CFD as a tool to optimize aeration tank design and operation

Abstract

In a novel development on previous computational fluid dynamics studies, the work reported here used an Eulerian two-fluid model with the shear stress transport k–ω turbulence closure model and bubble interaction models to simulate aeration tank performance at full scale and to identify process performance issues resulting from design parameters and operating conditions. The current operating scenario was found to produce a fully developed spiral flow. Reduction of the airflow rates to the average and minimum design values led to a deterioration of the mixing conditions and formation of extended unaerated fluid regions. The influence of bubble-induced mixing on the reactor performance was further assessed via simulations of the residence time distribution of the fluid. Internal flow recirculation ensured long contact times between the phases; however, hindered axial mixing and the presence of dead zones were also identified. Finally, two optimization schemes based on modified design and operating scenarios were evaluated. The adjustment of the airflow distribution between the control zones led to improved mixing and a 20% improvement to the mass transfer coefficient. Upgrading the diffuser grid was found to be an expensive and ineffective solution, leading to worsening of the mixing conditions and yielding the lowest mass transfer coefficient compared with the other optimization schemes studied.