Optimizing MBR Performance: CFD and Experimental Insights on Aeration Design for Fouling Cont

The optimization of membrane bioreactor systems is a critical challenge in mitigating membrane fouling. In this study, a two-phase experimental and computational approach was applied to evaluate the effect of the distance between the aeration pipe and the membrane module on antifouling performance. Flat-sheet PVC membranes were fabricated by the NIPS method and characterized through FESEM, pure water flux and contact angle measurements. Among the prepared membranes, M2 showed the highest pure water flux, equal to 134 L·m⁻²·h⁻¹, the lowest contact angle, equal to 80.0°, and a more favourable pore size distribution. A CFD model was then developed to simulate the hydrodynamic conditions around the selected membrane. The results showed that increasing the aeration pipe–membrane distance improved the uniformity of shear stress distribution. A distance of 60 mm was identified as the optimal configuration, providing the lowest average shear stress, approximately 0.30 Pa, a balanced stress regime, reduced localized abrasion and sufficient shear for antifouling control. The combined experimental–computational approach confirms the potential of optimized aeration design to improve MBR performance, extend membrane lifespan and reduce fouling.