Technical Bulletin 153

Optimization of Diffuser Systems

by:

Environmental Dynamics International

Published: 4/2012

DISCLAIMER

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headquartered in Columbia, Missouri USA. For additional more information regarding this
particular bulletin or your specific aeration application contact Environmental Dynamics
International by calling +1.573.474.9456, toll free at +1.877.EDI.AIR8 (877.334.2478),
(877.334
or via
email at techbulletins@wastewater.com
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Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

TECHNICAL BULLETIN 153 OPTIMIZATION OF DIFFUSER

USER SYSTEMS

DIFFUSED AERATION SYSTEM PERFORMANCE OPTIMIZATION

Operation of aeration systems for biological treatment is well documented as requiring the bulk of
energy in wastewater treatment plants (WWTP). Figure 1 shows the electricity requirements for the
primary operation
n in an activated sludge facility. Aeration contributes 50
50-70%
70% of the energy
requirements in the plant. With so much of the energy use in a WWTP concentrated at the aeration
system it is a logical target for energy conservation.
Figure 1. Energy Usage att a Typical WWTP

Historically aeration systems have been designed with general guidelines of system performance.
For diffused aeration, design criteria of 5.0 to 6.7% per meter (1.52 to 2.05% per foot) has been
applied universally with little considerat
consideration
ion of total cost of ownership (TCO). The following are key
factors in TCO, and may affect the optimized design of an aeration system:
1.
2.
3.
4.
5.

Todays cost of energy (cost/

(cost/kWh)
Long-term
term escalation of energy cost
Advancements in diffused aeration technology availa
available today
Opportunity cost for major TCO savings by aeration system optimization
Relative impact of TCO from aeration system optimization versus more traditional energy
conservation measures, such as high efficiency blowers.
6. Carbon credits

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

Aeration system optimization requires an integrated analysis of all major system components with
close attention to how they interface:
A.
B.
C.
D.
E.

Blower size, efficiency and cost

Electrical switchgear size and cost
Piping sizes and cost
Optimization of diffuser type or numbers for energy savings
Relative impact of diffuser system design on other components (i.e., increasing
diffuser efficiency may reduce the size and cost of items A through D above!)

Proper optimization of WWTP operating cost for minimum TCO requires a thorough evaluation of
diffuser system technology and selection of most appropriate diffuser type and diffuser design for
EACH application. General rules of design for diffuser efficiency are no longer acceptable as
thorough analysis results in major savings to the end user.
To date no effective method or easy to apply procedure for integrated aeration system optimization
is available for routine application by design engineers. Process model programs, such as
BioWin, use general rules of design for mechanical performance. They also give no indication to
total operating cost or payback on investments. An aeration system analysis that integrates the
key variables affecting cost can deliver major savings in annual operating costs and savings for
minimum TCO.
EDI has recognized the opportunity for savings for WWTP operation by developing and applying
"rational design" procedures for optimizing total aeration system design. EDIs Integrated Diffused
Aeration Design Procedures incorporate a 4-phase analysis to develop engineered solutions for
type of diffusers, number of diffusers, and blower sizing.

Phase I: Organize Design Parameters

To perform the optimized design calculations, it is necessary to have process design information
and physical site information. EDI Aeration Design Form provides a summary of many of the
necessary design criteria (Appendix A).
In addition to the project design data, a clear confirmation of factors such as biological treatment
process is required to establish a rational design. The treatment process selected has a major
impact on aeration system optimization. Examples may include the following common treatment
applications:
1.
2.
3.
4.
5.

Activated Sludge
Extended Aeration
SBR
Nutrient Removal (BNR)
Lagoon

6.
7.
8.
9.
10.

MBR
MBBR
Oxidation ditch
Digester
Other

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

Phase II: Select Diffuser Type and Establish SOTE Performance

To employ the most appropriate diffuser, a comparison of performance of various diffuser
platforms must be considered in the design. The most important performance values include
operating pressure and standard oxygen transfer efficiency (SOTE). This requires rational clean
water test results under ASCE or equivalent testing procedures. Figure 2 shows a typical SOTE
performance graph for a 9-inch (230 mm) diameter diffuser generated by clean water testing in
accordance with ASCE oxygen transfer procedures. For each project a type of diffuser (disc, tube,
etc) must be selected then the optimization process will incorporate data for calculations that are
diffuser platform specific. A separate set of calculations is required when comparing different
diffuser platforms, i.e., disc versus tube, versus MiniPanel, versus StreamLine.
Figure 2. Typical SOTE Performance Graph

Note: Proper SOTE performance will incorporate multiple factors influencing performance such as:
1.
2.
3.
4.
5.
6.

Standard test conditions. Multiple standards exist, including ASCE and German ATV
standards.
Density of diffusers (number of diffusers per area of tank, or membrane area per area of tank).
Airflow rate per diffuser.
Water depth and diffuser submergence.
Type of diffuser platform (Disc, Tube, Panel, StreamLine).
Diffuser Arrangement, such as grid, roll, or other

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

Phase III: Perform Aeration System Sizing Calculations

The initial aeration system optimization calculations begin with a EDIs Design Brief computation.
This computation uses the project data in Phase I to find the overall oxygen demand in the system.
The second half of the Design Brief uses the diffuser performance found in Phase II to calculate
the airflow requirements and proper diffuser count required in the aeration basin. This calculation
creates one design point of diffuser numbers, one air flow rate/diffuser; and total system air flow.
Output from this initial Design Brief calculation can confirm the basic system feasibility for aeration
to meet O2 demands of the process. Mixing criteria are also established based on the process and
basin geometry. It is now possible to use multiple iterations of Design Brief calculations to
establish an aeration performance envelope for the project.

Phase IV: Create Diffuser Performance Profiles

The Design Brief is the work vehicle used to establish performance profiles for SOTE, air volumes,
and number of diffusers as described below. This set of aeration profiles can be particularly useful
in developing blower sizing, motor and electrical switch gear sizing, plus the basis of future
evaluations of total cost of ownership.
Multiple designs from Phase III (design briefs) can be used to create an SOTE performance profile
when SOTE is plotted versus number of diffuser units. These same multiple designs from Phase
III also allow us to establish the air flow Performance Profile with air volume plotted versus the
number of diffusers. Both curves are typically plotted together as shown in Figure 3. Note:
Curves are independent and they do not show the optimum design point where they
intersect. Separate calculations or evaluations are required to find the optimum total aeration
solution.

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

Figure 3. Optimization of Fine Pore Aeration Diffusers

Using the curves of Figure 3, it is easy to determine:

1.
2.
3.
4.

Range of SOTE or Air Volume design opportunities by changing the quantity of diffuser
applied.
Total air volume based on a preliminary selection of operating SOTE or preferred number
of diffusers.
Comparison of energy mixing limits (i.e., airflow per basin floor area, or airflow per basin
volume) versus possible operating airflows.
Allows selection of energy efficiency to match existing compressor/blower units or size
limits. Also enables sizing blowers to stay within unit Hp (Kw) limits for the site, by
selecting the number of diffusers to deliver the desired air volume.

EXAMPLE: Optimize 9 inch Disc Design

1.
2.
3.
4.

Utilize design data from Aeration Design FormAppendix A.

Process oxygen required for extended aeration at 1.4 kg of O2 /kg BOD (1.4 lbs/lbs) plus
4.6 kg of O2/kg of ammonia (4.6lb)
No O2 recovery for denitrification (DN) in this design
Establish SOTE performance for 9-inch disc at 5.75 m diffuser submergence (6m SWD less
the height of diffusers). SOTE curves plotted versus air flow per disc, as shown in Figure 2.
Note: These performance curves for each diffuser platform are imbedded into the
Proprietary EDI Process Design Brief calculations. If running a separate or manual set of
iterations these SOTE curves must be established or obtained from the diffuser
manufacturer.

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

5.
6.

Using data from Figures 2 and 3 above run the Design Brief (Appendix B) to determine one
set of design conditions.
After review of the initial Design Brief, run several iterations of the design brief by varying
air flow per diffuser while holding the design load constant and solving for number of
diffusers, efficiency, air flow, etc. Plot Figure 3 and establish the diffuser performance
envelope using the Design Brief calculations.
A.
B.
C.

Create Curve of SOTE % versus number of 9-inch disc units for design diffuser
submergence.
Create curve of total air volume versus number of 9-inch discs for process
oxygenation (Note mixing limited cases may need to be reviewed).
Compute the energy cost/year based on $10/Kw and assumed blower efficiency of
70% plotted versus number of 9-inch discs.

Figure 4. Annual Energy Cost as a function of diffuser design.

7.

Select optimum diffuser design point to meet the project design objectives (i.e., Select the
number of diffusers).

The integrated aeration system optimization

developed. This incorporates present worth or
project. The cost of ownership calculations
"Opportunity" for savings, and is an in-depth
program shown here.

allows the project "Total Cost of Ownership" to be

net present value calculations over the design life of the
again require iterative procedures to create the NPV
analysis beyond the basic diffuser/blower optimization

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

Appendix A. Aeration Design Form Example

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

Appendix B. Design Brief Example

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

Appendix B. Design Brief Example - Continued

10

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved

Appendix B. Design Brief Example Continued

11

Technical Bulletin 153 Optimization of Diffuser Systems

Copyright Environmental Dynamics International 2012 All Rights Reserved