 1, where in the disc sectors are pinwheel structured disc sectors.

12. The filtration device of claim 1, wherein the includes (iii) the at least one cake flapping mechanism, the at least one flapping mechanism positioned between the first disc and a second disc to contact filter cakes formed on disc sectors of the second disc to consolidate, reposition interstices and/or fracture the filter cakes as well as contact the filter cakes during rotation of the first disc to consolidate, reposition interstices and/or fracture the filter cakes formed on the disc sectors to aid drying of the filter cakes during rotation of the first disc.

13. A process for filtering particulate material in a slurry, the process comprising: rotating a first disc such that disc sectors of the first disc are insertable into slurry retained in a slurry bath; distributing slurry from the slurry bath onto filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in a tent distribution when the disc sector is a lowest disc sector within the slurry bath during a revolution of the first disc; wherein the first disc is rotated via the rotating so that particulate material of the slurry is retained on the filter elements of the disc sectors to form filter cakes thereon for filtration of the slurry after the distributing of the slurry from the slurry bath onto the filter elements occurs.

14. The process of claim 13, comprising: scraping the filter cakes off the filter elements of each of the disc sectors to discharge the filter cakes during the revolution before the filter elements are rotated into the slurry bath.

15. The process of claim 13, wherein the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc comprises:

(i) agitating slurry positioned in the slurry bath adjacent to at least one slurry shaping structure positioned to direct the slurry onto the disc sectors of the first rotatable disc such that the slurry from the slurry bath is directed onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc; or

(ii) injecting at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc.

16. The process of claim 13, wherein the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc comprises:

(i) agitating slurry positioned in the slurry bath adjacent to at least one slurry shaping structure positioned to direct the slurry onto the disc sectors of the first rotatable disc such that the slurry from the slurry bath is directed onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc; and

17. The process of claim 13, comprising: consolidating, repositioning interstices and/or fracturing the filter cakes during rotation of the first disc to fracture the filter cakes formed on the disc sectors of the first disc to aid drying of the filter cakes during rotation of the first disc.

18. The process of claim 17, wherein the consolidating, repositioning interstices and/or fracturing is performed via at least one cake flapping mechanism positioned adjacent to the first disc to contact the filter cakes while the first disc is rotated and before the filter cakes are scraped off the filter elements.

19. The process of claim 18, comprising: scraping the filter cakes off the filter elements of each of the disc sectors to discharge the filter cakes during the revolution after the fracturing of the filter cakes occurs.

20. The process of claim 17, wherein the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc comprises:

21. The process of claim 17, wherein the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc comprises:

22. The process of claim 13, wherein the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc comprises: injecting pulses of at least one gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc.

23. The process of claim 13, wherein the distributing of the slurry from the slurry bath onto the filter elements of each of the disc sectors of the first disc as the first disc is rotated such that the slurry from the slurry bath is directed onto each of the disc sectors in the tent distribution when the disc sector is a lowest disc sector within the slurry bath during the revolution of the first disc comprises: injecting of at least one continuous gas injection flow within the slurry bath to direct the slurry onto each of the disc sectors when the disc sector is the lowest disc sector within the slurry bath during the revolution of the first disc.

24. The process of claim 13, comprising: consolidating, repositioning interstices and/or fracturing the fdter cakes during rotation of the first disc to fracture the filter cakes formed on the disc sectors of the first disc to aid drying of the filter cakes during rotation of the first disc and also fracturing filter cakes during rotation of a second disc to fracture the filter cakes formed on disc sectors of the second disc to aid drying of the filter cakes during rotation of the second disc.

25. The process of claim 24, wherein the consolidating, repositioning interstices and/or fracturing is performed via at least one cake flapping mechanism positioned between the first disc and second first disc.