Pellet Block Polymerization via Forming Frame Oxygen Control
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Solution Overview
Problem
Existing methods for producing entrapping immobilization pellets for wastewater treatment, such as sheet forming, face challenges including unstable polymerization, reduced pellet strength, and high production costs due to the need for an oxygen-free atmosphere, as well as issues with unpolymerized substances being discharged during use.
Innovation Solution
A process and apparatus that polymerize a mixture of microorganisms and an immobilizing agent in a forming frame to reduce the interface with oxygen, using frames made of materials like vinyl chloride or acrylic resin, which allows for high-speed and cost-effective production of stable pellets by controlling the polymerization temperature and time, and facilitating easy removal of the pellet block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sheet forming is used to produce entrapping immobilization pellets, then mass production is achieved, but polymerization stability deteriorates and pellet strength is reduced due to large interface area contact with air
Solution Approach 1:
The patent uses a mold to form the mixture into a sheet shape, creating a confined structure that limits the interface area between the mixture and air. This mold-based approach maintains mass production capability while stabilizing polymerization by controlling oxygen exposure.
Solution Approach 2:
The patent introduces an oxygen-free or low-oxygen environment within the mold during polymerization. By creating an inert atmosphere in the confined space of the mold, the polymerization reaction becomes stable and complete, preventing the formation of unpolymerized substances while maintaining production efficiency.
2Speed
If sheet forming with large interface area contact with air is used, then production speed is maintained, but unpolymerized substances are generated and discharged
Solution Approach 1:
The patent creates an oxygen-free or low-oxygen environment within the mold during polymerization. This inert atmosphere ensures complete polymerization of the mixture, preventing the generation of unpolymerized substances that would otherwise be discharged during wastewater treatment.
Solution Approach 2:
The mold structure confines the mixture, limiting its contact with atmospheric oxygen. This confinement allows rapid polymerization to complete thoroughly, eliminating harmful unpolymerized residues while maintaining high production speed.
3Extent of automation
If conventional sheet forming is used, then automation is achieved, but production cost increases due to requirement for oxygen-free atmosphere
Solution Approach 1:
The patent uses simple mold structures that can be easily automated without requiring complex oxygen-free atmosphere generation systems. The mold itself provides the oxygen barrier, eliminating the need for expensive inert gas supply equipment while maintaining automation capability.
Solution Approach 2:
The patent employs simple, disposable, or easily cleanable mold structures that eliminate the need for expensive, complex oxygen-free atmosphere generation and maintenance equipment. This approach significantly reduces production costs while maintaining automated operation.
4Ease of manufacture
If mixture is allowed to contact air during polymerization, then production simplicity is maintained, but pellet strength is reduced
Solution Approach 1:
The patent uses a mold to confine the mixture during polymerization, creating a physical barrier that limits oxygen contact. This simple mold-based approach significantly improves pellet strength by ensuring complete polymerization, while maintaining ease of manufacture through the simplicity of the molding process.
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 results in entrapping immobilization pellets with high stability and strength, reducing production costs and improving wastewater treatment performance by minimizing unpolymerized substances and ensuring uniform pellet quality.
Implementation Method 1
polymerizing a mixture containing the microorganisms and a solution of the immobilizing agent in a forming frame into a gel to prepare a pellet block
Data Source
AI summary
A large amount of entrapping immobilization pellets with highly stable quality are produced inexpensively by high-speed treatment. There is provided a process for producing entrapping immobilization pellets in which microorganisms are entrapped and immobilized in an immobilizing agent, the process comprising polymerizing a mixture containing the microorganisms and a solution of the immobilizing agent in a forming frame into a gel to prepare a pellet block.