CFD simulation of fluid dynamic and biokinetic processes within activated sludge reactors under intermittent aeration regime

Integrating biokinetics with computational fluid dynamics for energy performance analysis in anaerobic digestion

Anaerobic digestion (AD) is an effective process for decomposing organic matter in wastewater treatment plants (WWTPs) where highly efficient digesters properly mix the sludge. To ensure a uniform substance distribution, a comprehensive modeling method is necessary. Computational fluid dynamics (CFD) helps in the modeling of AD tanks but few studies have focused on integrating hydrodynamics with biokinetics because of complex AD processes. The current study presents a new CFD platform for estimating the biokinetics of WWTPs to assess the energy performance of AD tanks. The presented method is validated by numerical and experimental studies, and facilitates a link between methane production and mixing energy consumption. The on-site settings of the recirculation mixing system in the studied WWTP was able to prepare a uniform mixture of the material. However, reducing mixing rate to decrease energy consumption did not lead to proper mixing quality.

The best location for the application of static magnetic fields based on biokinetic coefficients in complete-mix activated sludge process

The use of the kinetic coefficients for the mathematical expression of the biochemical processes and the relationship between the effective parameters is importance. Change of the biokinetic coefficients in the complete-mix activated sludge processes were calculated for 1 month operation of the activated sludge model (ASM) in a Lab-scale in three series. 15 mT intensity of static magnetic fields (SMFs) applied on the aeration reactor (ASM 1), clarifier reactor (ASM 2) and, sludge returning systems (ASM 3) for 1 h, daily. During the operation of the systems, five basic biokinetic coefficients such as maximum specific substrate utilization rate (k), heterotrophic half-saturation substrate concentration (K_s), decay coefficient (k_d), yield coefficient (Y) and, maximum specific microbial growth rate (μ_max) were determined. The rate of k (g COD/g Cells.d) in ASM 1 was 2.69% and, 22.79% higher than ASM 2 and, ASM 3. The value of K_s (mg COD/L) was 54.44 and, 71.13 (mg/L) lower than the ASM 2 and, ASM 3. The rate of k_d ASM 1, ASM 2 and, ASM 3 was 0.070, 0.054 and, 0.516 (d^-1). The value of Y (kg VSS/kg COD) in ASM 1 was 0.58% and, 0.48% lower than ASM 2 and, ASM 3. The rate of μ_max (d^-1) in ASM 1 was 0.197, this value for ASM 2 and ASM 3 were 0.324 and 0.309 (d^-1). Related to the biokinetic coefficients analyses the best location for the application of 15 mT SMFs was the aeration reactor, where the present of oxygen, substrate and, SMFs have the greatest impact on the positive changes of these coefficients.

Model-based evaluation of the impacts of aeration on tightly bound and loosely bound extracellular polymeric substance production under non-steady-state conditions

Tightly bound extracellular polymeric substances (TB-EPS) and loosely bound extracellular polymeric substances (LB-EPS) affect the flocculability and settleability of sludge and the transfer of oxygen, which are highly related to aeration. In this study, we systemically evaluated the expanded unified model-TL2.1 for its long-term simulation of TB-EPS and LB-EPS. Two different aeration conditions and three different influent carbon sources were used to evaluate the model, and the simulation results fit well with the experimental data. TB-EPS and LB-EPS production increased with aeration intensity. The influence of aeration parameters on TB-EPS and LB-EPS production in a short-term batch system and long-term sequencing batch reactor (SBR) system was compared. The aeration parameters included the total transfer coefficient (k_La) and the concentration of dissolved oxygen at the interface (C_S). To ensure a high removal rate of substrates and ammonia nitrogen and achieve a stable active biomass concentration, the following aeration parameters can be adopted to reduce energy wastage during aeration: when C_S is 2 mg/L, k_La can be set above 30 h^-1 and below 50 h^-1; when k_La is 50 h^-1, C_S can be set above 1 mg/L and below 1.5 mg/L. This study systematically revealed the influence of aeration on TB-EPS and LB-EPS formation in an SBR system through a mathematical model, and it provides a theoretical basis for better understanding aeration.

Effect of flow regime on mass transfer diffusion and stability of aerobic granular sludge (AGS) in view of interfacial thermodynamic

Aerobic granular sludge (AGS) technology has been widely studied as "The Next Generation Wastewater Treatment technology". The effect of hydraulic conditions on the structural stability of AGS has been widely studied. However, the function of flow regime on the AGS stability, especially dissolved oxygen (DO) mass transfer, is still unknown. In this study, we used the Reynolds number (Re) to quantify the flow regime and selected different stages of AGS as experimental subjects. Results showed that the relatively suitable Re (Re = 150) could create lower DO mass transfer limitation (Lc = 27.4 μm) and increase protein (PN) contents and the abundance of hydrophobic functional groups in AGS. At this condition (Re = 150), the interfacial Gibbs free energy of sludge-water (ΔG_LS^a) was at a lower state (-129.75 ± 2.15 mJ·m^-2), which favored the stability of AGS. Principal component analysis (PCA) and correlation analysis indicated that the response of ΔG_LS^a was affected by Lc, PN, and hydrophobic groups. In addition, results obtained for unstable AGS further verified that suitable Re regulates the structural stability of AGS. This study deepens the understanding of Re as an important hydraulic parameter for structural stability of AGS, which is also of great significance for energy saving of sequential batch reactors (SBRs) with agitation in practical engineering.

Optimization of airflow and aeration cycles in a new structured bed reactor configuration for carbon and nitrogen removal

The Structured Bed Reactor with Recirculation and Intermittent Aeration (SBRRIA) is a reactor configuration that presents high efficiency of organic matter and nitrogen removal, besides low sludge production. However, operational parameters, as the recirculation rate, aeration time, and airflow, are not fully established. A bench-scale structured bed reactor with intermittent aeration was fed with synthetic effluent simulating the characteristics of sanitary sewage. The reactor was operated for 280 days with an operational hydraulic retention time (HRT) of 10 h. The reactor was operated without effluent recirculation for the first time since this approach was not yet reported, and was named Structured Bed Reactor with Intermittent Aeration (SBRIA). The COD removal was higher than 81% for all operational conditions, and the total nitrogen removal ranged from 10 to 80%. The highest efficiencies were obtained with an aeration time of 1 h 45 min (total cycle of 3 h) and an airflow rate of 4.5 L.min^-1. Different nitrification and denitrification behaviours were observed, resulting in nitrification efficiencies over 90% when the reactor was submitted to higher aeration times and denitrification efficiencies above 90% when the reactor was submitted to low aeration times. The airflow ranges tested in this study affected the nitrification and the total nitrogen efficiencies. Even without effluent recirculation, the temporal profile showed that there were no peaks in the concentration of the nitrogen forms in the reactor effluent, saving electrical energy up to 75% due to pumping.

Can a Wastewater Treatment Plant Power Itself? Results from a Novel Biokinetic-Thermodynamic Analysis

The water–energy nexus (WEN) has become increasingly important due to differences in supply and demand of both commodities. At the center of the WEN is wastewater treatment plants (WWTP), which can consume a significant portion of total electricity usage in many developed countries. In this study, a novel multigeneration energy system has been developed to provide an energetically self-sufficient WWTP. This system consists of four major subsystems: an activated sludge process, an anerobic digester, a gas power (Brayton) cycle, and a steam power (Rankine) cycle. Furthermore, a novel secondary compressor has been attached to the Brayton cycle to power aeration in the activated sludge system in order to increase the efficiency of the overall system. The energy and exergy efficiencies have been investigated by varying several parameters in both WWTP and power cycles. The effect of these parameters (biological oxygen demand, dissolved oxygen level, turbine inlet temperature, compression ratio and preheater temperature) on the self-efficiency has also been investigated. It was found here that up to 109% of the wastewater treatment energy demand can be produced using the proposed system. The turbine inlet temperature of the Brayton cycle has the largest effect on self-sufficiency of the system. Energy and exergy efficiencies of the overall system varied from 35.7% to 46.0% and from 30.6% to 33.55%, respectively.

Enhancement of biological nutrient removal process with advanced process control tools in full-scale wastewater treatment plant

One of the major challenges in existing WasteWater Treatment Plants (WWTPs) is to comply with the increasingly stringent nutrient discharge limits established by the competent authorities to enhance environmental protection, while keeping operation costs as low as possible. This paper describes the results obtained from upgrading a full-scale WWTP during seven years (2013-2020) applying five different Advanced Process Control (APC) strategies. Results show that implementation of APC and the development of ammonia-based aeration control, aeration/non-aeration cycles, improved internal/external recirculation and chemical dosage controls resulted in an improvement in nutrients removal rates (+25.48% and +9.25%, for nitrogen and phosphorus, respectively) and in a reduction (-21.79%) of the specific energy ratio. In addition, the promotion of an Enhanced Biological Phosphorous Removal (EBPR) process by APC resulted in an improvement in biological phosphorous removal (+43.90%), chemical savings (-20.00%) and nutrient recovery in the dewatered sludge. Molecular biology tools and laboratory batch tests confirmed the Polyphosphate Accumulating Organisms (PAOs) activity, specifically Tetrasphaera genera. Finally, an economic analysis was conducted, showing a rate of return for the incurred capital expenses with the implemented APC systems of about five years, being an affordable alternative to the upgrading existing WWTPs.

Performance of Full-Scale Thermophilic Membrane Bioreactor and Assessment of the Effect of the Aqueous Residue on Mesophilic Biological Activity

To date, the management of high-strength wastewater represents a serious problem. This work aims to evaluate the performance on chemical pollutants and on sludge production of one of the two full-scale thermophilic membrane bioreactors (ThMBRs) currently operational in Italy, based on monitoring data of the last two and a half years. Removal yields on COD, N-NOx, non-ionic and anionic surfactants (TAS and MBAS), increased with the input load up to 81.9%, 97.6%, 94.7%, and 98.4%, respectively. In the period of stability, a very low value of sludge production (0.052 kgVS kgCOD−1) was observed. Oxygen uptake rate (OUR) tests allowed us to exclude the possibility that mesophilic biomass generally exhibited any acute inhibition following contact with the aqueous residues (ARs), except for substrates that presented high concentrations of perfluoro alkyl substances (PFAS), cyanides and chlorides. In one case, nitrifying activity was partially inhibited by high chlorides and PFAS concentration, while in another the substrate determined a positive effect, stimulating the phenomenon of nitrification. Nitrogen uptake rate (NUR) tests highlighted the feasibility of reusing the organic carbon contained in the substrate as a source in denitrification, obtaining a value comparable with that obtained using the reference solution with methanol. Therefore, respirometric tests proved to be a valid tool to assess the acute effect of AR of ThMBR on the activity of mesophilic biomass in the case of recirculation.

An efficient hydrodynamic-biokinetic model for the optimization of operational strategy applied in a full-scale oxidation ditch by CFD integrated with ASM2

Oxidation ditches (ODs) are often used for wastewater treatment. However, limitations of ODs like high energy expenditure and increased sludge sedimentation hinder its wide application. In this study, the computational fluid dynamics (CFD) model integrated with Activated Sludge Model No. 2 (ASM2) was proposed and applied in a full-scale OD. The integrated model provided heterogeneous information on the characteristics of hydrodynamics and biokinetics of OD, especially with respect to the simulation of total phosphorus removal by CFD-ASM2 integration model for the first time. The simulated values of flow velocities, suspended solids (SS), dissolved oxygen, chemical oxygen demand, total nitrogen, ammonium nitrogen, and total phosphorus concentrations were well validated with the measured results, with the standard deviation errors of less than 5.56%, 0.28%, 0.74%, 7.39%, 3.17%, 5.27%, and 7.40%, respectively. Based on the integrated model, four different operational strategies were simulated. The proposed operational strategy of operating 7 surface aerators and 10 submerged impellers not only met the standard discharge requirements (GB 18918-2002) but also consumed less energy by 22.3%, compared with the original strategy of operating 9 surface aerators and 13 submerged impellers. Meanwhile, this proposed operational strategy also reduced the SS concentrations in the second and fourth channels, which was beneficial to elimination of sludge sedimentation. Moreover, the proposed operational strategy was successfully applied and validated in full-scale OD. The foregoing results collectively suggest that the CFD-AMS2 integration model is numerically capable to optimize the operational strategy of ODs.

Removal of Nutrients From Anaerobically Digested Swine Wastewater Using an Intermittent Cycle Extended Aeration System

Swine wastewater contains high concentrations of organic compounds, nutrients (nitrogen and phosphorus), heavy metals, and residual antibiotics, amongst others, that have negative impacts on the water environment. The main aim of this work was to remove nutrients from anaerobically digested swine wastewater using an intermittent cycle extended aeration system (ICEAS). The effects of operational parameters such as cycle time, organic loading rate, C/N ratio, and aeration/mixing ratio on the pollutant removal efficiencies of ICEAS were studied and compared with the performance of a conventional sequencing batch reactor (SBR). The following optimal conditions were obtained: cycle time, 6 h; organic loading rate, 0.86 kg COD m-3 day-1; C/N ratio, 2.49-2.82; and aeration/mixing ratio, 1.57. The pH was maintained in the range of 6.0-8.0. The total organic carbon (TOC), total nitrogen (TN), ammonium (NH4 +), total phosphorus (TP), and color removal efficiencies of ICEAS were higher than those of the conventional SBR, with removal efficiencies of 95.22, 88.29, 97.69, 85.81, and 97.84%, respectively, compared to 94.34, 81.16, 94.15, 77.94, and 96.95%, respectively, observed in the SBR. TOC, TN, NH4 +, TP, and the color removal efficiencies of ICEAS were higher by 0.88, 7.13, 3.54, 7.87, and 0.95%, respectively, than the conventional SBR. The good results from this study show that ICEAS is a promising technology for the removal of organic contaminants and nutrients from anaerobically digested swine wastewater and that the effluent water quality meets the Vietnamese discharge standard (QCVN 62-MT:2016/BTNMT) for swine wastewater effluents.

Predicting wastewater treatment plant performance during aeration demand shifting with a dual-layer reaction settling model

Demand response (DR) programmes encourage energy end users to adjust their consumption according to energy availability and price. Municipal wastewater treatment plants are suitable candidates for the application of such programmes. Demand shedding through aeration control, subject to maintaining the plant operational limits, could have a large impact on the plant DR potential. Decreasing the aeration intensity may promote the settling of the particulate components present in the reactor mixed liquor. The scope of this study is thus to develop a mathematical model to describe this phenomenon. For this purpose, Benchmark Simulation Model No.1 was extended by implementing a dual-layer settling model in one of the aerated tanks and combining it with biochemical reaction kinetic equations. The performance of this extended model was assessed in both steady-state and dynamic conditions, switching the aeration system off for 1 hour during each day of simulation. This model will have applications in the identification of potential benefits and issues related to DR events, as well as in the simulation of the plant operation where aerated tank settling is implemented.

Quantifying the Benefit of a Dynamic Performance Assessment of WWTP

In this work a comprehensive analysis of the environmental impact of the operation of a wastewater treatment plant (WWTP) using different control strategies is carried out considering the dynamic evolution of some environmental indicators and average operation costs. The selected strategies are PI (proportional integral) control schemes such as dissolved oxygen control in the aerobic zone (DO control), DO control and nitrates control in the anoxic zone (DO + NO control) and regulation of ammonium control at the end of aerobic zone (Cascade SNHSP) commonly used in WWTPs to maintain the conditions that ensure the desired effluent quality in a variable influent scenario. The main novelty of the work is the integration of potential insights into environmental impact from the analysis of dynamic evolution of environmental indicators at different time scales. The consideration of annual, bimonthly and weekly temporal windows to evaluate performance indicators makes it possible to capture seasonal effects of influent disturbances and control actions on environmental costs of wastewater treatment that are unnoticed in the annual-based performance evaluation. Then, in the case of periodic events, it is possible to find solutions to improve operation by the adjustment of the control variables in specific periods of time along the operation horizon. The analysis of the annual average and dynamic profiles (weekly and bimonthly) of environmental indicators showed that ammonium-based control (Cascade SNHSP) produce the best compromise solution between environmental and operation costs compared with DO control and DO + NO control. An alternative control strategy, named SNHSP var Qcarb var, has been defined considering a sequence of changes on ammonium set-point (SNHSP) and carbon dosage (Qcarb) on different temporal windows. It is compared with DO control considering weekly and bimonthly profiles and annual average values leading to the conclusion that both strategies, Cascade SNHSP and SNHSP var Qcarb var, produce an improvement of dynamic and annual average environmental performance and operation costs, but benefits of Cascade SNHSP strategy are associated with reduction of electricity consumption and emissions to water, while SNHSP var Qcarb var strategy reduces electricity consumption, use of chemicals (reducing external carbon dosage) and operation costs.

Study on Propellers Distribution and Flow Field in the Oxidation Ditch Based on Two-Phase CFD Model

The oxidation ditch (OD) plays an important role in wastewater treatment plants. With increasing demand and production costs, the energy consumption and sludge deposition occurring in the OD must be diminished to enhance its development. In this paper, a two-phase computational fluid dynamics (CFD) model of water and activated sludge examined the flow field characteristics of an OD, consisting of two side-by-side propellers. The system was studied under five configurations, where the spacing between the propellers was set equal to −0.2, −0.1, 0, 0.1, 0.2 times the length of the OD. The viscosity and settling rate of activated sludge was imported in the numerical simulation through a user defined function (UDF). The optimal scheme of the propeller’s power consumption, velocity distribution, and sludge concentration distribution was obtained. The result shows that sludge concentrations are linked with dead zone velocity but not necessarily with low velocities. Experiments confirmed the validity of the velocity flow field simulated by the two-phase CFD model. Overall, these findings form the basis for the propellers distribution optimization and allow a deeper insight into the flow field of OD systems.

Modelling gas-liquid mass transfer in wastewater treatment: when current knowledge needs to encounter engineering practice and vice versa

Gas-liquid mass transfer in wastewater treatment processes has received considerable attention over the last decades from both academia and industry. Indeed, improvements in modelling gas-liquid mass transfer can bring huge benefits in terms of reaction rates, plant energy expenditure, acid-base equilibria and greenhouse gas emissions. Despite these efforts, there is still no universally valid correlation between the design and operating parameters of a wastewater treatment plant and the gas-liquid mass transfer coefficients. That is why the current practice for oxygen mass transfer modelling is to apply overly simplified models, which come with multiple assumptions that are not valid for most applications. To deal with these complexities, correction factors were introduced over time. The most uncertain of them is the α-factor. To build fundamental gas-liquid mass transfer knowledge more advanced modelling paradigms have been applied more recently. Yet these come with a high level of complexity making them impractical for rapid process design and optimisation in an industrial setting. However, the knowledge gained from these more advanced models can help in improving the way the α-factor and thus gas-liquid mass transfer coefficient should be applied. That is why the presented work aims at clarifying the current state-of-the-art in gas-liquid mass transfer modelling of oxygen and other gases, but also to direct academic research efforts towards the needs of the industrial practitioners.

Simulation on flow field and gas hold-up of a pilot-scale oxidation ditch by using liquid-gas CFD model

A liquid-gas two-phase computational fluid dynamics (CFD) model was developed to simulate flow field and gas hold-up in a pilot-scale oxidation ditch (OD). The volume of fluid (VOF) model and the mass flow inlet boundary condition for gas injection were introduced in this model. The simulated values of the flow velocities and the gas hold-up were verified by experimental measurements in the pilot-scale OD. The results showed that the gas hold-up at test-site 3, immediately downstream of the surface aerator, was the highest among all three test-sites. Most of the gas existed in the upper portion of the ditch and was close to the inner side of the channel. Based on the liquid-gas two-phase CFD model, three operating conditions with different setting height ratios of the submerged impellers were simulated. The simulated results suggested that the setting heights of the submerged impellers have significant impacts on the flow velocity distribution. Lowering the setting height could increase the flow velocity in the pilot-scale OD. An optimal setting height ratio of 0.273 was proposed, which would be beneficial for minimizing sludge sedimentation, especially near the inner side of the curve bend.