Optimizing mixing efficiency of anaerobic digesters with high total solids concentrations using validated CFD simulations

Abstract

In this article, viscosity dependent mixing in anaerobic digestion (AD) towers is analysed using finite volume based computational fluid dynamics (CFD) simulations validated with ultrasound particle image velocimetry (uPIV). The study focuses on improving mixing characteristics for enhanced biogas production resulting from increased organic loading. Mixing of fluids with viscosity ranges found in real-life AD is investigated using the multiple reference frame (MRF) method. The aim is to increase the energetic efficiency of AD by reducing the energy demand required for sufficient mixing such that microorganisms and organic substrates are homogeneously distributed. The distinguishing feature of this work is the implementation of less power-consuming helical ribbon stirring devices (HRSD) for enhanced mixing in different reactor designs. It is demonstrated that HRSD become progressively effective for increasing total solids concentrations (% TS) ranging from 2.5 % TS to 12.1 % TS, particularly in cylindrical reactors. In comparison with conventional propeller-based mixers, innovative HRSD operation reduces dead volume (DV) by up to 22 %. Additionally, HRSD cause less shear forces and require less power due to lower rotational speed. The most energy-efficient mode of operation reduces the power demand by 9.29 % at 12 rpm, while still providing decreased DV of 13.38 % for the most viscous fluid investigated. The outcome is a more efficient and cost-effective mixing approach, which holds strong potential for mixing applications involving highly viscous fluids.