Search Results (247)

In oleaginous yeast submerged fermentation, dissolved oxygen (DO) regulates both metabolism and cell morphology. Under oxygen limitation, Trichosporon cutaneum transitions from yeast-form to hyphae-form; the yeast-form morphology is more suitable for lipid production. This study enhanced oxygen transfer via reactor engineering to maintain yeast morphology and improve lipid productivity. Three strategies were assessed: increased agitation/aeration, enriched air supply, and microporous ceramic membrane gas distributor (MCMGD). Fermentation kinetics were analyzed alongside computational fluid dynamics (CFD) simulations of volumetric mass transfer coefficient (k_La), gas holdup, bubble diameter, and flow fields. Conventional strategies only partially alleviated oxygen limitation (maximum 4.47 g/L lipid). Enriched air improved lipid content but induced early myceliation. The MCMGD (1.0 vvm, 150 rpm) shortened fermentation from 150 h to 60 h, achieving 12.06 g/L lipid (49.16% content)—a 2.16-fold lipid concentration increase. Mechanistically, it generated smaller bubbles (1.47 mm vs. 2.54 mm) and higher k_La (0.012 s⁻¹ vs. 0.0055 s⁻¹). CFD revealed improved axial flow, reduced dead zones, and uniform gas holdup, suppressing yeast-to-hyphae shift. By enhancing mass transfer under low shear, the MCMGD ensures adequate oxygenation, maintains productive morphology, and significantly improves lipid production—offering a promising strategy for industrial application. Full article

Urban micro-tidal canals frequently suffer from severe hypoxia due to restricted hydrodynamic exchange and untreated discharges. Field monitoring during a 2022 mass fish mortality event at the Dongsam tidal canal revealed that during the ‘tidal window gap’—a hydraulic stagnation period required for passive tidal flushing—bottom-layer dissolved oxygen (DO) plummeted to a lethal 0.44 mg/L. To address the limitations of passive tidal exchange, this study proposes a conceptual hybrid water purification framework integrating active ecological interventions: wall-mounted spiral flow aeration for continuous oxygenation and vertical bio-curtains for pollutant interception. By synergizing fluid mechanics with ecological engineering, core design parameters were systematically derived: an effective mixing width ($W_{eff}=2.2 h$), longitudinal spacing ($L_s$ = 13.6$\times W_{eff}$), an optimal root immersion ratio ($D_r/h$ = 0.6), and climate-adaptive planting densities (${\rho }_p\approx$12–32 plants/m²). Additionally, a corrosion-resistant FRP guide rail system was incorporated to facilitate autonomous adaptation to tidal fluctuations. The framework was conceptualized through a prototype design for the Dongsam canal and subsequently scaled to 15 international micro-tidal canals across diverse climatic zones. The optimized bilateral staggered configuration established a continuous 528 m² ecological refuge, ensuring DO levels recover above the critical 3 mg/L threshold. Ultimately, this research presents a comprehensive methodological framework and a flexible engineering toolkit to guide water quality and ecological resilience enhancements in shallow urban waterways worldwide. Full article

Treatment wetlands (TWs) are increasingly deployed as nature-based solutions for water and wastewater management due to their cost-effectiveness, operational simplicity, and provision of wider ecosystem benefits. The UK has been at the forefront of TW application since the 1980s. This study evaluated their development and performance within Southern Water, a water utility in the UK. In total, 35 sewage treatment sites have incorporated TWs since 1991, primarily for tertiary treatment and stormwater overflow control. Performance data were available for 16 sites, comprising 14 horizontal subsurface flow (HSSF) and two surface flow (SF) wetlands. HSSF wetlands achieved substantial reductions in TSSs (up to 97%), ${\mathrm{N}\mathrm{H}}_4^{+}$ (up to 99%), and BOD₅ (up to 92%). The COD removal showed more variance (0–62%) in the studied sites. In contrast, SF wetlands provided moderate reductions in TSSs (17–79%) and COD (36–67%) but were less effective for ${\mathrm{N}\mathrm{H}}_4^{+}$ and BOD₅ (14–65%). The TWs operated by Southern Water currently serve more than 100,000 people and illustrate the expanding role of such systems in meeting wastewater treatment needs. However, challenges and further research are needed, including risks of media clogging, the evaluation of emerging micropollutants treatment, and inconsistent maintenance. To address these, the study highlights opportunities for innovation through hybrid and aerated designs, advanced monitoring, and a more detailed understanding of plant–microbe interactions. The findings emphasise both the potential and future research needs of TWs and support their continued integration into wastewater management strategies under evolving environmental and regulatory pressures. Full article

Photosynthetic algae–microbial fuel cells (PAMFCs) are attractive for energy-positive wastewater treatment and carbon mitigation. However, PAMFC performance under continuous flow is often constrained by limited cathodic electron-acceptor supply and unstable photosynthetic biofilms, while the extent to which cathode interfacial engineering can stabilize diurnal power output and assimilative NH₄⁺–N removal remains unclear. In this study, the sponge-like and petal-like ZnO_0.2-NiO@rGO-modified carbon fibers (ZnO_0.2-NiO@rGO-pCFs and ZnO_0.2-NiO@rGO-pCFp) and pre-fabricated carbon felt (pCF) were used as cathode materials to construct three sets of PAMFC systems. Under light–dark cycling, the engineered cathodes reached steady operation within about 6.5 d and increased the steady-state voltage to approximately 0.35 V, compared with approximately 0.08 V for pCF. Under continuous-flow conditions, cathodic NH₄⁺–N removal exhibited a stable diurnal rhythm, with higher removal during illumination at about 43–51% than in the dark at about 29–30%, consistent with algal assimilation as the primary nitrogen sink, while cathode modification mainly improved the cathodic microenvironment and response stability. Compared with pCF, the ZnO_0.2–NiO@rGO cathode enriched a more even, Chlorophyta-dominated algal biofilm with an approximate relative abundance of 80%, indicating that its selective interfacial environment favors biofilm stabilization and sustains in situ oxygen production and cathodic electron-acceptor supply. Consequently, the composite cathode enhanced voltage output and stabilized light-enhanced, assimilative NH₄⁺–N removal under aeration-free operation, while establishing an interpretable link between electrochemical performance and 18S rDNA-derived community assembly features, thereby providing a low-cost cathode design basis for nitrogen removal in wastewater treatment. Full article

Wastewater treatment plants (WWTPs) are among the most energy-intensive components of urban infrastructure. In light of the revised EU directive on municipal wastewater treatment, which targets energy neutrality by 2045, effective energy management in this sector is becoming essential. This article reviews the current knowledge regarding energy consumption in WWTPs and analyses opportunities to increase their energy self-sufficiency by reducing energy demand and recovering energy. Key factors influencing energy consumption are discussed, including facility size, the range of technological processes used, automation level, and equipment condition. Attention is given to aeration systems, which account for the largest share of electricity consumption, and the possibilities for their modernization and optimization using energy-efficient diffusers and advanced process control systems. The potential for recovering chemical energy from sewage sludge is analyzed, with emphasis on anaerobic digestion and co-digestion with other organic wastes. Alternative sludge conversion methods, such as incineration, pyrolysis, gasification, and hydrothermal carbonization, are also presented. The analysis is complemented by technologies for recovering physical energy from wastewater, including the use of thermal energy via heat pumps and hydraulic energy from wastewater flow. The findings indicate that achieving energy self-sufficiency in WWTPs requires site-specific, hybrid solutions combining energy savings with selective energy recovery, considering technical and economic conditions. Full article

Energy dissipation in stepped weirs depends on the complex interaction between geometry, flow regime, and surface aeration. The research proposes a dimensionless empirical model (RE3T) to predict the overall energy dissipation in three-section stepped weirs with variable slopes. The formulation integrates dimensional analysis based on the Vaschy–Buckingham theorem, controlled physical experimentation, and three-dimensional numerical simulations using CFD employing the RANS–SST turbulence model implemented in ANSYS CFX. Eighteen numerical simulations were performed covering seven geometric configurations and four hydraulic inlet conditions, covering slug, transitional, and skimming flow regimes. The CFD model was previously validated by comparison with a physical scale model, obtaining a discrepancy of only 0.38% in relative energy dissipation. The validated dataset was then used to calibrate an empirical multiplicative correlation composed of eight dimensionless groups associated with sectional slopes, number of steps, overall geometric ratio, and upstream Froude number. The proposed model achieved a coefficient of determination R² = 0.81, with relative errors generally less than 1% and a maximum deviation of 2.34%. The statistical indicators (RMSE, MAE, and bias) confirm the absence of significant systematic trends within the defined domain of validity. The results show that the Froude number and the slopes of the sections are the variables with the greatest influence on overall dissipation. The RE3T formulation is a physically consistent and computationally efficient predictive tool for the design and analysis of stepped weirs with variable slopes, extending the scope of traditional correlations developed for uniform slopes. Full article

This study aims to clarify the influence mechanism of air–water–mineral three-phase flow behavior on separation efficiency in a graphite flotation column, addressing the issues of over-breaking of coarse graphite flakes and low recovery of fine particles caused by mismatched flow fields and operating parameters in traditional flotation columns. Using CFD numerical simulations based on the Eulerian multiphase flow model, the standard k-ε turbulence model, and scalable wall functions, the effects of feed velocity (0.8–2.4 m/s) and aeration velocity (1–5 m/s) on the flow field structure, gas holdup distribution, and weighted average bubble–particle collision probability inside the column were systematically analyzed. Key quantitative results show that under the synergistic condition of a feed velocity of 2 m/s and an aeration velocity of 3 m/s, an internal circulation flow field conducive to particle retention is formed. Under these conditions, the gas holdup in the collection zone reaches an optimal range (0.26–0.27), and the weighted average collision probability increases by approximately 22% compared to the baseline condition. Aeration velocity shows a significant positive correlation with gas holdup in the collection zone (~0.235 at 1 m/s, rising to ~0.285 at 5 m/s). While an increase in feed velocity reduces the overall gas volume fraction, it enhances turbulence and promotes uniform bubble dispersion through the spatial distribution of regions with high collision probability from the upper part to the upper–middle part of the column and improves the uniformity of distribution. The novelty of this study lies in being the first to quantitatively reveal, through CFD simulation, the coupled regulatory effects of feed velocity and aeration velocity on the stratified flow field structure and mineralization probability in a flotation column and to identify the key optimization threshold of “2 m/s feed velocity”. The practical significance is that it provides a clear theoretical basis and operational window for energy saving, consumption reduction, and process intensification in industrial flotation columns. It offers directly applicable parameter optimization strategies for the efficient recovery of fine-flake graphite and the protection of coarse flakes. Full article

Stilling basins are critical energy-dissipating structures in high-head hydraulic projects, yet conventional stilling basins often face challenges of insufficient energy dissipation and excessive bottom pressure under high water head and large unit discharge conditions. The integration of sudden expansion and drop sill into stilling basin design has emerged as a potential solution, but its hydraulic characteristics and the specific impact of sudden expansion remain inadequately quantified and understood. To address this research gap, this study experimentally investigates the hydraulic performance of stilling basins with sudden expansion and drop sill, conducting physical model tests on nine design schemes that contrast basins with and without sudden expansion. The tests measure time-averaged pressure, fluctuating pressure, and aeration concentration at key positions of the basin floor. The results demonstrate that the drop sill stilling basin with sudden expansion is technically feasible for application under conditions of high water head and large unit discharge. In the direction perpendicular to the flow, the distributions of time-averaged pressure, fluctuating pressure, and aeration concentration are non-uniform, generally exhibiting a decreasing trend in the order of the 1/4 centerline, chute extension line, 1/2 centerline, and near-sidewall line. Specifically, the time-averaged pressure, fluctuating pressure, and aeration concentration at the bottom of the sudden-expansion basin are, respectively, lower than those of the non-sudden-expansion basin. Notably, the primary protection zones of the sudden-expansion and drop sill stilling basin are situated between the chute extension line and the 1/4 centerline, as well as in the region ranging from the drop sill to 0.4l (with l denoting the stilling basin length). These findings verify that sudden expansion significantly modifies the hydraulic characteristics of stilling basins by reducing pressure and aeration concentration in key areas, and further provide quantitative design parameters and theoretical support for the optimization of sudden-expansion and drop sill stilling basins in high-head hydraulic engineering projects. Full article

This study assessed whether electrochemical activation of mixing water can enhance autoclaved aerated concrete (AAC), in which fly ash replaces sand as the siliceous component. Mixing water was electrolyzed in a diaphragm-type “Melesta” unit to obtain the catholyte and anolyte, and fly ash was pre-exposed to the catholyte for up to 15 min. The material’s behavior was evaluated using slurry flow tests, scanning electron microscopy, Fourier-transform infrared spectroscopy, macropore-uniformity analysis, mercury intrusion porosimetry, and shrinkage and short-term durability indicators. At an approximately constant density class near 600 kg/m³, the catholyte-pretreated fly-ash AAC mixes showed a near-monotonic increase in compressive strength with increasing fly-ash replacement (relative to the sand-based reference), while fresh-mixture fluidity decreased. The pore structure became more uniform, as indicated by a decrease in the standard deviation of pore diameters from 0.175 to 0.133 mm, and porosimetry indicated a higher micro-porosity fraction in fly-ash AAC than in sand-based AAC. Capillary shrinkage remained essentially unchanged, and short-term durability indicators (durability coefficients after 25 cycles) showed a small improvement. Overall, electrochemically activated water promoted a more regular pore system and stronger interpore walls under autoclave curing, supporting higher fly-ash utilization without loss of dimensional stability. The results are limited to one fly-ash source (Ekibastuz TPP); transferability should be verified using ashes with different glass content, fineness, and carbon/LOI. Full article

In the present work, three-dimensional (3D) simulations have been performed for the characterization of a rectangular column for a uniform gas distributor with µm-sized holes at a ratio of 5. The model is first validated with experimental data from the literature. Simulations are then performed for a gas distributor with identical pitch but two different hole sizes, namely 600 µm and 200 µm. Three superficial gas velocities, namely 0.002 m/s, 0.004 m/s, and 0.006 m/s, were used for each distributor type. The gas movement in the fluid is found to be a strong function of hole size. For a 600 µm hole size, the operating condition has minimal impact on gas plume movement and moves centrally in a fully aerated regime. However, for a hole size of 200 µm, for all superficial velocities, the gas plume movement is dynamic and partially aerated. The plume moves along the right wall initially and then follows vertically. These characteristics are different from the meandering plume in centrally located spargers. The liquid mixing in the bulk is a function of time. During the plume development flow, different shapes are observed. Based on the analogy with the shapes found in nature, these shapes have been termed as balloon, cap, jet or candle flame, bull horn, mushroom, tree shape, and disintegrated mushroom shapes. Quantitative insights have been obtained in the form of time-averaged radial profiles of both volume fractions and liquid axial velocities. A symmetric parabolic shape for a hole size of 600 µm and skewed asymmetric shapes for a 200 µm hole size for three different axial positions, namely 0.1, 0.25, and 0.4 m, are observed. Correlations for gas holdup and liquid velocity have been proposed for low superficial velocities, which are in good agreement with the CFD simulation data, with a deviation of 15–20%. The deviations are partly due to the use of the k-ε turbulent model. The correlations perform better than the correlations available in the reported literature for similar superficial gas velocities. Full article

Aeration is one of the most energy-intensive operations in wastewater treatment plants, with its efficiency strongly affected by the presence of surfactants. This study investigates the impact of Sodium Dodecyl Sulphate (SDS) on oxygen mass transfer using a commercial fine-bubble diffuser. Oxygen transfer experiments were performed under varying air flow rates and SDS concentrations. Key parameters, including the volumetric mass transfer coefficient ($k_{L}a$), gas holdup, bubble size, and interfacial area, were experimentally measured and analysed. SDS reduces the average bubble diameter by up to 50%; above 4 mg/L, further increases in concentration do not change the bubble size. Gas holdup increases by approximately 2% per mg L⁻¹ of SDS, and a new empirical correlation was proposed to predict gas holdup as a function of air flow rate and surfactant concentration, achieving an R² of 0.97 with deviations below 10%. Despite the increase in interfacial area, SDS strongly suppresses interfacial turbulence, reducing the liquid-side mass transfer coefficient ($k_L$) by up to 70%, which ultimately leads to a significant loss of overall oxygen transfer efficiency. The Sardeing model, originally developed for single bubbles, successfully predicted $k_L$ within ±15% of the experimental values, demonstrating its potential as a practical tool for estimating oxygen transfer in aeration systems. These findings highlight the substantial impact of surfactants on fine-bubble aeration performance and underscore the need to account for their effects in the design and operation of industrial aeration systems. Full article

The classical assumption of self-similarity in flow velocities and turbulence statistics has been successfully validated for fully developed flows in open channels, pipes, and boundary layers. However, its application in developing boundary-layer flows in channels with steep slopes and large roughness elements has not yet been thoroughly scrutinized. This study investigates whether turbulence statistics exhibit self-similar behavior when properly scaled in steep-stepped spillways. Specifically, it explores the influence of roughness height ($k_s$)—representing the cavity size of a steep-stepped spillway—on turbulence statistics in the non-aerated skimming flow region. Numerical simulations, extensively validated against experimental data, were conducted for a stepped spillway with a fixed slope angle of 51.34°, using five roughness heights ($k_s$ = 6.25, 3.12, 1.56, 0.78 and 0.39 cm), corresponding to step height-to-length ratios of 10:8, 5:4, 2.5:2, 1.25:1 and 0.625:0.5, respectively. The results show that the dimensionless profiles of turbulent kinetic energy (TKE) at the step edges collapse onto a single curve when rescaled by a factor of ${\left(\delta /k_s\right)}^n$ with $n~0.4$. Likewise, the dissipation rate of TKE follows a similar collapse with $n~0.3$. For the turbulent eddy viscosity, an exponent of $n~0.5$ was adopted based on dimensional analysis, although the values for the smoothest configuration deviate from the curve. Full article

This study employed Computational Fluid Dynamics (CFD) simulations using FLOW-3D v11.2 software to systematically investigate the hydraulic characteristics of Asymmetric Triangular Labyrinth Weirs (ATLWs), with a comparative analysis against conventional Symmetric Triangular Labyrinth Weirs (STLWs). The Volume of Fluid (VOF) method and the Renormalization Group (RNG) k-ε turbulence model were adopted to accurately capture the free-surface and turbulence behaviors. The results demonstrate that ATLWs induce significant flow deflection, leading to the formation of distinctive local cavities and a unique flow regime characterized by the coexistence of fully aerated nappe flow and local submergence. Compared to STLWs, this asymmetric configuration generates more complex three-dimensional flow structures and altered pressure distribution patterns. Under low headwater conditions, the hydraulic performance (C_d and Q/Q_n) of both weir types is similar; however, under high headwater conditions, the C_d of STLWs is approximately 5.4–14.3% higher than that of ATLWs. A noteworthy finding is that increasing the cycle number (n) significantly enhances the discharge capacity of ATLWs, whereas this effect is not pronounced in STLWs. Based on comprehensive parametric analysis, this study developed a generalized empirical formula with exceptionally high predictive accuracy for estimating C_d, providing a practical tool for optimizing ATLW designs in engineering applications. Full article

Near-complete (>99%) dissolution of lithium and cobalt was achieved by the leaching of black mass from spent (end-of-life) lithium-ion batteries (LiBs) using 4 M H₂SO₄ or HCl at 60 °C. Raising the temperature to 90 °C did not increase the overall extraction of lithium or cobalt, but it increased the rate of extraction. At 60 °C, 2 M H₂SO₄ or 2 M HCl performed similarly to the 4 M H₂SO₄/HCl solution, although extractions were lower using 1 M H₂SO₄ or HCl (~95% and 98%, respectively). High extractions were also observed by leaching in low pulp density (15 g/L) at 60 °C with 2 M CH₂ClCOOH. Leaching was much slower with hydrogen peroxide reductant concentrations below 0.5 mol/L, with cobalt extractions of 90–95% after 3 h. Pulp densities of up to 250 g/L were tested when leaching with 4 M H₂SO₄ or HCl, with the stoichiometric limit estimated for each test based on the metal content of the black mass. Extractions were consistently high, above 95% for Li/Ni/Mn/Cu with a pulp density of 150 g/L, dropping sharply above this point because of insufficient remaining acid in the solution in the later stages of leaching. The final component of the test work used leaching parameters identified in the previous experiments as producing the largest extractions, and just sulphuric acid. A seven-stage semi-continuous sulphuric acid leach at 60 °C of black mass from LiBs that had undergone an oxidising roast (2h in a tube furnace at 500 °C under flowing air) to remove binder material resulted in high (93%) extraction of cobalt and near total (98–100%) extractions of lithium, nickel, manganese, and copper. Higher cobalt extraction (>98%) was expected, but a refractory spinel-type cobalt oxide, Co₃O₄, was generated during the oxidising roast as a result of inefficient aeration, which reduced the extraction efficiency. Full article

Our study investigates how non-spherical bubble shapes influence gas–liquid mass transfer across the bubble interface. An analytical shape descriptor, namely Superformula, is used to parametrically define the bubble interface, enabling efficient CFD simulations over a range of Reynolds ($Re$) and Eötvös ($Eo$) numbers. By prescribing the bubble geometry analytically, we avoid expensive interface-capturing simulations and directly compute the concentration field without transient boundary shape pre-equilibration. The represented approach is computationally efficient and captures the impact of bubble shape and flow parameters on the dissolved gas concentration gradients in the surrounding liquid. Results show that bubble deformation alters the distribution of dissolved gas around the bubble and the overall mass transfer rate, with higher $Re$ enhancing convective transport and higher $Eo$ (more deformed bubbles), leading to anisotropic concentration boundary layers. The developed framework not only advances a fundamental understanding of bubble-driven mass transfer mechanisms but also directly addresses industrial needs, particularly in optimizing oxygen delivery within bioreactors contour and similar aerated processes. The proposed efficient modeling strategy provides a basis for developing fast surrogate tools in hybrid modeling frameworks, where high-fidelity CFD insights are incorporated into larger-scale multiphase process simulations. Full article