Assessing the applicability of the 1D flux theory to full-scale secondary settling tank design with a 2D hydrodynamic model

The applicability of the one-dimensional idealized flux theory (1DFT) for the design of secondary settling tanks (SSTs) is evaluated by comparing its predicted maximum surface overflow (SOR) and solids loading (SLR) rates with that calculated with the two-dimensional computational fluid dynamics model SettlerCAD using as a basis 35 full-scale SST stress tests conducted on different SSTs with diameters from 30 to 45 m and 2.25–4.1 m side water depth (SWD), with and without Stamford baffles. From the simulations, a relatively consistent pattern appeared, i.e. that the 1DFT can be used for design but its predicted maximum SLR needs to be reduced by an appropriate flux rating, the magnitude of which depends mainly on SST depth and hydraulic loading rate (HLR). Simulations of the Watts et al. (Water Res. 30(9)(1996)2112) SST, with doubled SWDs and the Darvill new (4.1 m) and old (2.5 m) SSTs with interchanged depths, were run to confirm the sensitivity of the flux rating to depth and HLR. Simulations with and without a Stamford baffle were also performed. While the design of the internal features of the SST, such as baffling, has a marked influence on the effluent SS concentration while the SST is underloaded, these features appeared to have only a small influence on the flux rating, i.e. capacity, of the SST. Until more information is obtained, it would appear from the simulations that the flux rating of 0.80 of the 1DFT maximum SLR recommended by Ekama and Marais (Water Pollut. Control 85(1)(1986)101) remains a reasonable value to apply in the design of full-scale SSTs—for deep SSTs (4 m SWD) the flux rating could be increased to 0.85 and for shallow SSTs (2.5 m SWD) decreased to 0.75. It is recommended that (i) while the apparent interrelationship between SST flux rating and depth suggests some optimization of the volume of the SST, this be avoided and (ii) the depth of the SST be designed independently of the surface area as is usually the practice and once selected, the appropriate flux rating applied to the 1DFT estimate of the surface area.