Nonwoven Fibrous Slurry Recycling With Neutral pH Flocculation
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Solution Overview
Problem
Existing processes for making nonwoven fibrous materials using aqueous slurries discard waste water, requiring costly water treatment and failing to effectively recycle it due to pH imbalances caused by flocculents, leading to premature flocculation and reduced structural integrity of the resulting materials.
Innovation Solution
A method that recycles waste water from a first slurry to form a second slurry with a neutral pH flocculent, maintaining the pH neutrality and preventing premature flocculation, allowing for the reuse of significant quantities of waste water without adverse effects on the flocculation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If waste water is discarded from the slurry process, then environmental compliance is achieved through water treatment, but water resources are lost and treatment costs increase
Solution Approach 1:
The patent recovers waste water from the slurry process that would otherwise be discarded, treating it for reuse in subsequent slurries. This transforms a waste stream into a valuable resource, reducing both water loss and treatment costs by implementing a circular water management system within the manufacturing process.
Solution Approach 2:
The patent converts the harmful aspect of waste water (which requires treatment and represents loss) into a beneficial resource by demonstrating that properly managed waste water can be reused effectively in subsequent slurries without adversely affecting flocculation or material quality, thereby eliminating both the harm and the associated treatment costs.
2Loss of substance
If waste water is reused in subsequent slurries, then water resources are conserved and treatment costs are reduced, but pH imbalances cause premature flocculation and reduced structural integrity
Solution Approach 1:
The patent addresses pH imbalances in recycled waste water by adjusting chemical parameters through the addition of alkaline substances or by blending with fresh water to achieve optimal pH levels. This parameter adjustment prevents premature flocculation and ensures the structural integrity of the nonwoven material is maintained while enabling effective water recycling.
3Reliability
If neutral pH flocculent is used in recycled waste water, then flocculation effectiveness is maintained and structural integrity is preserved, but process complexity increases
Solution Approach 1:
The patent employs neutral pH flocculents that are specifically designed to function effectively in the recycled waste water environment, allowing the system to self-regulate flocculation processes without requiring complex external control mechanisms. The neutral pH flocculent adapts to the recycled water conditions and maintains effectiveness autonomously, reducing the need for additional process complexity.
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
This approach enables the reuse of up to 100% of waste water, reducing treatment costs and maintaining the structural integrity of nonwoven fibrous materials suitable for pollution control devices and firestop applications by ensuring effective flocculation and pH neutrality.
Implementation Method 1
a first neutral pH flocculent; providing a second slurry comprising a quantity of the first waste water, an optional quantity of relatively clean water, second inorganic fibers, a second organic binder, and a second flocculent that is the same and/or a different flocculent than that used in the first slurry
Data Source
AI summary
A method of making nonwoven fibrous materials suitable for use in a pollution control device or as a firestop, where the method comprises: providing a first slurry comprising water, first inorganic fibers, a first organic binder, and a first neutral pH flocculent; removing first waste water from the first slurry; optionally forming a first nonwoven fibrous material from the first slurry; providing a second slurry comprising a quantity of the first waste water, an optional quantity of relatively clean water, second inorganic fibers, a second organic binder, and a second flocculent that is the same and/or a different flocculent than that used in the first slurry; and forming a second nonwoven fibrous material from the second slurry. The addition of the first waste water in the second slurry does not adversely affect the flocculation of the second organic binder in the second slurry.