Biological reactor retrofitting using CFD-ASM modelling

In recent years, the interest in modelling activated sludge (AS) systems by means of Computational Fluid Dynamics (CFD) techniques has significantly increased. This work shows a successful case study combining CFD hydrodynamics and biokinetic modelling. The hydrodynamics is analysed by using the Reynolds-averaged Navier-Stokes equation for incompressible non-Newtonian fluids and SST turbulence model. Biokinetics has been included in the CFD as transport equations with source and sink terms defined by the Activated Sludge Model n degrees 1 (ASM1). Furthermore, a strategy for reducing the computational cost while maintaining accuracy of the results of these calculations has been proposed. This strategy is based on a two-step solver configuration and the definition of a variable timestep scheme. The resulting CFD-ASM approach permits a proper evaluation of denitrification in the anoxic tanks as well as the reproduction of nitrate and readily biodegradable substrate distributions. To demonstrate the strength of the proposed CFD-ASM, it has been used to evaluate the operation of a full-scale AS system and optimize its performance through changes in the biological reactor anoxic zone. The original configuration has been retrofitted and modified after detecting intrinsic defects in the fluid behaviour within the tank. This study has been assessed by analysing hydrodynamics in detail and validating the simulation results with tracer tests and flow velocity measurements. Substantial variations on the Residence Time Distribution have been confirmed when modifying the internal elements of the tank configuration: the wall-bushing and the stirrer positioning. As a result of this work, an influential short circuiting was corrected improving hydrodynamics and increasing mean residence time, all favouring denitrification efficiency. Outcomes of this study show the benefit of CFD when applied to AS tanks.