KR101666463B1 - Filter media, manufacture method thereof and micro filtration apparatus with the same - Google Patents

Abstract

The present invention relates to filter media, a manufacturing method thereof, and a microfiltration apparatus using the same. The manufacturing method of filter media comprises the following steps of: (a) laminating a plurality of plane-shaped web filter media manufactured by using a fiber having the elasticity; and (b) manufacturing cushion-shaped filter media by sealing the edges of the plurality of laminated web filter media. The microfiltration apparatus using the same filters pollutants by the compression and the relaxation of the filter media, by using a fusion-type elastic fiber having high elasticity and durability, can actively generate the delamination phenomena during the back washing, and can obtain effects in extending a lifespan of a product by improving the durability of the filter media.

Description

FIELD OF THE INVENTION The present invention relates to a filtration material,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filter medium, a method of manufacturing the same, and a microfiltration apparatus using the filter medium. More particularly, the present invention relates to a filter medium to filter the entire filtration fluid such as industrial water for reuse.

In recent years, water shortage has intensified, and precision filtration technology for securing alternative water resources or reusing water has been developed.

To date, the water reuse market has been limited to low-value-added hydrophilic / irrigation water, so it is necessary to expand the high-quality reuse water to secure economic efficiency for utilizing high value-added industrial water.

As a result, the government has provided KRW 100 billion in wastewater treatment reuse-related projects by 2016, and is pursuing profitable projects for the private sector.

Generally, in the field of microfiltration, a sand filtration method or a method using a microfiltration material is used.

For example, Patent Document 1 below discloses a sand filtration method using sand particles as a filter material and a sand filtration apparatus technology using the sand filtration method.

The present applicant has already filed a patent application for a microfiltration filter and a method for manufacturing the same in many of the following Patent Documents 2 and 3.

Patent Document 1) Korean Patent Publication No. 10-2003-0009891 (published February 5, 2003) Korean Patent Registration No. 10-0706935 (Announcement on April 13, 2007)

However, the sand filtration method according to the prior art has a problem that environmental pollution is caused by the use of chemicals, a large amount of sludge is generated, facility investment cost is high, and large-scale site is required.

When a precision filter medium is used, turbidity of turbidity of 0.4 NTU or more, which shows turbidity due to suspended solids in water, shows unstable water quality, filtration flow rate is low, durability of membrane module is poor, There was a low problem.

Therefore, it is required to develop a technology that simplifies the structure and minimizes the volume so that high-quality reused water can be produced to secure high quality reused water, reduce the production cost of reused water, and apply it to sewage treatment plants in urban areas.

On the other hand, in the filtration apparatus according to the related art, there is a problem that the use of a ball type filter medium causes separation of the fibers constituting the filter medium, resulting in deterioration of durability.

Accordingly, it is required to develop a technique that prevents separation of the fibers constituting the filter medium, improves the elasticity of the filter medium, and improves durability.

SUMMARY OF THE INVENTION An object of the present invention is to provide a filter material capable of filtering and back washing contaminants by compression and relaxation of high-elasticity fibers, and a method for producing the same.

Another object of the present invention is to provide a filter material capable of preventing separation of the high-elasticity fiber material and improving durability, and a method for producing the same.

According to an aspect of the present invention, there is provided a method of manufacturing a filter medium, the method including: (a) laminating a plurality of planar web materials produced using fibers having elasticity; and (b) And sealing the edges of the web material to produce a cushion-shaped filtering material.

(C) further comprising forming a plurality of layers by thermally fusing a plurality of web materials stacked in a stacked state before sealing the edges of the plurality of web materials stacked in the step (b) , And the step (c) is characterized in that a plurality of laminated web webs are fused by a laminating process and a heat fusion process.

The web material is produced by composite spinning a plurality of polymers having different melting points.

The web material is produced by mixing an elastic fiber and an elastomer and then spinning the composite fiber.

Wherein the plurality of layers are formed by a plurality of web media having different characteristics by changing a mixing ratio of a plurality of polymers having different melting points or changing a manufacturing process.

In order to achieve the above-mentioned object, the filter material according to the present invention comprises a plurality of layers formed by laminating planar web materials produced using fibers having elasticity by a method of manufacturing a filter material, And is formed into a cushion-like shape by sealing the edges of the filter material.

In order to accomplish the above object, the present invention provides a microfiltration apparatus using a filter medium, comprising: a flocculation reaction unit for flocculating the solid fine particles contained in the filtration liquid; A first filtration unit which compresses a plurality of filter media by a pressure of the filtration liquid supplied from the first filtration unit and is in close contact with each other to adjust the air gap between the plurality of filter media to first filter the filtration liquid, And a second filtration unit for performing a second filtration of the filtrate supplied from the first filtration unit.

As described above, according to the filter medium, the method for producing the same, and the microfiltration apparatus using the filter medium according to the present invention, by using the fusion-type elastic fibers having high elasticity and durability, the contaminants are filtered by compression and relaxation of the filter medium, A segregation phenomenon can be actively generated, the durability of the filter medium can be improved, and the life of the product can be prolonged.

Particularly, according to the present invention, by providing a plurality of layers using a plurality of web filter media having different pore sizes, it is possible to obtain an effect that the removal efficiency during backwashing and filtration can be increased by using the density gradient of each layer.

According to the present invention, when the filter medium is compressed by the pressure of the entire filtration fluid, the gap between the plurality of filter mediums is adjusted to improve the filtration efficiency and the plurality of web media are laminated to form a cushion shape having a plurality of layers. It is possible to obtain an effect of increasing the filtration flow rate by improving the area.

Further, according to the present invention, since the filter medium is formed in a cushion shape having a plurality of layers, the dead zone generated inside the ball-type filter medium can be removed to improve the filtration performance and prevent the filter medium from being damaged Loses.

Further, according to the present invention, it is possible to prevent the pore change and deformation of the web filter material due to the bending life and the high temperature during the bending process by eliminating the bending process in the production of the filter material, improve the uniformity of the pore size, .

According to the present invention, it is possible to prevent deformation of the filter material due to the relaxation operation during compression and backwashing in the filtration process by sealing the edges of the filter material by ultrasonic sealing, and since there is no residual heat after the sealing process, It is possible to minimize the deviation and to prevent secondary contamination.

Thus, according to the present invention, it is possible to improve the filtration flow rate by increasing the filtration area and to maintain the uniform filtration performance even after the filtration time has elapsed.

As a result, according to the present invention, it is possible to produce a large amount of highly recycled water.

1 is a configuration diagram of a filtration apparatus using a filter medium according to a preferred embodiment of the present invention,
2 is a view of a general ball type filter medium,
3 is a perspective view of a filter medium according to a preferred embodiment of the present invention,
4 is a cross-sectional view of the filter medium,
FIG. 5 is a graph showing the pore size distribution of the filter medium shown in FIG. 3,
FIGS. 6 and 7 are graphs showing the filtration performance of the filter material shown in FIG. 3,
FIG. 8 is a process diagram for explaining steps of the method for manufacturing a filter medium according to a preferred embodiment of the present invention,
FIG. 9 is a state diagram of filtration and backwashing of a filter medium according to a preferred embodiment of the present invention. FIG.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a filter medium according to a preferred embodiment of the present invention, a method of manufacturing the same, and a microfiltration apparatus using the filter medium will be described in detail with reference to the accompanying drawings.

1 is a block diagram of a microfiltration apparatus using a filter according to a preferred embodiment of the present invention.

As shown in FIG. 1, the microfiltration apparatus using a filter medium according to a preferred embodiment of the present invention includes a flocculation reaction unit 10 for flocculating the solid fine particles contained in the filtration liquid, filtration supplied from the flocculation reaction unit 10 A first filtration unit 20 for compressing a plurality of filter media 40 by a total pressure while being compressed to adjust volume of a gap between the plurality of filter media 40 to filter the entire filtration media, And a second filtration unit 30 for secondarily filtering the filtrate supplied from the first filtration unit 20 using the first filtration unit 31.

The coagulation reaction unit 10 may be provided with a coagulant supply device (not shown) for supplying a coagulant to coagulate the solid fine particles contained in the filtration liquid.

The flocculant supply device adjusts the amount of the flocculant injected according to the influent load such as the flow rate or pressure of the filtration liquid flowing into the flocculation reaction section 10 so as to be an optimum condition for flocculating the solid fine particles to form floc .

The first filtering unit 20 compresses the plurality of filter media 40 provided therein by the pressure of the filtration liquid supplied from the flocculation and reaction unit 10 to be in close contact with each other, The filtration is firstly filtered by regulating the air gap, and the filter medium 40 is backwashed by using washing water to restore the original shape.

To this end, a feed pipe between the first filtration unit 20 and the flocculation reaction unit 10 is provided with a feed pump (not shown) for feeding the filtration fluid in which the solid fine particles are aggregated in the flocculation reaction unit 10 to the first filtration unit 20 A pump may be provided.

The first filtration unit 20 includes a filtration tank 21 that receives the entire filtrate through a lower side thereof, a plurality of filtration media 40 disposed at a central portion of the filtration tank 21, To the second filtration unit (30).

The second filtration unit 30 functions to precisely filter the filtrate filtered first under low differential pressure and low energy conditions using the membrane module 31 and to backwash the membrane module 31 using wash water.

For this purpose, a transfer pump provided between the first filtration unit 20 and the second filtration unit 30 is provided with a transfer pump for performing a pumping operation to supply the first filtration filtrate to the second filtration unit 30 .

The membrane module 31 may be provided as a hollow fiber type ultrafiltration membrane module.

On the other hand, the present invention is not limited thereto, and the configuration of the filtration device can be variously changed.

2 to 4, the structure of a filter medium according to a preferred embodiment of the present invention will be described in detail.

FIG. 2 is a view of a general ball type filter medium, FIG. 3 is a perspective view of a filter medium according to a preferred embodiment of the present invention, and FIG. 4 is a sectional view of the filter medium.

A typical ball-type filter medium is formed into a spherical shape using a fiber filter material, as shown in Fig. 2 (a).

Here, since the fiber filter material applied to a general ball-type filter medium is made of a material having no elasticity, it has low compressive force and restoring force, has poor durability, has a short life time, and is limited in application.

Particularly, as shown in FIG. 2 (b), the ball-type filter medium is used for filtration only when the filtering operation is performed, and dead zones are generated at the center thereof to reduce the filtration efficiency.

In addition, the ball type filter medium is difficult to cause sloughing when backwashing, the filtration area is limited to the surface area of the sphere, and a large amount of fiber filter material is required in manufacturing.

In addition, the ball-type filter medium is difficult to control the pore and has a high possibility of causing secondary pollution due to contaminants attached to the filter medium in the filtration process, and thus there is a limit in producing highly reclaimed water through microfiltration.

In order to solve such problems, the filter medium 40 according to the preferred embodiment of the present invention has a structure in which a planar web material fabricated using elastic fibers having elasticity, as shown in Figs. 3 and 4, (41 to 45).

For example, the filter material 40 may be manufactured by manufacturing a highly elastic web material of flat plate shape using a fusion-type elastic fiber having high elasticity and durability, and the web material produced as shown in Fig. 3 is divided into a plurality of layers 41 and 42 ), And they can be manufactured in a cushion shape by sealing the edges of each web material.

Accordingly, the filtration area of the filter media 40 can be calculated by summing the top and bottom areas of the filter media 40, which are convexly formed upward and downward, respectively.

The high elasticity web material can be produced by conjugating two polymers having different melting points to improve the recovery rate after compression and to facilitate backwashing.

For example, a high-elasticity web material is manufactured by mixing an elastic fiber and an elastomer, which is a rubbery polymer having elasticity and thermoplastic, .

The elastomer is used for an environment-friendly elastic nonwoven fabric, and is capable of being melted at a low temperature for molding, and has an excellent adhesion ability.

Accordingly, elastomers are now widely applied to seat cushions such as automobiles, trains, and sofas, padding such as bedclothes and clothes, and mattresses.

That is, when the web material is manufactured using only the elastic fibers, there is a problem that the nonwoven fabric is excessively melted during thermoforming and the workability is poor.

Accordingly, the present invention can solve the above-mentioned problems by mixing the elastic fibers and the elastomer mixedly and spinning them.

In FIG. 4, the filter medium 40 is formed of two layers of two web materials laminated, but the present invention is not limited thereto.

That is, the filter medium 40 of the present invention can be made of at least two layers by stacking a plurality of web filter media.

Here, each of the web materials constituting each layer may be provided with a web material having the same pore size, but preferably has different pore sizes.

That is, considering the optimization of the fiber cross-linking and the morphological stability, the filter medium 40 may be formed by laminating two or more web media having different properties by changing the mixing ratio of the elastic fibers and the elastomer, And may be manufactured to have a plurality of layers 41 and 42 through a thermal fusion process.

When the filter medium 40 having the plurality of layers 41 and 42 is formed using the web filter material having different pore sizes as described above, the pores of the web material forming the outer surface of the filter material 40 are provided inside It can be provided as a web filter having pores larger than pores of the web filter media.

On the other hand, the applicant of the present invention fabricated a flat elastic high-elasticity web material by using elastic and durable fusible elastic fibers having high elasticity and durability, bending the produced web material in pleated filter form a plurality of times, (Korean Patent Application No. 10-2014-0050560, hereinafter referred to as " prior application ").

However, since the filter material according to the preceding application is manufactured through bending and heat-sealing processes, the manufacturing process is complicated, the shape of the filter material is deformed for a long period of use, and the separation of the fiber material and separation between the fibers There is a problem that the durability is deteriorated.

In addition, the filter material according to the prior application has a problem in that the pore is deformed by the bending life and the high heat in the bending and heat fusion process, and the pore distribution of the fiber filter material becomes uneven.

Accordingly, the present invention eliminates the bending process and improves the elasticity of the filter material and improves the uniformity of the pore distribution by sealing both ends of the filter material by the ultrasonic sealing method.

5 is a graph of the pore size distribution of the filter medium shown in Fig.

As shown in FIG. 5, the filter material according to the present embodiment has a uniform pore distribution with a diameter of about 3.5 μm because the pore deformation does not occur by removing the bending process.

FIG. 6 and FIG. 7 are graphs showing the filtration performance of the filter material shown in FIG. 3.

FIG. 6 shows the result of the forward filtration performance test of the filter medium, and FIG. 7 shows the results of the reverse filtration performance test of the filter medium.

According to the filtration performance test results, it was confirmed that the filtration media according to the present embodiment had 99% or more removed at about 3.5 탆 in forward filtration as shown in FIG.

In addition, the filtration performance of the filter material according to the present example was measured for 10 minutes to 60 minutes in units of 10 minutes. As a result, it was confirmed that the filtration performance was stabilized over time, maintaining almost similar filtration performance over time.

As shown in FIG. 7, it was confirmed that the filtration material according to the present embodiment was removed at about 99% or more from about 3.5 탆 in the same manner as in the forward filtration.

Here, it was confirmed that the filtration performance deteriorated slightly after 20 minutes elapsed, but after that, the filtration performance was restored at the initial stage (about 10 minutes elapsed).

Meanwhile, after the filtration performance test as described above, the recovery rate of the filter according to the prior application and the present invention was tested.

The recovery rate test was performed for six times for 10 minutes, followed by compression for 24 hours with a disk filter (DISC), and the recovery condition of the compressed filter medium was measured for 30 minutes.

According to the results of the recovery rate test, the recovery rate of the filter material according to the prior application was about 70%.

On the other hand, it was confirmed that the filter material according to the present example exhibited a recovery rate of about 90% or more.

As described above, according to the present invention, since the filter material is manufactured in the form of a cushion by laminating a plurality of web filter materials, the filtration area is somewhat reduced as compared with the prior application, but the elasticity of the filter material is increased to improve the durability, The pore size can be uniformized and the filtration performance and stability can be improved.

Also, since the recovery rate of the filter is about 90% or more even in the recovery test conducted in the state of being compressed for 24 hours after the filtration performance test, the elasticity and durability of the filter can be greatly increased and the service life can be prolonged.

Next, a method of manufacturing a filter medium according to a preferred embodiment of the present invention will be described in detail with reference to FIG.

FIG. 8 is a process diagram for explaining steps of a method for manufacturing a filter medium according to a preferred embodiment of the present invention.

In step S10 of FIG. 8, two polymers having different melting points, such as an elastic fiber and an elastomer, are mixed and spin-mixed to produce a plate-like highly elastic web material.

At this time, in consideration of optimization of fiber-to-fiber cross-linking and shape safety, a plurality of web filter media having different characteristics are manufactured by changing the mixing ratio of the elastic fiber and the elastomer or by changing the manufacturing process.

In step S12, a plurality of web materials are laminated and fused by a laminating process and a heat fusion process.

Accordingly, the present invention can produce a filter material having a plurality of layers by laminating a plurality of fused web materials.

Subsequently, the filter material 40 is cut into a predetermined length so as to be cut into a predetermined standard so as to have a uniform shape and molded into a cushion shape (S14).

Lastly, the edge of each cut filter medium 40 is sealed to manufacture a cushion-shaped filter medium 40 (S16).

At this time, the sealing process may be performed by an ultrasonic sealing method in which sealing is performed using frictional heat generated by applying strong ultrasonic vibration to the web filter material to prevent deformation of the filter material 40 due to heat.

As described above, according to the present invention, the edges of the filter material are ultrasonically sealed to prevent deformation of the filter material due to the relaxation operation during compression and backwashing in the filtration process, and since there is no residual heat after the sealing process, Can be minimized to prevent secondary contamination.

In addition, the present invention can improve the durability of the filter medium during forward and backward filtration by improving the elasticity of the filter medium.

Further, since the ultrasonic sealing process can seal the edge of the filter medium within a short time, the operation time can be shortened, so that the manufacturing speed of the filter medium can be increased and the workability can be improved.

Next, the filtering operation of the filtration apparatus using the filter medium according to the preferred embodiment of the present invention will be described in detail with reference to FIGS. 1 and 9. FIG.

FIG. 9 is a state diagram of filtration and backwashing of a filter medium according to a preferred embodiment of the present invention.

As shown in FIG. 1, when a plurality of filter media 40 are installed in the filtration tank 21 of the first filter module 20, and the filtration media 40 is supplied by the pressure of the filtration media 40 They are compressed and come into close contact with each other.

Accordingly, as shown in Fig. 9A, the contaminants are pore-filtered while the air gap between the filter media 40 is reduced.

On the other hand, the backwashing filter medium 40 is relaxed and restored to its original shape as shown in FIG. 9 (b), and the contaminants attached to the filter medium 40 are desorbed and backwashed.

As described above, according to the present invention, by using the fusible elastic fibers having high elasticity and durability, the contaminants are filtered by compression and relaxation of the filter material, so that the desorption phenomenon can be actively generated during backwashing and the durability of the filter material can be improved The life of the product can be extended.

Particularly, the present invention provides a plurality of layers by using a plurality of web media having different pore sizes, so that the removal efficiency during backwashing and filtration can be increased by using the density gradient of each layer.

According to the present invention, the filtration efficiency is improved by controlling the air gap between the plurality of filter media when the filter medium is compressed by the pressure of the filtration liquid, and a plurality of layers of the filter media are laminated to form a cushion having a plurality of layers. So that the filtration flow rate can be increased.

Particularly, since the present invention is formed in a cushion shape having a plurality of layers, it is possible to improve the filtration performance and to prevent the filter medium from being damaged by removing dead zones generated in the ball type filter medium.

Through the above-described process, the present invention can control the gap by the compression and relaxation operation of the elastic filter medium, thereby preventing damage to the filter medium and extending the service life.

Although the invention made by the present inventors has been described concretely with reference to the above embodiments, the present invention is not limited to the above embodiments, and it goes without saying that various changes can be made without departing from the gist of the present invention.

The present invention is applied to a filtration material and a microfiltration device which can control the gap by compression and relaxation of the filter material having elasticity, prevent damage to the filter material, and prolong the life span of the filter material.

10: coagulation reaction unit 20: first filtration unit
21: Filtration tank 22: Transfer pipe
30: second filtration part 31: membrane module
40: filter medium 41, 42: layer

Claims (7)

A method for manufacturing a filter medium in which a plurality of filter media are compressed to reduce the volume of the filter media by a pressure supplied to the filter media,
(a) laminating a plurality of planar web media produced by using elastic fibers,
(b) forming a plurality of layers by thermally fusing a plurality of web media in a superimposed state, and
(c) sealing the edges of a plurality of web media formed with a plurality of layers to produce a cushion-like filter medium,
In the step (b), a plurality of laminated web materials are fused by a laminating process and a heat fusion process,
The web material is prepared by composite spinning a plurality of polymers having different melting points,
Wherein the plurality of layers are formed by a plurality of web materials having different characteristics by changing a mixing ratio of a plurality of polymers having different melting points or changing manufacturing processes. delete delete The method according to claim 1,
Wherein the web material is produced by mixing elastic fibers and an elastomer to composite fibers. delete A method for producing a filter medium according to any one of claims 1 to 4, wherein a plurality of layers are formed by laminating planar web material produced using fibers having elasticity, sealing the edges of the laminated web material, Lt; / RTI >
Wherein each of the filter media is compressed so that the volume thereof is reduced by the pressure to which the filtration fluid is supplied, and the filter media are closely contacted with each other to adjust the gap between the plurality of filter media to filter the filtrate. A flocculation reaction unit for flocculating the solid fine particles contained in the filtrate,
Wherein a plurality of the filter media according to claim 6 are installed inside the filter media and the plurality of filter media are compressed to reduce the volume by the pressure of the filtration fluid supplied from the coagulation and reaction part, A first filtration part for firstly filtering the entire liquid and
And a second filtration unit for performing a second filtration of the filtrate supplied from the first filtration unit using the membrane module.

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