Mathematical Model Development and 3D Printing of Cylindrically Shaped Biofilm Carrier Media from Recycled Plastic Waste for Wastewater Treatment

Wastewater management and purification remain one of the greatest problems of mankind. The biological wastewater treatment technique uses a biofilm media carrier where microorganisms attach themselves to the surface. This biofilter is usually made from virgin plastic pellets and can also be produced from recycled waste plastic and used in wastewater treatment. The need to treat water using low-cost carrier media has led to finding alternative sources of materials for biofilter manufacturing. Therefore, this work is cen-tered on the recycling of waste plastic to make filaments which are then used for 3D printing of a high specific surface area (SSA) less clogging biofilm carrier through the parametric redesign. In the current study, the polypropylene material was recycled to make a 2.85 mm diameter filament compatible with the Ultimaker S3. Moreover, analytical models and governing equations were developed for the design of the K3 Kaldnes and MB3 media. Empirical surface area (SA), specific surface area, and volume of the respective carriers were determined using the model developed. SolidWorks was used to design and evaluate the same parameters which were then compared to model results. The errors in SSA obtained from the model with respect to the SolidWorks results for both the K3 Kaldnes and MB3 media were 0.34% and 0.76% respectively. Consequently, the deployment of such biofilters will enhance efficient wastewater treatment for a cleaner environment and the wellbeing of human race.