DIY Ozone Reactor

sisterlimonpot

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Keno and Javon who have fairly large systems and they've been having great success with ozone reactors. Over the last year or so they've been proclaiming how great they are for organic breakdown and water clarity. The pessimist in me goes straight to all the negative stories I've read about them and found myself dismissing any necessary need for my tank. Yes, from time to time I would visit their tanks and comment on how clear the water was, it was as if the fish were floating in air. Don't get me wrong, when I look at the reactors something in the back of my mind forces me to dissect it to the basic concepts to full understand the process and because I do that, I think of ways to build one.

Every trip to those guys' house pushed me closer to making a reactor for myself. It wasn't until Bill sent me a text saying that he recently added an ozone generator and ran it through his skimmer that I started to think this might be a good time to make one. I mean come on, the weather is starting to cool off and it's time to start some projects in the shop!! I told Bill that I've read that larger systems don't benefit from just a generator pumping into a skimmer. I believe it has a lot to do with home safety, running it through a skimmer doesn't allow you to turn the ozone high enough or long enough to make a difference before you start to put you and your families health at risk [by emitting ozone into the house].

I discovered that in order to be beneficial to larger systems you need a reactor to increase contact time and a method to remove any excess O3 from leaking out of the effluent. Basically all the reaction is taking place inside the reactor and preventing any health concerns we may have by adding activated carbon to remove any ozone before it enters the tank.

I was passing that knowledge off to Bill, you know the larger systems requiring a reactor, and that I've been toying with the idea to make one. Make one, mostly because I see the price of reactors and know that I can easily cut that in half and have a nice looking finish product at the end. He insisted that I should make one for him as well. That was the nudge I needed to get the ball rolling.

The next day, I started to put together a rough list of materials needed. O3 is corrosive and can degrade certain plastics in no time. Material selection is critical when picking out the right equipment and parts. I started reading up and it turns out that many plastics we already use are naturally ozone resistant like silicone, acrylic, PVC, even the printed filament PETG. My research also pointed me to a plastic called kynar, which seems to be the one of the industry standards for machines that incorporate O3.

I'm also going to be looking at some of the ozone reactors that are on the market for inspiration, the 2 that always come to mind are the avast marine one and the one from geo.

With all this: I spent the last few days consolidating a list of materials, and I think I've ordered just about everything that I can think of. certain things I was able to get locally, like the acrylic cylinders and an assortment of the sch80 PVC plumping parts. The bulk of the stuff is coming from US plastics (kynar fittings and ozone resistant hose) and an online plumbing supply.

While parts start to trickle in, I'm going to be spending my time taking what's in my head and designing it on solidowrks. Stick around, this should be fun...

here's 3", 3.5", and 4.5" acrylic..
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sisterlimonpot

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Alright, let's get this party started. All the parts came in and I will try to document this as I go along.

I'm going to start with the top lid for the reactor. This is following the avast marine design, it has a rain spout attached to the top. the only difference is that I'm going to make that rain spout screw off for easy maintenance down the road.

I had to design and 3d print some roller cradles for each specific diameter of tube. the first one I made was for the 3.5" tube. Follow along as I cut a 1.5" section off of the acrylic tube. Enjoy:


Because this will be solvent welded, I need to sand away the blade marks. I use a wooden straight edge with self adhesive sand paper. After that I cut some pieces out on the laser and print some parts to make the rain spout removable.


Now it's time to design and cut out the top lid and put a NPT tap through the center, then glue it all up.... See if you can spot my screw up.






Stick around, the reactor body and media are next.
 

sisterlimonpot

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Todays progress was minimal, I have another side project that I share my free time with and today it commanded more of its fair share... hehe

None the less, I improved on the cylinder cutting, then designed the flange and bottom plate of the main reactor.


And my failed attempt to explain the bottom plate only to find out I didn't run the NPT tap through far enough...

 

sisterlimonpot

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Todays installment is cutting the groove for the o-ring and exploring ideas on how to diffuse the water cycling through the reactor. You can definitely tell that I'm exhausted. I can't even find the right words to use in the video. But you'll still get the gist.


 

sisterlimonpot

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I have everything ready to weld together. I mock it up so that you have an idea of how it all goes together.

 
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sisterlimonpot

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Sometimes, the things you want to do vs the things you have to do, don't align and your priorities takes precedence. This project stalled out, but hopefully it's back on track...

Part of the reason I stalled out, is because I wanted to design and 3D print a stand for the reactor, but I DID NOT want to simply 'extrude boss' a bunch if simple shapes. I know that it may come off a bit conceited, but as I progress with my CAD skills I feel that I should be further along than that.

I spent the week thinking of ways to steer clear of a simple design. For some reason, I couldn't come up with anything out of the ordinary. I was over my buddy Bill's house (he's the one that I building a 2nd ozone reactor for), and told him why the project came to a halt. He told me that it doesn't need to be spectacular, it's going to sit in the sump and not be seen anyway. Meh!!! what the fahq does he know? My signature used to read, "DIY shouldn't look like a 2 year old finger painting" and he had the balls to tell me that he disagreed... Hmm!

Well, you might say that I gave into peer pressure and reverted to 'extruding rectangles' to design the stand. In reality, the fact is, I was stumped. So here's my best mediocre attempt.

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sisterlimonpot

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I stopped early today. Got the majority of the carbon chamber cut out, I just need to glue everything.

 
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sisterlimonpot

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Here's the last installment before I start running it through its paces. Everything is put together and ready to test... I'm eager to see how the printed diffusers work...

 

sisterlimonpot

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I already have mine up and running but I just realized that I don't have any pictures of the finished product... So I took some of the one I'm giving to Bill.

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And the last thing I wanted to do was put the effluent into the inlet of the skimmer. I pulled the inlet tube off the skimmer and took some measurements. then designed and printed this to slide over the top.

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Now I get to see if the skimmate is darker and smellier than normal.
 

sisterlimonpot

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I dare you to ask Bill where he put the reactor? The stand could've been made of a shoddy bomb casing full of used pinball machine parts!
 
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