CN111621140A - 一种发泡海绵填料及其制备方法 - Google Patents

一种发泡海绵填料及其制备方法 Download PDF

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CN111621140A
CN111621140A CN202010353688.7A CN202010353688A CN111621140A CN 111621140 A CN111621140 A CN 111621140A CN 202010353688 A CN202010353688 A CN 202010353688A CN 111621140 A CN111621140 A CN 111621140A
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foaming
parts
sponge filler
steps
straw
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黎鹏
王霞
邬剑宇
曹亚丽
王磊
周超
吴良
杨力凯
赵雨
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China Design Group Environmental Technology Co ltd
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Abstract

本发明公开了一种发泡海绵填料制备方法，包括以下步骤：步骤a、在高分子发泡反应液中加入植物纤维分散相；步骤b、将植物纤维搅拌分散均匀后进行发泡反应；步骤c、固化定型。其中，高分子发泡反应液包括但不限于聚氨酯预聚体、EVA发泡组分、PVA发泡组分或者三聚氰胺发泡组分，植物纤维分散相包括但不限于小麦秸秆、水稻秸秆、玉米秸秆、油菜秸秆、棉花秸秆或者玉米芯，粒径为20～120目。本发明还公开一种发泡海绵填料，由上述制备方法制备得到。本发明提供的一种发泡海绵填料及其制备方法，有利于微生物的附着与生存，而且兼具缓释碳源功能，能够在污水处理过程中减少额外补加碳源，保证污水处理效果。

Description

一种发泡海绵填料及其制备方法
技术领域
本发明涉及一种发泡海绵填料以及制备方法，具体涉及一种兼具微生物依附载体及碳源缓释功能的水处理用发泡海绵填料及其制备方法，属于污水处理辅助材料技术领域。
背景技术
随着经济的发展和人们的环境意识增强，污水处理已经成为研究的重点。生物膜法是目前最常用的污水处理工艺之一，生物膜法使用填料作为微生物的重要载体，填料的性能及所负载的生物量将直接影响出水水质。在生物膜法水处理工艺中，海绵填料与其他填料相比，具有非常高的比表面积和孔隙率，能够在保持足够的微生物数量的同时，实现与水良好的分离，内部为功能菌的附着生长提供良好空间。
采用生物膜法处理污水，因反硝化过程中需要消耗大量的有机碳源，而污废水中C/N较低时，致使反硝化过程所需碳源不足，造成脱氮效率下降，需额外补加碳源以保证出水TN、TP达标，增加了运营控制难度及运营成本。
发明内容
本发明要解决的技术问题是，提供一种有利于微生物的生存，而且兼具缓释碳源功能，污水处理过程中减少额外补加碳源，保证污水处理效果的发泡海绵填料以及制备方法。
为解决上述技术问题，本发明采用的技术方案为：
一种发泡海绵填料制备方法，包括以下步骤：
步骤a、在高分子发泡反应液中加入植物纤维分散相；
步骤b、将植物纤维搅拌分散均匀后进行发泡反应；
步骤c、发泡反应后进行固化定型。
步骤a中，高分子发泡反应液包括但不限于聚氨酯预聚体、EVA 发泡组分、PVA发泡组分或者三聚氰胺发泡组分。
步骤a中，植物纤维分散相包括但不限于小麦秸秆、水稻秸秆、玉米秸秆、油菜秸秆、棉花秸秆或者玉米芯，粒径为20～120目。
高分子发泡反应液中主组分与植物纤维分散相的重量比为100： 5～100。
高分子发泡反应液选为聚氨酯预聚体，以重量计，聚氨酯预聚体配方为：聚醚三元醇100份、水2-10份、三乙烯二胺0.18份、硅油 3.8份、辛酸亚锡0.4份、二氯甲烷25-40份、TDI(80/20)80-120 份；发泡海绵填料制备步骤为在25℃下将聚醚三元醇、植物纤维、 TDI(80/20)混合后，加入水、三乙烯二胺、硅油、辛酸亚锡和二氯甲烷进行高速搅拌混合后倒入模具发泡、固化定型。
高分子发泡反应液选为EVA发泡组分，以重量计，EVA发泡组分配方为：EVA共聚物100份、聚乙烯40-50份、锌氧粉10-15份、硬脂酸1.5份、硬脂酸锌0.5份、过氧化二异丙苯1.8份、偶氮二甲酰胺5-7份、碳酸氢钠8份、三烯丙基氰脲酸酯0.5份；发泡海绵填料制备步骤为将EVA发泡组分和植物纤维加入密炼机中混合搅拌， 90℃下密炼10分钟后于50℃下开炼、85℃下造粒，造粒后混合物输入螺杆机90℃塑化加工，注射入模具内加温至180℃下发泡10分钟， 50℃热处理定型。
高分子发泡反应液选为PVA发泡组分，以重量计，PVA发泡组分配方为：PVA100份、表面活性剂K12 5-25份、硫酸150份、甲醛 75份、碳酸氢钠1.5-3份；发泡海绵填料制备步骤为在50℃下将植物纤维搅拌分散于10％PVA水溶液中，加入表面活性剂K12、硫酸， 1700rpm高速搅拌下加入甲醛和碳酸氢钠，发泡5min后倒入模具， 65℃下保温固化定型。
高分子发泡反应液选为三聚氰胺发泡组分，以重量计，三聚氰胺发泡组分配方为：三聚氰胺100份、多聚甲醛12-18份、碳酸钠2-10 份、正戊烷8份、表面活性剂K12 2-5份、乙酸5份、聚硅氧烷4份；发泡海绵填料制备步骤为将三聚氰胺、多聚甲醛、植物纤维混合均匀，输入螺杆机，加入碱液调节PH值为8-10之间，80℃下反应10分钟挤出造粒，造粒后与碳酸钠、正戊烷、表面活性剂K12、乙酸、聚硅氧烷混合均匀后输入螺杆机塑化，注射入模具，置于微波发泡炉内发泡定型。
一种发泡海绵填料，由所述发泡海绵填料制备方法制备得到。
该发泡海绵填料兼具微生物依附载体和碳源缓释功能。
本发明的有益效果：
1、植物纤维的加入，改善了发泡海绵填料的生物亲和性，更有利于挂膜，挂膜时间短，微生物附着量大。
2、植物纤维的加入，明显提升了发泡海绵填料的理化性能，纤维的交织增强作用，显著提高了海绵填料的力学强度、孔隙结构及填料的耐磨性，增加海绵填料的使用寿命。
3、植物纤维的加入，进一步提高了发泡海绵填料的吸水倍率，同时还实现对发泡海绵填料的密度和表面粗糙度的控制，更易于微生物的附着和生长。
4、植物纤维中的纤维素、半纤维素等成分在缓慢降解过程中，逐步形成低碳链分子，可被反硝化菌作为有机碳源加以利用，减少甚至无需在反硝化过程中额外补加碳源，提高污水处理效果的同时，降低污水处理过程的运维难度及成本。
5、制备方法条件温和、工艺简单、生产效率高、生产周期短，制备过程所添加的植物纤维为农林废弃物等，实现农林废弃物的二次利用的同时降低了产品的生产成本。
具体实施方式
下面对本发明作进一步描述，以下实施例仅用于更加清楚地说明本发明的技术方案，而不能以此来限制本发明的保护范围。
具体实施例1
本实施制备聚氨酯/油菜秸秆发泡海绵填料，以聚氨酯预聚体为基体，与油菜秸秆为分散相混合发泡而成，其制备方法包括以下步骤：
1)油菜秸秆经干燥脱水、碱处理、粉碎制得60目油菜秸秆颗粒。
2)25℃下将100份聚醚三元醇、60份油菜秸秆颗粒、80份TDI 搅拌混合均匀后，迅速加入4份水、0.18份三乙烯二胺、3.8份硅油、 0.4份辛酸亚锡、35份二氯甲烷进行高速搅拌混合后倒入模具发泡、固化定型。
3)脱模、清洗、干燥，切割成边长1cm的立方体快。
所制得的聚氨酯/油菜秸秆发泡海绵填料的平均孔径1.48mm，孔隙率为85％，拉伸强度0.32MPa。
具体实施例2
本实施制备聚氨酯/小麦秸秆发泡海绵填料，以聚氨酯预聚体为基体，与小麦秸秆为分散相混合发泡而成。其制备方法包括以下步骤：
1)小麦秸秆经干燥脱水、碱处理、粉碎制得100目小麦秸秆颗粒。
2)25℃下将100份聚醚三元醇、40份小麦秸秆颗粒、100份TDI 搅拌混合均匀后，迅速加入6份水、0.18份三乙烯二胺、3.8份硅油、 0.4份辛酸亚锡、25份二氯甲烷进行高速搅拌混合后倒入模具发泡、固化定型。
3)脱模、清洗、干燥，切割成边长1cm的立方体快。
所制得的聚氨酯/小麦秸秆发泡海绵填料的平均孔径0.73mm，孔隙率为69％，拉伸强度0.22MPa。
具体实施例3
本实施制备聚氨酯/水稻秸秆发泡海绵填料，以聚氨酯预聚体为基体，与水稻秸秆为分散相混合发泡而成。其制备方法包括以下步骤：
1)水稻秸秆经干燥脱水、碱处理、粉碎制得80目水稻秸秆颗粒。
2)25℃下将100份聚醚三元醇、80份油菜秸秆颗粒、120份TDI 搅拌混合均匀后，迅速加入10份水、0.18份三乙烯二胺、3.8份硅油、 0.4份辛酸亚锡、40份二氯甲烷进行高速搅拌混合后倒入模具发泡、固化定型。
3)脱模、清洗、干燥，切割成边长1cm的立方体快。
所制得的聚氨酯/水稻秸秆发泡海绵填料的平均孔径1.76mm，孔隙率为92％，拉伸强度0.31MPa。
具体实施例4
本实施制备EVA/玉米芯发泡海绵填料，以EVA共聚物为基体，与玉米芯颗粒为分散相混合发泡而成。其制备方法包括以下步骤：
1)玉米芯经干燥脱水、碱处理、粉碎制得120目玉米芯颗粒。
2)将100份EVA共聚物、40份玉米芯颗粒、40份聚乙烯、15 份锌氧粉、1.5份硬脂酸、0.5份硬脂酸锌、1.8份过氧化二异丙苯、5 份偶氮二甲酰胺、8份碳酸氢钠和0.5份三烯丙基氰脲酸酯加入密炼机中混合搅拌，90℃下密炼10分钟后于50℃下开炼、85℃下造粒，造粒后混合物输入螺杆机90℃塑化加工，注射入模具内加温至180℃下发泡10分钟，50℃热处理定型。
3)脱模、清洗、干燥，切割成边长1cm的立方体快。
所制得的EVA/玉米芯发泡海绵填料的平均孔径0.52mm，孔隙率为54％，拉伸强度0.51MPa。
具体实施例5
本实施制备PVA/玉米秸秆发泡海绵填料，以PVA聚合物为基体，与玉米秸秆颗粒为分散相混合发泡而成。其制备方法包括以下步骤：
1)玉米秸秆经干燥脱水、碱处理、粉碎制得20目玉米秸秆颗粒。
2)将100份PVA聚合物溶于水中制备成10％PVA水溶液，50℃下加入100份玉米秸秆颗粒，搅拌分散均匀后，加入20份K12，150 份硫酸，1700rpm高速搅拌下加入75份甲醛和3份碳酸氢钠，发泡5min后倒入模具，65℃下保温固化定型。
3)脱模、清洗、干燥，切割成边长1cm的立方体快。
所制得的PVA/玉米秸秆发泡海绵填料的平均孔径1.93mm，孔隙率为90％，拉伸强度0.48MPa。
具体实施例6
本实施制备三聚氰胺/棉花秸秆发泡海绵填料，以反应产物蜜胺树脂为基体，与棉花秸秆颗粒为分散相混合发泡而成。其制备方法包括以下步骤：
1)棉花秸秆经干燥脱水、碱处理、粉碎制得120目玉米秸秆颗粒。
2)将100份三聚氰胺、12份多聚甲醛、5份玉米秸秆颗粒混合均匀，输入螺杆机，加入碱液调节PH值为8-10之间，80℃下反应 10分钟挤出造粒，造粒后与10份碳酸钠、8份正戊烷、4份表面活性剂K12、5份乙酸和4份的聚硅氧烷混合均匀后输入螺杆机塑化，注射入模具，置于微波发泡炉内发泡定型。
3)脱模、清洗、干燥，切割成边长1cm的立方体快。
所制得的三聚氰胺/棉花秸秆发泡海绵填料的平均孔径0.40mm，孔隙率为72％，拉伸强度0.21MPa。
以上所述仅是本发明的优选实施方式，应当指出：对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (10)

1.一种发泡海绵填料制备方法，其特征在于：包括以下步骤：
步骤a、在高分子发泡反应液中加入植物纤维分散相；
步骤b、将植物纤维搅拌分散均匀后进行发泡反应；
步骤c、发泡反应后进行固化定型。
2.根据权利要求1所述的一种发泡海绵填料制备方法，其特征在于：步骤a中，高分子发泡反应液包括但不限于聚氨酯预聚体、EVA发泡组分、PVA发泡组分或者三聚氰胺发泡组分。
3.根据权利要求1所述的一种发泡海绵填料制备方法，其特征在于：步骤a中，植物纤维分散相包括但不限于小麦秸秆、水稻秸秆、玉米秸秆、油菜秸秆、棉花秸秆或者玉米芯，粒径为20～120目。
4.根据权利要求1所述的一种发泡海绵填料制备方法，其特征在于：高分子发泡反应液中主组分与植物纤维分散相的重量比为100：5～100。
5.根据权利要求2所述的一种发泡海绵填料制备方法，其特征在于：高分子发泡反应液选为聚氨酯预聚体，以重量计，聚氨酯预聚体配方为：聚醚三元醇100份、水2-10份、三乙烯二胺0.18份、硅油3.8份、辛酸亚锡0.4份、二氯甲烷25-40份、TDI(80/20)80-120份；发泡海绵填料制备步骤为在25℃下将聚醚三元醇、植物纤维、TDI(80/20)混合后，加入水、三乙烯二胺、硅油、辛酸亚锡和二氯甲烷进行高速搅拌混合后倒入模具发泡、固化定型。
6.根据权利要求2所述的一种发泡海绵填料制备方法，其特征在于：高分子发泡反应液选为EVA发泡组分，以重量计，EVA发泡组分配方为：EVA共聚物100份、聚乙烯40-50份、锌氧粉10-15份、硬脂酸1.5份、硬脂酸锌0.5份、过氧化二异丙苯1.8份、偶氮二甲酰胺5-7份、碳酸氢钠8份、三烯丙基氰脲酸酯0.5份；发泡海绵填料制备步骤为将EVA发泡组分和植物纤维加入密炼机中混合搅拌，90℃下密炼10分钟后于50℃下开炼、85℃下造粒，造粒后混合物输入螺杆机90℃塑化加工，注射入模具内加温至180℃下发泡10分钟，50℃热处理定型。
7.根据权利要求2所述的一种发泡海绵填料制备方法，其特征在于：高分子发泡反应液选为PVA发泡组分，以重量计，PVA发泡组分配方为：PVA100份、表面活性剂K12 5-25份、硫酸150份、甲醛75份、碳酸氢钠1.5-3份；发泡海绵填料制备步骤为在50℃下将植物纤维搅拌分散于10％PVA水溶液中，加入表面活性剂K12、硫酸，1700rpm高速搅拌下加入甲醛和碳酸氢钠，发泡5min后倒入模具，65℃下保温固化定型。
8.根据权利要求2所述的一种发泡海绵填料制备方法，其特征在于：高分子发泡反应液选为三聚氰胺发泡组分，以重量计，三聚氰胺发泡组分配方为：三聚氰胺100份、多聚甲醛12-18份、碳酸钠2-10份、正戊烷8份、表面活性剂K12 2-5份、乙酸5份、聚硅氧烷4份；发泡海绵填料制备步骤为将三聚氰胺、多聚甲醛、植物纤维混合均匀，输入螺杆机，加入碱液调节PH值为8-10之间，80℃下反应10分钟挤出造粒，造粒后与碳酸钠、正戊烷、表面活性剂K12、乙酸、聚硅氧烷混合均匀后输入螺杆机塑化，注射入模具，置于微波发泡炉内发泡定型。
9.一种发泡海绵填料，其特征在于：由权利要求1到权利要求8任一所述发泡海绵填料制备方法制备得到。
10.根据权利要求9所述的一种发泡海绵填料，其特征在于：该发泡海绵填料兼具微生物依附载体和碳源缓释功能。
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CN109734180A (zh) * 2019-01-22 2019-05-10 浙江工业大学 生物炭/聚乙烯醇缩甲醛多孔复合填料及其制备方法与应用

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CN112759066B (zh) * 2021-01-15 2023-11-03 华设设计集团环境科技有限公司 一种污水处理用秸秆类填料及其制备方法
CN114621486A (zh) * 2022-03-30 2022-06-14 北京博汇特环保科技股份有限公司 一种微膨胀生物载体及其制备方法与应用
CN116766734A (zh) * 2023-08-23 2023-09-19 苏州迪天机器人自动化有限公司 一种柔性高灵敏触觉传感器的制作工艺

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