Modelling a Lab-Scale Continuous Flow Aerobic Granular Sludge Reactor: Optimisation Pathways for Scale-Up

Wastewater treatment plants (WWTPs) face increasing pressure to handle higher volumes of water due to climate change causing storm surges, which current infrastructure cannot handle. Aerobic granular sludge (AGS) is a promising alternative to activated sludge systems due to their improved settleability property, lowering the land footprint and improving efficiency. This research investigates the optimisation of a lab-scale sequencing batch reactor (SBR) into a continuous flow reactor through mathematical modelling, sensitivity analysis, and a computational fluid dynamic model. This is all applied for the future goal of scaling up the model designed to a full-scale continuous flow reactor. The mathematical model developed analyses microbial kinetics, COD degradation, and mixing flows using Reynolds and Froude numbers. To perform a sensitivity analysis, a Python code was developed to investigate the stability when influent concentrations and flow rates vary. Finally, CFD simulations on ANSYS Fluent evaluated the mixing within the reactor. An 82% COD removal efficiency was derived from the model and validated against the SBR data and other configurations. The sensitivity analysis highlighted the reactor’s inefficiency in handling high-concentration influents and fast flow rates. CFD simulations revealed good mixing within the reactor; however, they did show issues where biomass washout would be highly likely if applied in continuous flow operation. All of these results were taken under deep consideration to provide a new reactor configuration to be studied that may resolve all these downfalls.