Numerical and experimental design of ultrasonic particle filters for water treatment

Due to limited water resources available in the world and the ever growing world population, there is an increasing need for water recycling, recovery and multi-sourcing strategies. One of the new physical process technologies being investigated for water purification and/or constituent recycling is ultrasonic particle separation. This technology is especially interesting for harvesting particles with an almost neutral buoyancy. An ultrasonic particle filter does not use a filter medium, like sand or a membrane, but filters on a basis of acoustic forces in ultrasonic standing waves, which are able to immobilise particles in flowing water. The objective of this study was to develop an ultrasonic separation device for particle recovery and water purification. This separator should be fit for industrial applications treating cubic meters of water per hour. In order to reach this objective, a combined numerical-experimental approach was proposed to develop a model-based design of an ultrasonic separator. Each individual component of this separator was modelled using a finite element (FE) approach. The numerical simulations were continuously cross-checked with experiments in order to find the best solution possible. In this thesis, the source of the acoustic wave is a piezoelectric transducer attached to a glass matching layer of the acoustic cavity, which couples the transducer to the fluid inside the cavity, forming an acoustic resonator/separator. In order to obtain a valid FE transducer model, a limited set of material parameters for the piezoelectric transducer were obtained from the manufacturer, thus preserving prior physical knowledge to a large extent. The remaining unknown parameters were estimated from impedance (admittance) analysis combined with a numerical optimisation routine using 2D and 3D FE models. Thus, a full set of physically interpretable material parameters was obtained. The approach provided adequate accuracy of the estimates of the material parameters, near 1%. A similar approach as used for the transducer was applied to an existing ultrasonic separator, again preserving known physical parameters and estimating the remaining unknown or less certain parameters. The results showed that the approach led to a fully calibrated 2D model of the emptyseparator, which was subsequently validated with experiments on a filledseparator chamber. The large sensitivity of the separator to small variations indicated that either such system should be made and operated within tight specifications to obtain the required performance. Alternatively, the operation of the system should be adaptable to cope with a slightly off-spec system, requiring a feedback controller. Starting from a fully characterised existing separator with all material parameters found so far, the subsequent step was the actual design of, or extrapolation to, a new separator. A basic design for an industrial scale acoustic separator was obtained based on simulated flow characteristics inside the separation chamber, on acoustic analysis within the chamber and simulated particle trajectories combining these two analyses. Results showed that positioning the piezoelectric transducer surfaces perpendicular to the flow direction and introducing chamber partitioning with multiple flow lanes to enforce laminar flow, resulted in high particle retention. The average particle displacement was found to be related to acoustic pressure in the fluid, showing large retention at peak pressures above 1 MPa or average pressures above 0.5 MPa for small (10 µm), near buoyant (1100 kg/m3) particles at a flow speed of 3.5 cm/s, thus providing comprehensible criteria for subsequent optimisation. This basic ultrasonic standing wave separator design was optimised with respect to separation efficiency, throughput and energy consumption. The methodology, using a design of experiments (DOE) approach, showed that it was possible to improve system performance based on acoustic pressure profiles, separation efficiency and flow robustness. Compromising the energy consumption and aiming for maximum separation efficiency with a laminar stable flow up to 5 ml/s resulted in a separator with inner dimensions of 70 mm length, 20 mm width and 28.5 mm height using two transducers perpendicular to the direction of flow and three parallel flow lanes with 9.5 mm height each. The lowest power consumption (with an average of 30 W) with adequate pressure to trap the particles was obtained when it was not operated at the main eigenfrequency. Finally, this new ultrasonic particle filter was built and evaluated experimentally. The particle filter was a three channel device, manufactured from glass with four in/outlet ports made of ABS. It was operated in sequenced batch mode and the separation efficiency was determined at three flow rates ranging from 1 to 3 ml/s, using a stock suspension of insoluble potato starch of 1 g/l (1000 ppm). Concentrations of stock, filtrate and concentrate were measured using a turbidity meter and significant effects of acoustic particle concentration were measured at both outlets of the process. The maximum filtration efficiency and concentration efficiency were 54% and 76%, respectively. The performance found was lower than the 100% that was expected for 10 µm particles from the model based design study. The deviation in performance is mainly a result of (i) the pulsation of the feed pump, (ii) differences between the model and the actual prototype, (iii) the limited power supply of only 10 W used and (iv) (too) small particles, below 10 µm, occurring in the starch suspension. The best dimensions for an acoustic separator were obtained, but thus far operational characteristics were not yet studied. Operational characterisation and optimisation is the last step in the process of obtaining the best possible solution for operation. With the aim to achieve a high separation efficiency with minimal energy consumption, a model-based open-loop switching control strategy was designed for the commercially available BioSep, using a numerical-experimental approach. Firstly, a dynamic BioSep model structure was derived from mass balances and its system properties were studied. Then, the unknown system parameters were estimated from steady state and dynamic experimental data and subsequently, the switching times of the control input were determined. The model with switching control outputs was then validated by experiments. Finally, the control strategy was implemented in an experimental setup and tested using suspended potato starch. Results showed that the optimal control strategy reached a mass separation efficiency of 96%, which was an improvement of 4% with respect to the initial settings, while using less energy. Concluding, a stepwise numerical-experimental approach to acoustic separator design was presented in this study. The minimum power required was estimated to be 22-34 W, resulting in an average electric energy consumption of 1-1.5 kWh/m3. The practical concentration efficiency obtained was 76% at a flow rate of 2 ml/s and a filtration efficiency of 54% at 1 ml/s with a real power input of 8.8 W. An optimal open loop control strategy showed that it is possible to operate an acoustic separator with high separation efficiency using the least power possible. Parallelisation, instead of enlarging the separator, is recommended to scale this system up to larger, industrial flows.</p

Numerical modeling, calibration, and validation of an ultrasonic separator

Our overall goal is to apply acoustic separation technology for the recovery of valuable particulate matter from wastewater in industry. Such large-scale separator systems require detailed design and evaluation to optimize the system performance at the earliest stage possible. Numerical models can facilitate and accelerate the design of this application; therefore, a finite element (FE) model of an ultrasonic particle separator is a prerequisite. In our application, the particle separator consists of a glass resonator chamber with a piezoelectric transducer attached to the glass by means of epoxy adhesive. Separation occurs most efficiently when the system is operated at its main eigenfrequency. The goal of the paper is to calibrate and validate a model of a demonstrator ultrasonic separator, preserving known physical parameters and estimating the remaining unknown or less-certain parameters to allow extrapolation of the model beyond the measured system. A two-step approach was applied to obtain a validated model of the separator. The first step involved the calibration of the piezoelectric transducer. The second step, the subject of this paper, involves the calibration and validation of the entire separator using nonlinear optimization techniques. The results show that the approach lead to a fully calibrated 2-D model of the empty separator, which was validated with experiments on a filled separator chamber. The large sensitivity of the separator to small variations indicated that such a system should either be made and operated within tight specifications to obtain the required performance or the operation of the system should be adaptable to cope with a slightly off-spec system, requiring a feedback controlle

Design basis of industrial acoustic separators

This study presents the process of obtaining a basic design for an industrial scale acoustic separator based on flow characteristics inside the separation chamber, on acoustic analysis within the chamber and calculated particle trajectories combining these two analyses. Adequate criteria for subsequent optimisation were evaluated. Results showed that positioning the piezoelectric transducer surfaces perpendicular to the flow direction and introducing chamber partitioning with multiple flow lanes to enforce laminar flow, resulted in high particle retention. The average particle displacement was found to be related to acoustic pressure in the fluid, showing large retention at peak pressures above 1 MPa or average pressures above 0.5 MPa for small (10 µm), near buoyant (1100 kg/m3) particles at a flow speed of 3.5 cm/s, thus providing comprehensible criteria for subsequent optimisation

Concentration based flow control in acoustic separation of suspensions

Acoustic separation is a relatively new method for recovering valuable particulate matter from suspensions. This separation method is mainly used in medical technology, but may well be applicable as water purification and material recovery technique. The key question then is what separation efficiency can be reached and whether this can be realised in an energy-efficient way. In the current study, a commercially available acoustic separator, named BioSep, which employs ultrasound enhanced sedimentation, was used. With the aim to achieve a high separation efficiency with minimal energy consumption, a model-based open-loop switching control strategy was designed for the BioSep, using a numerical-experimental approach. Firstly, a dynamic BioSep model structure was derived from mass balances and its system properties were studied. Then, the unknown system parameters were estimated from steady state and dynamic experimental data and subsequently, the switching times of the control input were determined. The model with switching control outputs was then validated by experiments. Finally, the control strategy was implemented in the experimental setup and tested using suspended potato starch. Results showed that the optimal control strategy reached a mass separation efficiency of 96%, which was an improvement of 4% with respect to the initial settings, while using less energy

Set-membership parameter estimation based on Voronoi vertices

Identification of complex systems often face structural modelling errors and limited or low quality data, which hinder statistical characterisations. An alternative is the set-membership approach, where errors are assumed unknown-but-bounded. Set-membership estimation aims to find a feasible parameter set (FPS), which produces model outputs that fit within given error bounds. Most algorithms are limited to linear models, small number of parameters, or to discrete approximation of the FPS. These limitations hinder parameter estimation for relatively complex systems. We present an efficient sampling-based set-membership algorithm with low computational complexity that improves the coverage of a discrete approximation of the FPS, characterised by hyperspheres from a Voronoi diagram of the parameter space. Additionally, we suggest a measure for set-membership accuracy based on deviations between the given error bounds and the feasible model output set. Our algorithm provides a balance between accuracy and computational complexity, and a tool to investigate practical identifiability

Human volunteer head-Tl response for oblique impact conditions

The development of modern smart restraint systems requires access to human surrogates with a biofidelic performance, which includes details on timing and local deformations. Therefore volunteer head neck responses for oblique impacts from the Naval BioDynamics Laboratory are re-analysed using a method developed by Thunnissen (1995). Response parameters were chosen to allow a straightforward comparison of crash dummies with volunteers. The response parameters are time histories of 3D kinematics relative to the sled of the head centre of gravity and the anatomical defined Tl, in extension to work by Wismans (1968a, 1987). Kinematics of the head relative to a rotating Tl and all six occipital load components are presented. A general applicable method to calculate 3D head flexion and twist is developed. The result is a set of time history corridors and mean peak + standard deviation windows, which can be used in the evaluation of human surogates in addition to existing frontal and lateral response specifications

Ultrasound standing-wave bio-reactor design and testing on aerobic activated sludge

This study experimentally investigated the ultrasonic separation efficiency of water-activated sludge suspensions, which is in line with our previous work on modeling and control in acoustic separation of suspensions using a numerical-experimental approach. The main conclusion is that ultrasound separation provides a promising technique that could have industrial application for activated sludge separation in the future