Fiber ball production process
1.Raw material processing and fiber modification
Substrate selection:
Polyester (PET), polypropylene (PP), or copolymer modified polymer materials (such as ethylene and acrylic monomer copolymers) are selected as raw materials, requiring corrosion resistance (pH 2-12), temperature resistance (≤ 120 ℃), and high strength characteristics.
Modified fibers adjust their surface chemical properties through copolymerization reactions, enhancing their hydrophilicity or adsorption performance.
Pre treatment process:
The molecular chain arrangement of fiber filaments is adjusted by steam stretching to enhance elasticity and tensile strength; Subsequently, acid or alkali washing is carried out to remove surface impurities, and the moisture content after drying is ≤ 3%.
2.FILTER BALL Forming and Structural Optimization
Curling and pore construction:
Using needle punching or hot melt technology to curl and shape fiber bundles, forming a multi-layered porous structure (specific surface area 800-1200m ²/m ³) with internal channel diameters of 1-3mm.
Dynamic core rotary extrusion technology is used to manufacture hollow spherical fillers, enhancing filtration efficiency and compressive strength (≥ 50kPa).
Spherical assembly:
Fiber bundles are tied into spheres using a tying machine, with a tying point density of ≥ 5/cm ² to ensure structural stability.
Surface composite aldehyde fiber or carbon fiber layer enhances impact resistance and microbial adhesion.
3. Post processing and performance enhancement
Functional processing of bio balls:
High temperature heat setting (120-150 ℃) fixes the three-dimensional structure of fibers to avoid deformation during use.
Immersing with surfactants such as polyvinyl alcohol can shorten the film-forming period to 3-5 days and improve the efficiency of wastewater treatment.
Quality inspection of bio filter balls:
Compressive strength test (≥ 50kPa), porosity analysis (≥ 90%), and verification of interception capacity (≥ 12kg/m ³).
Simulate sewage environment testing for regeneration times (≥ 500 times) to ensure durability.
Packaging, storage and transportation:
After cutting and standardizing the size, use moisture-proof woven bags (such as 25kg/bag) for packaging, and label the performance parameters; The storage temperature should be ≤ 30 ℃ and avoid direct ultraviolet radiation.