A method and system for designing a bioreactor
By integrating a high-frequency ultrasonic transducer and titanium electrodes into the biofilm reactor, combined with water quality sensors and sludge analysis methods, automated sludge cleaning of the biofilm reactor was achieved, solving the problem of low sludge cleaning efficiency in existing technologies and ensuring continuous and efficient operation of the reactor.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- CHINA NAT INST OF STANDARDIZATION
- Filing Date
- 2025-11-26
- Publication Date
- 2026-07-07
AI Technical Summary
In existing bioreactor design methods, sludge cleaning of biofilm reactors mainly relies on shutdown disassembly and cleaning or mechanical rotation cleaning, lacking an automated cleaning mechanism, resulting in low cleaning efficiency and affecting reactor operating efficiency.
By integrating a high-frequency ultrasonic transducer and titanium electrode into a biofilm reactor, combined with water quality sensors and sludge analysis, the sludge concentration and deposition location are monitored in real time, the cleaning points are automatically identified, and cleaning is performed using the high-frequency ultrasonic transducer and titanium electrode.
The system enables automated cleaning of biofilm reactors, avoiding interruptions to reactor operation during cleaning, improving sludge cleaning efficiency, and ensuring continuous and efficient reactor operation.
Smart Images
Figure CN121615342B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of bioreactor technology, specifically to a bioreactor design method and system. Background Technology
[0002] A bioreactor is a device system that uses organisms to carry out biochemical reactions to produce target products. Its core function is to provide a suitable growth environment for organisms and achieve large-scale production by controlling metabolic processes. The main structural components of a bioreactor include a container, a stirrer, a gas distribution device, sensors, and a control system. Its reaction mechanism mainly promotes cell growth or enzyme-catalyzed reactions by simulating the biological metabolic environment.
[0003] Existing methods for bioreactor design typically focus on improving the accuracy of tank model construction. For example, updating pipe inlet positions in advance within mechanical 3D design software saves time on modeling in the software, reduces design time, and avoids errors during secondary review, thus improving tank model accuracy. While this approach improves tank modeling efficiency and accuracy, it fails to effectively improve the actual operation and control of the bioreactor. For instance, in sludge cleaning of biofilm reactors, methods rely solely on shutdown disassembly or mechanical rotation, resulting in low sludge cleaning efficiency and impacting reactor operation due to the lack of automated cleaning mechanisms and the need to interrupt reactor operation during cleaning. For example, patent application CN116882193A discloses a bioreactor... The design method for bioreactor tanks or fermentation tanks involves updating the pipe positions in mechanical 3D design software to generate the final tank drawing. This eliminates the need to export the tank model's three-view drawings from the pipeline 3D design software for review, saving design time for 3D designers and avoiding errors caused by secondary verification. This increases the accuracy of the bioreactor tank model. Other improvements to bioreactor design methods typically focus on assessing effluent quality based on reactor volume and aeration tank air supply. However, these improvements still cannot address sludge cleaning in biofilm reactors. The current methods rely solely on shutdown disassembly and mechanical rotation for cleaning, resulting in low sludge cleaning efficiency and impacting reactor operating efficiency due to the lack of automated cleaning mechanisms and the need to interrupt reactor operation during cleaning. Therefore, it is necessary to improve existing bioreactor design methods. Summary of the Invention
[0004] This invention aims to at least partially solve one of the technical problems in the prior art by proposing a design method and system for a bioreactor. This addresses the issue that existing bioreactor design methods, in terms of sludge cleaning in biofilm reactors, can only rely on shutdown for disassembly and cleaning or mechanical rotation for cleaning. This results in a lack of automated cleaning mechanisms and requires interrupting reactor operation during cleaning, leading to low sludge cleaning efficiency and affecting reactor operating efficiency.
[0005] To achieve the above objectives, in a first aspect, this application provides a method for designing a bioreactor, comprising the following steps:
[0006] Based on the cleaning standards and historical cleaning data of the biofilm reactor, the lowest concentration of sludge in the biofilm reactor during cleaning is recorded as the lowest concentration in the reactor; water quality sensors are used to monitor the liquid in the biofilm reactor, and the monitored sludge concentration is recorded as the sludge concentration in the reactor.
[0007] The biofilm reactor was monitored using a water quality sensor, and sludge analysis parameters were obtained, including sludge deposition location and sludge thickness. The sludge analysis parameters were analyzed using sludge analysis methods, and the undetermined vibration point location and sludge group value were obtained based on the analysis results.
[0008] Based on the sludge group value of each undetermined vibration point, the vibration analysis method is used to obtain the sludge vibration point in the biofilm reactor, and the sludge thickness range corresponding to each sludge vibration point is obtained.
[0009] A high-frequency ultrasonic transducer and titanium electrodes are integrated into the biofilm reactor. When the biofilm reactor is running, the high-frequency ultrasonic transducer and titanium electrodes are used to clean the biofilm reactor based on the real-time sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges.
[0010] Furthermore, water quality sensors were used to monitor the biofilm reactor and obtain sludge analysis parameters, including:
[0011] A water quality sensor was placed inside the biofilm reactor, and the liquid inside the biofilm reactor under operation was monitored for a duration of T days after placement. A plane rectangular coordinate system was established and denoted as the sludge analysis coordinate system, where the units of the X-axis and Y-axis of the sludge analysis coordinate system are days and mg / L, respectively.
[0012] Based on the time the water quality sensor is placed in the biofilm reactor and the monitored sludge concentration inside the reactor, a time-concentration relationship curve is plotted in the sludge analysis coordinate system and recorded as the sludge monitoring curve; the region in the sludge monitoring curve that is higher than Y = the lowest concentration inside the reactor is recorded as the parameter acquisition curve, where there may be multiple parameter acquisition curves.
[0013] Furthermore, monitoring the biofilm reactor using water quality sensors and obtaining sludge analysis parameters also includes:
[0014] For any parameter acquisition curve: when the operation of the biofilm reactor is within the time range corresponding to the parameter acquisition curve, a camera is used to image the inside of the biofilm reactor in real time, and the image obtained is processed based on image analysis software, and the location of the sludge inside the biofilm reactor is recorded as the sludge deposition location.
[0015] For any sludge deposition location: the wall of the biofilm reactor where the sludge adheres at the sludge deposition location is denoted as the sludge-adhering wall, and n sampling points are uniformly obtained on the sludge surface at the sludge deposition location, denoted as sludge thickness sampling points; perpendicular lines are drawn from all sludge thickness sampling points to the sludge-adhering wall, and the length of the longest perpendicular line is denoted as the sludge thickness.
[0016] When the biofilm reactor is operating within the time range corresponding to the acquisition curves of all parameters, obtain all sludge deposition locations and the sludge thickness corresponding to each sludge deposition location.
[0017] Furthermore, sludge analysis methods include:
[0018] Obtain the dimensional data of the biofilm reactor, including length, height, and width data; construct a corresponding model in a spatial coordinate system based on the dimensional data of the biofilm reactor, and denote it as the reactor model;
[0019] Based on the positional relationship between all sludge deposition locations and the biofilm reactor, the points corresponding to all sludge deposition locations are marked in the reactor model and recorded as sludge deposition points. For any sludge deposition point, the sludge thickness at the corresponding sludge deposition location is recorded as the quantitative parameter of the sludge deposition point.
[0020] Furthermore, sludge analysis methods also include:
[0021] The largest area of the reactor model is denoted as the largest base, and the smallest circumscribed circle of the largest base is denoted as L.
[0022] For any two sludge deposition points α1 and α2: when the length of the line connecting sludge deposition points α1 and α2 is greater than L, sludge deposition points α1 and α2 are denoted as a sludge group, and the midpoint of the line connecting sludge deposition points α1 and α2 is denoted as the undetermined vibration point; the sum of the quantization parameters of sludge deposition points α1 and α2 is denoted as the sludge group value.
[0023] Obtain all undetermined vibration points corresponding to all sludge deposition points, and the sludge group value corresponding to each undetermined vibration point.
[0024] Furthermore, vibration analysis methods include:
[0025] The quantified parameters of sludge deposition sites that are not in any sludge group are recorded as conventional parameters; the conventional parameters corresponding to all sludge deposition sites are obtained, and the average value of all conventional parameters is recorded as the conventional mean.
[0026] Obtain an empty biofilm reactor β, and uniformly coat the inner wall of the biofilm reactor β with sludge of a thickness equal to the conventional average value; for any sludge deposition point γ in at least one sludge group: coat the position corresponding to the sludge deposition point γ in the biofilm reactor β with sludge of a thickness equal to the quantified parameter of the sludge deposition point γ.
[0027] The biofilm reactor β obtained after applying sludge is denoted as the vibration analysis reactor, and the total amount of sludge in the vibration reactor is denoted as the pre-vibration weight in grams.
[0028] Furthermore, vibration analysis methods also include:
[0029] Based on the process objectives of the biofilm reactor, an aqueous solution is filled into the vibration analysis reactor. For any undetermined vibration point: based on the frequency standard of industrial cleaning, a high-frequency ultrasonic transducer is integrated at the undetermined vibration point, and the high-frequency ultrasonic transducer is started at rated power for a vibration duration of Qmin. When the high-frequency ultrasonic transducer stops vibrating, the total amount of sludge in the vibrating reactor is recorded as the post-vibration weight in grams, and the sum of the sludge thicknesses at the two sludge deposition points corresponding to the undetermined vibration point is recorded as the sludge vibration value. The post-vibration weight in grams divided by the pre-vibration weight in grams is recorded as k1, and the sludge vibration value divided by the sludge group values at the two sludge deposition points corresponding to the undetermined vibration point is recorded as k2. The sum of k1 and k2 is recorded as the vibration screening value.
[0030] Obtain the vibration screening values of all undetermined vibration points, and record the average value of all vibration screening values as the vibration screening mean; record the undetermined vibration points whose vibration screening values are less than the vibration screening mean as sludge vibration points, and record the [sludge vibration value, sludge group value] corresponding to the sludge vibration points as the sludge thickness range.
[0031] Furthermore, a high-frequency ultrasonic transducer and titanium electrodes are integrated into the biofilm reactor. When the biofilm reactor is running, based on the real-time acquired sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges, the high-frequency ultrasonic transducer and titanium electrodes are used to clean the biofilm reactor, including:
[0032] During the operation of the biofilm reactor, the sludge thickness at the two sludge deposition points corresponding to all sludge vibration points is acquired in real time.
[0033] When the sum of the sludge thicknesses of the two sludge deposition points corresponding to any sludge vibration point δ is within the sludge thickness range of the sludge vibration point δ, a high-frequency ultrasonic transducer is integrated at the sludge vibration point δ, and a titanium electrode is integrated in the biofilm reactor.
[0034] The high-frequency ultrasonic transducer is started with rated power to vibrate, and hypochlorous acid is generated by electrolysis using titanium electrodes until the sum of the sludge thicknesses at the two sludge deposition points corresponding to the sludge vibration point δ is 0.
[0035] Secondly, this application also provides a bioreactor design system, including a sludge monitoring module, a sludge parameter analysis module, a vibration point positioning module, and a real-time cleaning module.
[0036] The sludge monitoring module is used to record the lowest sludge concentration in the biofilm reactor during cleaning, based on the cleaning standards and historical cleaning data of the biofilm reactor, as the lowest concentration in the reactor; and to use a water quality sensor to monitor the liquid in the biofilm reactor and record the monitored sludge concentration as the sludge concentration in the reactor.
[0037] The sludge parameter analysis module is used to monitor the biofilm reactor using water quality sensors and obtain sludge analysis parameters, including sludge deposition location and sludge thickness. The sludge analysis parameters are analyzed using sludge analysis methods, and the undetermined vibration point location and sludge group value are obtained based on the analysis results.
[0038] The vibration point location module is used to obtain the sludge vibration point in the biofilm reactor based on the sludge group value of each unknown vibration point using vibration analysis, and to obtain the sludge thickness range corresponding to each sludge vibration point.
[0039] The real-time cleaning module integrates a high-frequency ultrasonic transducer and titanium electrodes within the biofilm reactor. When the biofilm reactor is running, it cleans the biofilm reactor using the high-frequency ultrasonic transducer and titanium electrodes based on the real-time acquired sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges.
[0040] The beneficial effects of this invention are as follows: This application first uses a water quality sensor to monitor the biofilm reactor and obtain sludge analysis parameters; then it uses a sludge analysis method to analyze the sludge analysis parameters and obtains the undetermined vibration points and sludge group values based on the analysis results. The advantage of this is that by obtaining the undetermined vibration points and sludge group values based on the sludge analysis parameters, the location of sludge accumulation during the operation of the biofilm reactor can be analyzed. Based on the location of thicker sludge, multiple points that can be vibrated using high-frequency ultrasonic transducers can be obtained within the biofilm reactor. This allows for the selection of undetermined vibration points that are more effective for sludge removal during subsequent analysis, thereby achieving the purpose of automatically cleaning the sludge inside the biofilm reactor by placing high-frequency ultrasonic transducers.
[0041] This application also uses vibration analysis to obtain the vibration points of sludge in the biofilm reactor and the corresponding sludge thickness range for each vibration point. Finally, based on the real-time sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges, a high-frequency ultrasonic transducer and titanium electrodes are used to clean the biofilm reactor. The advantage of this is that by obtaining the real-time sludge thickness, the placement point of the high-frequency ultrasonic transducer during vibration cleaning can be determined based on the sludge vibration points corresponding to all sludge thickness ranges. This allows for the automatic cleaning of the biofilm reactor by placing the high-frequency ultrasonic transducer and titanium electrodes, thus avoiding interruption of reactor operation and affecting reactor operating efficiency. Attached Figure Description
[0042] Figure 1 This is a schematic diagram of the system of the present invention;
[0043] Figure 2 This is a flowchart illustrating the steps of the method of the present invention;
[0044] Figure 3 This is a schematic diagram of the sludge analysis coordinate system of the present invention;
[0045] Figure 4 This is a schematic diagram of the sludge adhering to the wall at the sludge deposition location of the present invention;
[0046] Figure 5 This is a schematic diagram of the electronic device of the present invention. Detailed Implementation
[0047] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0048] Example 1, please refer to Figure 1 As shown, this application provides a bioreactor design system, including a sludge monitoring module, a sludge parameter analysis module, a vibration point positioning module, and a real-time cleaning module;
[0049] The sludge monitoring module is used to record the lowest sludge concentration in the biofilm reactor during cleaning, based on the cleaning standards and historical cleaning data of the biofilm reactor, as the lowest concentration in the reactor; and to use a water quality sensor to monitor the liquid in the biofilm reactor and record the monitored sludge concentration as the sludge concentration in the reactor.
[0050] The sludge parameter analysis module is used to monitor the biofilm reactor using water quality sensors and obtain sludge analysis parameters, including sludge deposition location and sludge thickness. The sludge analysis parameters are analyzed using sludge analysis methods, and the undetermined vibration point location and sludge group value are obtained based on the analysis results.
[0051] The sludge parameter analysis module includes a sludge parameter analysis unit, which is configured with sludge parameter analysis strategies. These strategies include:
[0052] A water quality sensor was placed inside the biofilm reactor, and the liquid inside the biofilm reactor under operation was monitored for a duration of T days after placement. A plane rectangular coordinate system was established and denoted as the sludge analysis coordinate system, where the units of the X-axis and Y-axis of the sludge analysis coordinate system are days and mg / L, respectively.
[0053] In specific implementation, for example, during a data analysis, the value of T is set to 3, meaning that the liquid in the operating biofilm reactor is monitored for 3 days after the water quality sensor is placed; by acquiring the monitoring data, a sludge analysis coordinate system is constructed as follows: Figure 3 As shown, curve WJ is the sludge monitoring curve. Based on the cleaning standard of the biofilm reactor, the lowest concentration inside the reactor is 3000 mg / L. Analysis reveals that... Figure 3Curves CH1 to CH4 in the figure are all parameter acquisition curves. By extracting the parameter acquisition curves, the sludge deposition location and sludge thickness can be obtained in subsequent analysis. This allows us to determine the state of the biofilm reactor when the sludge concentration exceeds the minimum standard for cleaning. Thus, we can determine the location and thickness of the sludge in the biofilm reactor when sludge cleaning is required. This facilitates the integration of high-frequency ultrasonic transducers for vibration cleaning of the sludge in subsequent analysis.
[0054] Based on the time the water quality sensor is placed in the biofilm reactor and the monitored sludge concentration inside the reactor, a time-concentration relationship curve is plotted in the sludge analysis coordinate system and recorded as the sludge monitoring curve; the region in the sludge monitoring curve that is higher than Y = the lowest concentration inside the reactor is recorded as the parameter acquisition curve, where there may be multiple parameter acquisition curves.
[0055] The sludge parameter analysis strategy also includes: for any parameter acquisition curve: when the operation of the biofilm reactor is within the time range corresponding to the parameter acquisition curve, use a camera to perform real-time imaging of the inside of the biofilm reactor, and process the image obtained based on image analysis software to record the location of the sludge in the biofilm reactor as the sludge deposition location.
[0056] For any sludge deposition location: the wall of the biofilm reactor where the sludge adheres at the sludge deposition location is denoted as the sludge-adhering wall, and n sampling points are uniformly obtained on the sludge surface at the sludge deposition location, denoted as sludge thickness sampling points; perpendicular lines are drawn from all sludge thickness sampling points to the sludge-adhering wall, and the length of the longest perpendicular line is denoted as the sludge thickness.
[0057] In the specific implementation process, for example, during a data analysis, the relationship between sludge and the sludge adhering to the wall at a sludge deposition location is obtained, such as... Figure 4 As shown, where, Figure 4 The area where WN is located corresponds to the sludge area, WB is the sludge adhering wall, and points NH1 to NH5 are sludge thickness sampling points. Through analysis, it can be seen that the dashed line where each sludge thickness sampling point is located is a perpendicular line drawn from the sludge thickness sampling point to the sludge adhering wall. That is, the length of the longest dashed line among the dashed lines where points NH1 to NH5 are located corresponds to the sludge thickness. Through data acquisition, the lengths of the dashed lines where NH1 to NH5 are located are 1.7mm, 2.6mm, 3mm, 2mm and 1.5mm respectively. Therefore, through analysis, the sludge thickness is 3mm.
[0058] When the biofilm reactor is operating within the time range corresponding to the acquisition curves of all parameters, obtain all sludge deposition locations and the sludge thickness corresponding to each sludge deposition location.
[0059] The sludge analysis method includes: obtaining the dimensional data of the biofilm reactor, including length, height, and width data; constructing a corresponding model in a spatial coordinate system based on the dimensional data of the biofilm reactor, and denoting it as the reactor model;
[0060] Based on the positional relationship between all sludge deposition locations and the biofilm reactor, the points corresponding to all sludge deposition locations are marked in the reactor model and recorded as sludge deposition points. For any sludge deposition point, the sludge thickness at the corresponding sludge deposition location is recorded as the quantitative parameter of the sludge deposition point.
[0061] The sludge analysis method also includes: designating the bottom surface with the largest area of the reactor model as the maximum bottom surface, and designating the diameter of the smallest circumscribed circle of the maximum bottom surface as L;
[0062] For any two sludge deposition points α1 and α2: when the length of the line connecting sludge deposition points α1 and α2 is greater than L, sludge deposition points α1 and α2 are denoted as a sludge group, and the midpoint of the line connecting sludge deposition points α1 and α2 is denoted as the undetermined vibration point; the sum of the quantization parameters of sludge deposition points α1 and α2 is denoted as the sludge group value.
[0063] In the specific implementation process, for example, if the reactor model with the largest area obtained in a data analysis is a circle with a diameter of 80cm, then L can be directly recorded as 80cm. If the reactor model has a rectangular, trapezoidal or other irregular shape in the actual analysis, then L can be set by obtaining the diameter of the smallest circumscribed circle of the bottom surface. By comparing the distance between two sludge deposition points with L, it can be prevented that after determining the sludge vibration point, the position of the high-frequency ultrasonic transducer is too close to some sludge deposition points and too far from other sludge deposition points, thus affecting the actual sludge removal effect. Therefore, in this embodiment, the sludge deposition points with a line length greater than L are recorded as sludge groups, and the corresponding undetermined vibration points are obtained. This can ensure that the sludge vibration points obtained later can effectively remove sludge from most sludge deposition points after the high-frequency ultrasonic transducer is placed.
[0064] In this embodiment, for example, during a data analysis, the quantitative parameters corresponding to two sludge deposition points of a sludge group are 3mm and 4mm, respectively. Then, by calculation, the sludge group value of the undetermined vibration point corresponding to the sludge group is 7mm. If the undetermined vibration point of the sludge group is recorded as the sludge vibration point in subsequent analysis, then in practical applications, if the sum of the sludge thicknesses corresponding to the above two sludge deposition points is 7mm, a high-frequency ultrasonic transducer can be placed at the sludge vibration point corresponding to the sludge group for vibration cleaning.
[0065] Obtain all undetermined vibration points corresponding to all sludge deposition points, and the sludge group value corresponding to each undetermined vibration point.
[0066] The vibration point location module is used to obtain the sludge vibration point in the biofilm reactor based on the sludge group value of each unknown vibration point using vibration analysis, and to obtain the sludge thickness range corresponding to each sludge vibration point.
[0067] Vibration analysis includes: recording the quantitative parameters of sludge deposition points not located in any sludge group as conventional parameters; obtaining the conventional parameters corresponding to all sludge deposition points, and recording the average value of all conventional parameters as the conventional mean;
[0068] In the specific implementation process, for example, during a data analysis, 10 sludge deposition points were obtained through the above analysis, and 6 of these sludge deposition points were located within the sludge group. The quantitative parameters corresponding to the remaining 4 sludge deposition points were 1 mm, 0.6 mm, 1.1 mm, and 0.7 mm, respectively. Through calculation, the conventional average value is 0.85 mm. In subsequent analysis, 0.85 mm can be used as the sludge thickness in the biofilm reactor, excluding the sludge deposition points, thereby constructing a biofilm reactor β with unwashed sludge and testing the vibration cleaning effect of placing high-frequency ultrasonic transducers at each undetermined vibration point.
[0069] Obtain an empty biofilm reactor β, and uniformly coat the inner wall of the biofilm reactor β with sludge of a thickness equal to the conventional average value; for any sludge deposition point γ in at least one sludge group: coat the position corresponding to the sludge deposition point γ in the biofilm reactor β with sludge of a thickness equal to the quantified parameter of the sludge deposition point γ.
[0070] The biofilm reactor β obtained after applying sludge is denoted as the vibration analysis reactor, and the total amount of sludge in the vibration reactor is denoted as the pre-vibration weight in grams.
[0071] The vibration analysis method also includes: based on the process objectives of the biofilm reactor, filling the vibration analysis reactor with an aqueous solution; for any unknown vibration point: based on the frequency standard of industrial cleaning, integrating a high-frequency ultrasonic transducer at the unknown vibration point, and starting the high-frequency ultrasonic transducer at rated power for a duration of Qmin; when the high-frequency ultrasonic transducer stops vibrating, recording the total amount of sludge in the vibrating reactor in grams as the post-vibration gram value, and recording the sum of the sludge thicknesses at the two sludge deposition points corresponding to the unknown vibration point as the sludge vibration value; recording the post-vibration gram value divided by the pre-vibration gram value as k1, recording the sludge vibration value divided by the sludge group values at the two sludge deposition points corresponding to the unknown vibration point as k2, and recording the sum of k1 and k2 as the vibration screening value;
[0072] In the specific implementation process, the value of Q can be determined according to the thickness of sludge in the biofilm reactor β. If the quantitative parameters of the sludge deposition points are large based on the conventional average value, the vibration time of the high-frequency ultrasonic transducer can be extended by increasing the value of Q to ensure effective removal of sludge in the biofilm reactor. For example, with the goal of removing half of the sludge at the sludge deposition points, the vibration time of the high-frequency ultrasonic transducer is set to Q when the thickness of the sludge at the sludge deposition points is half of that before vibration. The value of Q is then used in subsequent analysis of other sludge deposition points.
[0073] For example, in a data analysis, the value of Q is 10, the sludge thickness of the two sludge deposition points corresponding to the undetermined vibration point is 3mm and 4mm respectively, and the sludge thickness of the two sludge deposition points obtained after vibrating the undetermined vibration point for 10 minutes using a high-frequency ultrasonic transducer is 1.5mm and 2mm respectively. Then, by calculation, the sludge vibration value is 3.5mm, the sludge group value of the two sludge deposition points corresponding to the undetermined vibration point is 7mm, and k2 is 0.5.
[0074] In this embodiment, the smaller the values of k1 and k2, the less sludge is in the biofilm reactor after vibration with a high-frequency ultrasonic transducer, and the thinner the sludge at the sludge deposition point. In other words, the vibration cleaning effect of the high-frequency ultrasonic transducer is better. Therefore, by screening the vibration points based on the vibration screening values, the points with better vibration effects can be used as sludge vibration points and placed as high-frequency ultrasonic transducer placement points during actual operation to effectively clean the sludge.
[0075] Obtain the vibration screening values of all undetermined vibration points, and record the average value of all vibration screening values as the vibration screening mean; record the undetermined vibration points with vibration screening values less than the vibration screening mean as sludge vibration points, and record the [sludge vibration value, sludge group value] corresponding to the sludge vibration points as the sludge thickness range;
[0076] In specific implementation, for example, if the sludge vibration value is 3.5mm and the sludge group value is 7mm during a data analysis, the sludge thickness range corresponding to the sludge vibration point can be set to [3.5mm, 7mm]. This means that when the sum of the sludge thickness of the two sludge deposition points corresponding to the sludge vibration point is within [3.5mm, 7mm], sludge cleaning can be performed by placing a high-frequency ultrasonic transducer at the sludge vibration point.
[0077] The real-time cleaning module is used to integrate a high-frequency ultrasonic transducer and titanium electrodes in the biofilm reactor. When the biofilm reactor is running, the high-frequency ultrasonic transducer and titanium electrodes are used to clean the biofilm reactor based on the real-time sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges.
[0078] The real-time cleaning module includes a real-time cleaning unit, which is configured with a real-time cleaning strategy. The real-time cleaning strategy includes:
[0079] During the operation of the biofilm reactor, the sludge thickness at the two sludge deposition points corresponding to all sludge vibration points is acquired in real time.
[0080] When the sum of the sludge thicknesses of the two sludge deposition points corresponding to any sludge vibration point δ is within the sludge thickness range of the sludge vibration point δ, a high-frequency ultrasonic transducer is integrated at the sludge vibration point δ, and a titanium electrode is integrated in the biofilm reactor.
[0081] The high-frequency ultrasonic transducer is started with rated power to vibrate, and hypochlorous acid is generated by electrolysis using titanium electrodes until the sum of the sludge thicknesses at the two sludge deposition points corresponding to the sludge vibration point δ is 0.
[0082] In the specific implementation process, the titanium electrode can be modified according to the composition of the sludge in the actual biofilm reactor, so as to achieve the purpose of sludge cleaning by electrolysis after the sludge is vibrated by the high-frequency ultrasonic transducer.
[0083] Example 2, please refer to Figure 2 As shown, this application also provides a method for designing a bioreactor, comprising the following steps:
[0084] Step S1: Based on the cleaning standards and historical cleaning data of the biofilm reactor, the lowest concentration of sludge in the biofilm reactor during cleaning is recorded as the lowest concentration in the reactor; a water quality sensor is used to monitor the liquid in the biofilm reactor, and the monitored sludge concentration is recorded as the sludge concentration in the reactor.
[0085] Step S2: Use a water quality sensor to monitor the biofilm reactor and obtain sludge analysis parameters, including sludge deposition location and sludge thickness; use sludge analysis methods to analyze the sludge analysis parameters, and obtain the undetermined vibration point location and sludge group value based on the analysis results;
[0086] Step S2 includes: Step S201, placing a water quality sensor in the biofilm reactor, and monitoring the liquid in the biofilm reactor in operation for a duration of T days after placement; establishing a plane rectangular coordinate system, denoted as the sludge analysis coordinate system, wherein the units of the X-axis and Y-axis of the sludge analysis coordinate system are days and mg / L, respectively.
[0087] Step S202: Based on the time the water quality sensor is placed in the biofilm reactor and the monitored sludge concentration inside the reactor, plot the relationship curve between time and concentration in the sludge analysis coordinate system and record it as the sludge monitoring curve; the area in the sludge monitoring curve that is higher than Y = the lowest concentration inside the reactor is recorded as the parameter acquisition curve, wherein there may be multiple parameter acquisition curves.
[0088] Step S2 also includes: Step S203, for any parameter acquisition curve: when the operation of the biofilm reactor is within the time range corresponding to the parameter acquisition curve, a camera is used to perform real-time imaging of the inside of the biofilm reactor, and the image obtained is processed based on image analysis software, and the location of the sludge in the biofilm reactor is recorded as the sludge deposition location.
[0089] Step S204: For any sludge deposition location: the wall of the biofilm reactor where the sludge adheres at the sludge deposition location is denoted as the sludge-adhering wall, and n sampling points are uniformly obtained on the sludge surface at the sludge deposition location, which are denoted as sludge thickness sampling points; perpendicular lines are drawn from all sludge thickness sampling points to the sludge-adhering wall, and the length of the longest perpendicular line is denoted as the sludge thickness.
[0090] Step S205: Obtain all sludge deposition locations and the sludge thickness corresponding to each sludge deposition location when the biofilm reactor is operating within the time range corresponding to the acquisition curves of all parameters.
[0091] Step S206, the sludge analysis method includes: Step S2061, obtaining the size data of the biofilm reactor, wherein the size data includes length data, height data and width data; constructing a corresponding model in the spatial coordinate system based on the size data of the biofilm reactor, and recording it as the reactor model;
[0092] Step S2062: Based on the positional relationship between all sludge deposition locations and the biofilm reactor, mark the points corresponding to all sludge deposition locations within the reactor model and record them as sludge deposition points; for any sludge deposition point: record the sludge thickness at the sludge deposition location corresponding to the sludge deposition point as the quantitative parameter of the sludge deposition point.
[0093] The sludge analysis method also includes: step S2063, which records the bottom surface with the largest area of the reactor model as the maximum bottom surface, and records the diameter of the smallest circumscribed circle of the maximum bottom surface as L;
[0094] Step S2064: For any two sludge deposition points α1 and α2: when the length of the line connecting sludge deposition point α1 and α2 is greater than L, sludge deposition point α1 and α2 are recorded as a sludge group, and the midpoint of the line connecting sludge deposition point α1 and α2 is recorded as the undetermined vibration point; the sum of the quantization parameters of sludge deposition point α1 and α2 is recorded as the sludge group value.
[0095] Step S2065: Obtain all undetermined vibration points corresponding to all sludge deposition points and the sludge group value corresponding to each undetermined vibration point.
[0096] Step S3: Based on the sludge group value of each undetermined vibration point, use vibration analysis to obtain the sludge vibration point in the biofilm reactor, and obtain the sludge thickness range corresponding to each sludge vibration point.
[0097] The vibration analysis method includes: step S301, recording the quantitative parameters of sludge deposition points that are not in any sludge group as conventional parameters; obtaining the conventional parameters corresponding to all sludge deposition points, and recording the average value of all conventional parameters as the conventional mean;
[0098] Step S302: Obtain an empty biofilm reactor β, and uniformly coat the inner wall of the biofilm reactor β with sludge of a thickness equal to the conventional average value; for any sludge deposition point γ in at least one sludge group: coat the position corresponding to the sludge deposition point γ in the biofilm reactor β with sludge of a thickness equal to the quantified parameter of the sludge deposition point γ.
[0099] Step S303: The biofilm reactor β obtained after applying sludge is denoted as the vibration analysis reactor, and the total amount of sludge in the vibration reactor is denoted as the pre-vibration weight in grams.
[0100] The vibration analysis method also includes: step S304, based on the process objectives of the biofilm reactor, filling the vibration analysis reactor with an aqueous solution; for any unknown vibration point: based on the frequency standard of industrial cleaning, integrating a high-frequency ultrasonic transducer at the unknown vibration point, and starting the high-frequency ultrasonic transducer with rated power for a duration of Qmin; when the high-frequency ultrasonic transducer stops vibrating, recording the total amount of sludge in the vibrating reactor in grams as the post-vibration gram value, and recording the sum of the sludge thicknesses at the two sludge deposition points corresponding to the unknown vibration point as the sludge vibration value; recording the post-vibration gram value divided by the pre-vibration gram value as k1, recording the sludge vibration value divided by the sludge group values at the two sludge deposition points corresponding to the unknown vibration point as k2, and recording the sum of k1 and k2 as the vibration screening value;
[0101] Step S305: Obtain the vibration screening values of all undetermined vibration points, and record the average value of all vibration screening values as the vibration screening mean; record the undetermined vibration points with vibration screening values less than the vibration screening mean as sludge vibration points, and record the [sludge vibration value, sludge group value] corresponding to the sludge vibration points as the sludge thickness range.
[0102] Step S4: Integrate a high-frequency ultrasonic transducer and a titanium electrode into the biofilm reactor; When the biofilm reactor is running, clean the biofilm reactor using the high-frequency ultrasonic transducer and titanium electrode based on the real-time acquired sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges.
[0103] Step S4 includes: Step S401, during the operation of the biofilm reactor, the sludge thickness at the two sludge deposition points corresponding to all sludge vibration points is acquired in real time.
[0104] Step S402: When the sum of the sludge thicknesses of the two sludge deposition points corresponding to any sludge vibration point δ is within the sludge thickness range of the sludge vibration point δ, a high-frequency ultrasonic transducer is integrated at the sludge vibration point δ, and a titanium electrode is integrated in the biofilm reactor.
[0105] Step S403: Start the high-frequency ultrasonic transducer with rated power to vibrate, and use titanium electrodes to electrolyze and generate hypochlorous acid until the sum of the sludge thicknesses of the two sludge deposition points corresponding to the sludge vibration point δ is 0.
[0106] Example 3, please refer to Figure 5 As shown, Figure 5The example illustrates the structure of an electronic device, which may include a processor, a communication interface, a memory, and a communication bus, wherein the processor, the communication interface, and the memory communicate with each other through the communication bus. The memory stores computer-readable instructions, which the processor can call. When the computer-readable instructions are executed by the processor, steps such as those in a bioreactor design method are performed to achieve the following functions: First, based on the cleaning standards and historical cleaning data of the biofilm reactor, the lowest concentration of sludge in the biofilm reactor during cleaning is recorded as the lowest concentration in the reactor; then, a water quality sensor is used to monitor the biofilm reactor and acquire sludge analysis parameters; the sludge analysis parameters are analyzed using sludge analysis methods, and the undetermined vibration points and sludge group values are obtained based on the analysis results; furthermore, based on the sludge group values of each undetermined vibration point, vibration analysis methods are used to obtain the sludge vibration points in the biofilm reactor and the corresponding sludge thickness range for each vibration point; finally, a high-frequency ultrasonic transducer and titanium electrodes are integrated into the biofilm reactor; when the biofilm reactor is running, based on the real-time acquired sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges, the high-frequency ultrasonic transducer and titanium electrodes are used to clean the biofilm reactor.
[0107] Furthermore, when the logical instructions in the aforementioned memory can be implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.
[0108] Example 4: This application also provides a computer-readable storage medium storing a computer program. When the computer program is executed by a processor, it runs the steps in the above-described bioreactor design method to achieve the following functions: First, based on the cleaning standards and historical cleaning data of the biofilm reactor, the lowest concentration of sludge in the biofilm reactor during cleaning is recorded as the lowest concentration in the reactor; then, a water quality sensor is used to monitor the biofilm reactor and obtain sludge analysis parameters; the sludge analysis parameters are analyzed using a sludge analysis method, and the undetermined vibration points and sludge group values are obtained based on the analysis results; furthermore, based on the sludge group values of each undetermined vibration point, a vibration analysis method is used to obtain the sludge vibration points in the biofilm reactor and the sludge thickness range corresponding to each sludge vibration point; finally, a high-frequency ultrasonic transducer and titanium electrodes are integrated into the biofilm reactor; when the biofilm reactor is running, based on the real-time obtained sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges, the high-frequency ultrasonic transducer and titanium electrodes are used to clean the biofilm reactor.
[0109] Based on the above description of the embodiments, the embodiments of the present invention can be provided as methods, systems, or computer program products. Based on this understanding, the above technical solutions, in essence or in terms of their contribution to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or certain parts of the embodiments.
[0110] In the embodiments provided in this application, it should be understood that the disclosed system or method can be implemented in other ways. The embodiments described above are merely illustrative. For example, the division of modules or units is only a logical functional division, and there may be other division methods in actual implementation. Furthermore, multiple modules or units may be combined or integrated into another system, or some features may be ignored or not executed. Additionally, the coupling or direct coupling or communication connection shown or discussed may be through some communication interfaces. The indirect coupling or communication connection between systems, modules, and units may be electrical, mechanical, or other forms.
[0111] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.
Claims
1. A method for designing a bioreactor, characterized in that, Includes the following steps: Based on the cleaning standards and historical cleaning data of the biofilm reactor, the lowest concentration of sludge in the biofilm reactor during cleaning is recorded as the lowest concentration in the reactor; water quality sensors are used to monitor the liquid in the biofilm reactor, and the monitored sludge concentration is recorded as the sludge concentration in the reactor. The biofilm reactor was monitored using a water quality sensor, and sludge analysis parameters were obtained, including sludge deposition location and sludge thickness. The sludge analysis parameters were analyzed using sludge analysis methods, and the undetermined vibration point location and sludge group value were obtained based on the analysis results. Based on the sludge group value of each undetermined vibration point, the vibration analysis method is used to obtain the sludge vibration point in the biofilm reactor, and the sludge thickness range corresponding to each sludge vibration point is obtained. A high-frequency ultrasonic transducer and titanium electrodes are integrated into the biofilm reactor. When the biofilm reactor is running, the high-frequency ultrasonic transducer and titanium electrodes are used to clean the biofilm reactor based on the real-time sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges. The sludge analysis method includes: obtaining the dimensional data of the biofilm reactor, including length, height, and width data; constructing a corresponding model in a spatial coordinate system based on the dimensional data of the biofilm reactor, and denoting it as the reactor model; Based on the positional relationship between all sludge deposition locations and the biofilm reactor, the points corresponding to all sludge deposition locations are marked in the reactor model and recorded as sludge deposition points; for any sludge deposition point: the sludge thickness at the sludge deposition location corresponding to the sludge deposition point is recorded as the quantitative parameter of the sludge deposition point. The largest area of the reactor model is denoted as the largest base, and the smallest circumscribed circle of the largest base is denoted as L. For any two sludge deposition points α1 and α2: when the length of the line connecting sludge deposition points α1 and α2 is greater than L, sludge deposition points α1 and α2 are denoted as a sludge group, and the midpoint of the line connecting sludge deposition points α1 and α2 is denoted as the undetermined vibration point; the sum of the quantization parameters of sludge deposition points α1 and α2 is denoted as the sludge group value. Obtain all undetermined vibration points corresponding to all sludge deposition points and the sludge group value corresponding to each undetermined vibration point. Vibration analysis includes: recording the quantitative parameters of sludge deposition points not located in any sludge group as conventional parameters; obtaining the conventional parameters corresponding to all sludge deposition points, and recording the average value of all conventional parameters as the conventional mean; Obtain an empty biofilm reactor β, and uniformly coat the inner wall of the biofilm reactor β with sludge of a thickness equal to the conventional average value; for any sludge deposition point γ in at least one sludge group: coat the position corresponding to the sludge deposition point γ in the biofilm reactor β with sludge of a thickness equal to the quantified parameter of the sludge deposition point γ. The biofilm reactor β obtained after applying sludge is denoted as the vibration analysis reactor, and the total amount of sludge in the vibration reactor is denoted as the pre-vibration weight in grams. Based on the process objectives of the biofilm reactor, an aqueous solution is filled into the vibration analysis reactor. For any undetermined vibration point: based on the frequency standard of industrial cleaning, a high-frequency ultrasonic transducer is integrated at the undetermined vibration point, and the high-frequency ultrasonic transducer is started at rated power for a vibration duration of Qmin. When the high-frequency ultrasonic transducer stops vibrating, the total amount of sludge in the vibrating reactor is recorded as the post-vibration weight in grams, and the sum of the sludge thicknesses at the two sludge deposition points corresponding to the undetermined vibration point is recorded as the sludge vibration value. The post-vibration weight in grams divided by the pre-vibration weight in grams is recorded as k1, and the sludge vibration value divided by the sludge group values at the two sludge deposition points corresponding to the undetermined vibration point is recorded as k2. The sum of k1 and k2 is recorded as the vibration screening value. Obtain the vibration screening values of all undetermined vibration points, and record the average value of all vibration screening values as the vibration screening mean; record the undetermined vibration points whose vibration screening values are less than the vibration screening mean as sludge vibration points, and record the [sludge vibration value, sludge group value] corresponding to the sludge vibration points as the sludge thickness range.
2. The design method for a bioreactor according to claim 1, characterized in that, Water quality sensors were used to monitor the biofilm reactor and obtain sludge analysis parameters, including: A water quality sensor was placed inside the biofilm reactor, and the liquid inside the biofilm reactor under operation was monitored for a duration of T days after placement. A plane rectangular coordinate system was established and denoted as the sludge analysis coordinate system, where the units of the X-axis and Y-axis of the sludge analysis coordinate system are days and mg / L, respectively. Based on the time the water quality sensor is placed in the biofilm reactor and the monitored sludge concentration inside the reactor, a time-concentration relationship curve is plotted in the sludge analysis coordinate system and recorded as the sludge monitoring curve; the region in the sludge monitoring curve that is higher than Y = the lowest concentration inside the reactor is recorded as the parameter acquisition curve, where there may be multiple parameter acquisition curves.
3. The design method for a bioreactor according to claim 2, characterized in that, Monitoring biofilm reactors using water quality sensors and obtaining sludge analysis parameters also includes: For any parameter acquisition curve: when the operation of the biofilm reactor is within the time range corresponding to the parameter acquisition curve, a camera is used to image the inside of the biofilm reactor in real time, and the image obtained is processed based on image analysis software, and the location of the sludge inside the biofilm reactor is recorded as the sludge deposition location. For any sludge deposition location: the wall of the biofilm reactor where the sludge adheres at the sludge deposition location is denoted as the sludge-adhering wall, and n sampling points are uniformly obtained on the sludge surface at the sludge deposition location, denoted as sludge thickness sampling points; perpendicular lines are drawn from all sludge thickness sampling points to the sludge-adhering wall, and the length of the longest perpendicular line is denoted as the sludge thickness. When the biofilm reactor is operating within the time range corresponding to the acquisition curves of all parameters, obtain all sludge deposition locations and the sludge thickness corresponding to each sludge deposition location.
4. The bioreactor design method according to claim 3, characterized in that, A high-frequency ultrasonic transducer and titanium electrodes are integrated into the biofilm reactor. When the biofilm reactor is running, based on the real-time acquired sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges, the high-frequency ultrasonic transducer and titanium electrodes are used to clean the biofilm reactor, including: During the operation of the biofilm reactor, the sludge thickness at the two sludge deposition points corresponding to all sludge vibration points is acquired in real time. When the sum of the sludge thicknesses of the two sludge deposition points corresponding to any sludge vibration point δ is within the sludge thickness range of the sludge vibration point δ, a high-frequency ultrasonic transducer is integrated at the sludge vibration point δ, and a titanium electrode is integrated in the biofilm reactor. The high-frequency ultrasonic transducer is started with rated power to vibrate, and hypochlorous acid is generated by electrolysis using titanium electrodes until the sum of the sludge thicknesses at the two sludge deposition points corresponding to the sludge vibration point δ is 0.
5. A bioreactor design system for implementing the bioreactor design method according to any one of claims 1-4, characterized in that, It includes a sludge monitoring module, a sludge parameter analysis module, a vibration point positioning module, and a real-time cleaning module; The sludge monitoring module is used to record the lowest sludge concentration in the biofilm reactor during cleaning, based on the cleaning standards and historical cleaning data of the biofilm reactor, as the lowest concentration in the reactor; and to use a water quality sensor to monitor the liquid in the biofilm reactor and record the monitored sludge concentration as the sludge concentration in the reactor. The sludge parameter analysis module is used to monitor the biofilm reactor using water quality sensors and obtain sludge analysis parameters, including sludge deposition location and sludge thickness. The sludge analysis parameters are analyzed using sludge analysis methods, and the undetermined vibration point location and sludge group value are obtained based on the analysis results. The vibration point location module is used to obtain the sludge vibration point in the biofilm reactor based on the sludge group value of each unknown vibration point using vibration analysis, and to obtain the sludge thickness range corresponding to each sludge vibration point. The real-time cleaning module integrates a high-frequency ultrasonic transducer and titanium electrodes within the biofilm reactor. When the biofilm reactor is running, it cleans the biofilm reactor using the high-frequency ultrasonic transducer and titanium electrodes based on the real-time acquired sludge thickness and the sludge vibration points corresponding to all sludge thickness ranges.