Flow-Through AGS Reactor Layout for Continuous Granule Formation

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Solution Overview

Problem

There is no known process or mechanism to replicate the sequencing batch reactor (SBR) cycles in a continuous flow through activated sludge basin configuration, which is prevalent in the United States and Canada, limiting the application of aerobic granular sludge (AGS) processes in these regions.

Innovation Solution

A flow through reactor system is designed to replicate the environmental and physical conditions of SBRs, incorporating alternating aerated and unaerated zones, mixing devices, and selector systems to promote and maintain AGS granule formation in a continuous flow configuration, suitable for existing activated sludge basins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If SBR cycles are used for AGS treatment, then AGS granule formation is achieved, but the reactor configuration is complex and not suitable for existing activated sludge basins

Engineering Contradiction:

ImproveAGS granule formationVSAvoidreactor configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The continuous flow reactor is segmented into multiple zones with different operational characteristics (aerated zones, unaerated zones, selector zones) to replicate the functional sequence of SBR cycles without requiring batch operation. This spatial segmentation allows AGS granule formation to occur in a continuous flow configuration suitable for existing basins.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reactor incorporates periodic aeration and unaeration cycles within different zones to create the feast-famine conditions necessary for AGS granule formation. This periodic environmental variation mimics the temporal cycles of SBRs while maintaining continuous flow through the reactor.

Inventive Principle:

Principle #19Periodic action

2Ease of operation

If conventional activated sludge floc is used, then the system is simple to operate, but settling and liquid solids separation are inefficient

Engineering Contradiction:

Improvesystem operationVSAvoidsettling and separation

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system changes the physical parameters of the biomass by promoting granule formation through controlled environmental conditions (aeration cycles, substrate loading). This transforms the biomass from loose floc to dense, spherical granules with superior settling characteristics, improving separation efficiency while maintaining operational simplicity.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If higher biomass inventory is achieved through AGS, then treatment capacity increases, but reactor volume requirements decrease

Engineering Contradiction:

Improvetreatment capacityVSAvoidreactor volume

Core Design Contradiction:

ProductivityVSVolume of stationary object

Solution Approach 1:

The system creates composite biomass structures (granules) with enhanced properties including higher density, improved settling velocity, and increased biomass inventory concentration. These composite granular structures allow higher productivity in smaller reactor volumes by maximizing the biomass concentration that can be maintained in suspension.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system enables the development and sustenance of AGS granules, enhancing pollutant removal efficiency and reducing reactor volume requirements by maintaining high biomass concentrations, facilitating improved liquid/solids separation and compact reactor footprints.

Implementation Method 1

a first adsorption zone, wherein the first adsorption zone includes AGS granules

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

a first aerated zone downstream of the first unaerated zone, wherein the first aerated zone is under aerobic conditions

Methodology Applied

Scientific EffectGas absorption: Absorption (physical)

Implementation Method 3

movement of granules within a water column through use of mixers, aeration, or gravity to encourage agglomeration of biomass to the granules and promote sphericity

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 4

The density and sphericity of the AGS allows for improved settling and liquid solids separation compared to conventional activated sludge floc

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS20250361165A1Flow Through Aerobic Granular Sludge System and Method

Publication Date: 2025.11.27 CAROLLO ENGINEERS INC

AI summary

A flow through aerobic granular sludge (AGS) system includes a flow through reactor. The flow through reactor includes a first adsorption zone, first and second unaerated and aerated zones, and a wastewater distribution system. The first adsorption zone includes AGS granules introduced to a top of the first adsorption zone. The first and second unaerated zones are under anaerobic, anoxic, or both anaerobic and anoxic conditions. The first and second aerated zones are under aerobic conditions. The wastewater distribution system includes a distribution grid of piping or an underdrain system at a bottom of the adsorption zone. The flow through reactor is configured such that, in operation, the wastewater and AGS granules flow continuously from the first adsorption zone through the first unaerated zone, the first aerated zone, the second unaerated zone, and the second aerated zone.