Enhancing ozonation technology: A case study on full-scale airlift reactor upgrades in the existing wastewater treatment plant's ozonation tank using CFD

Traditional pneumatic bubble column reactors (PBCRs) in wastewater treatment often have limitations in ozone distribution and disinfection efficacy. This study introduces an optimized Airlift Reactor (ALR) design, enhanced with Computational Fluid Dynamics (CFD), to improve ozone contact time and uniform distribution. Tailored for the SONATRACH GP1/Z Complex in Bethioua, Algeria, the ALR addresses the treatment needs of the facility's WWTP Phase-1, handling domestic wastewater. The study is unique for its full-scale implementation of the ALR, as previous research focused on lab-scale cases. Advanced CFD simulations optimized the ALR design, focusing on baffle configurations to enhance ozone disinfection. The upgraded One Side Baffled Airlift (OS-BALR) variant achieved a Total Coliform inactivation rate of 94.52 %, compared to 74 % with the traditional design. The OS-BALR also demonstrated a lower ozone mass transfer coefficient (KLa) of 0.0048 s−1, improving treatment efficiency and reducing energy consumption. While the Baffled Bubble Column (BBC) reactor showed a higher KLa of 0.0055 s−1 and a microbial removal efficacy of 96.12 %, it is more energy-intensive. This study advances wastewater treatment by bridging innovation with industrial application, contributing to sustainable wastewater management practices globally. [Display omitted] •Optimized Airlift Reactor (ALR) designed with advanced CFD simulations.•Increased Total Coliform inactivation (94.52%) compared to (74%) of the existing designs.•Low ozone (KLa) of 0.00048 s-1 and energy consumption with high treatment efficiency.•Validated CFD models with empirical benchmarks for improved accuracy and reliability.•Superior performance compared to conventional bubble column reactors (PBCRs).