Invert Emulsion Double Particle Size Sludge Dewatering
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Solution Overview
Problem
Current sludge dewatering methods using inorganic conditioners like lime, fly ash, and iron salts are inefficient, requiring high dosages and resulting in increased sludge volume and disposal costs, with uneven mixing of organic conditioners leading to suboptimal synergistic effects.
Innovation Solution
An invert emulsion with double particle size distribution is developed through a three-stage polymerization reaction, using emulsifiers and initiators to create a stable flocculant with small and large particle sizes, allowing for efficient sludge dewatering without additional conditioners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic conditioners (lime, fly ash, iron salts) are used for sludge dewatering, then flocculation and sedimentation can be achieved, but the dosage required is excessively high (total dosage ratio >20% of absolutely dry sludge, up to 40%), leading to increased sludge volume and disposal costs
Solution Approach 1:
The patent changes the chemical parameters of the conditioner by using organic compounds with specific functional groups (carboxyl, hydroxyl, amino, carbonyl) instead of inorganic conditioners. This parameter change enables effective dewatering at much lower dosages (reducing conditioner dosage to below 20% of absolutely dry sludge), thereby resolving the contradiction between dewatering effectiveness and conditioner dosage
Solution Approach 2:
The patent employs composite organic compounds combining multiple functional groups (carboxyl, hydroxyl, amino, carbonyl) within single molecules to achieve synergistic effects. This composite approach enhances the conditioning capability, allowing effective sludge dewatering with reduced dosage, thus addressing the contradiction between reliability and quantity
2Reliability
If a mixture of various organic conditioners is used (short-chain polyacrylamide, high-ionic polyacrylamide, quaternary ammonium salt, chitosan), then dewatering function can be achieved, but the physical compounding process results in uneven mixing and different components have different forms and solubility, preventing maximum synergistic effect
Solution Approach 1:
The patent merges multiple functional groups (carboxyl, hydroxyl, amino, carbonyl) into single organic compound molecules rather than using physical mixtures of separate conditioners. This merging ensures uniform molecular structure and consistent solubility, achieving homogeneous mixing at the molecular level and maximizing synergistic effects while eliminating the mixing uniformity problems of physical combinations
Solution Approach 2:
The patent designs organic compounds with homogeneous molecular structures that ensure uniform solubility and distribution in sludge. The consistent chemical nature of the compound molecules guarantees homogeneous mixing and uniform action throughout the sludge mass, resolving the contradiction between dewatering function and mixing uniformity
3Volume of stationary object
If inorganic conditioners are added in the form of dry solids, then the sludge volume is reduced after dewatering, but the total amount of final sludge to be disposed is increased, leading to secondary increase in disposal costs
Solution Approach 1:
The patent changes the physical state and chemical composition of conditioners from inorganic dry solids to organic compounds with higher biodegradability. This parameter change allows the conditioner to be degraded and mineralized, reducing the accumulation of solid residue and thereby reducing disposal costs while maintaining sludge volume reduction benefits
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The invert emulsion achieves a filter cake water content below 50%, reducing sludge volume and disposal costs, with high solid content and fast dissolution, meeting the requirements of minimization, stabilization, and resource utilization.
Implementation Method 1
preparing in one step an invert emulsion the particle size of which has bimodal distribution by means of a three-stage polymerization reaction between the emulsion A and the emulsion B in the same system
Implementation Method 2
forming an emulsion A and an emulsion B having different particle sizes by controlling an emulsifier system and an emulsification means
Implementation Method 3
the chemically bound water can be removed by breaking chemical bonds due to its strong binding force
Implementation Method 4
a polymeric flocculant, such as polyacrylamide, is added for flocculation and sedimentation
Implementation Method 5
The aggregate structure finally settles in water to form sludge
Data Source
AI summary
An invert emulsion having double particle size distribution, the invert emulsion having a particle size distribution of latex particles between 20 nm and 70 nm and between 100 nm and 500 nm in the same invert emulsion system. A preparation method for an invert emulsion comprises: forming an emulsion A and an emulsion B having different particle sizes by controlling an emulsifier system and an emulsification means, and preparing in one step an invert emulsion the particle size of which has bimodal distribution by means of a three-stage polymerization reaction between the emulsion A and the emulsion B in the same system. The invert emulsion is used as a water treatment flocculant, a sludge dewatering agent and a papermaking auxiliary agent, and in particular, the sludge dewatering agent fabricated from the invert emulsion is used for dewatering sludge.