Hydro International and the University of Exeter have completed a ground-breaking two-year research project to optimise the performance of the company’s advanced wastewater grit removal technology.

Suspended solids carried in water can cause a range of harmful effects in rivers, lakes and oceans, making the capture and removal of these solids critical for effective environmental protection. To address this problem, the project focused on optimising the stacked trays that remove high levels of suspended solids from wastewater.
Combining optimisation methods and computational fluid dynamics (CFD), the project was able to derive new designs for hydrodynamic solids removal components that would have been difficult or impossible to achieve using traditional engineering methods.

The research was part of a Knowledge Transfer Partnership (KTP), supported by the UK government’s innovation body Innovate UK, which began in July 2019 and ran until September 2021. It builds on years of collaboration between Hydro International and the University of Exeter in the field of CFD.

The core of the project involved the optimisation of stacked trays that enable the removal of high levels of suspended solids in wastewater, with the primary objectives being to improve performance and reduce maintenance requirements. This was a complex, multi-objective, high-dimensional problem, so the team needed to adopt an unconventional approach in order to solve it.

To tackle the problem the project team coupled Bayesian optimisation techniques and CFD modelling, using a Bayesian optimisation toolset originally developed by the world-renowned Machine Learning Group at the University of Exeter. Bayesian optimisation was selected as it can be an order of magnitude more efficient than alternative approaches, such as genetic algorithms, on such complex design problems.
The Bayesian optimisation toolset was then connected to CFD simulations, allowing the team to use computing power to automate the design and evaluation process. The team ran the CFD simulations using supercomputers in Exeter and Bristol, with each optimisation run modelling some 300 designs at a time. This would have been impossible to achieve using other optimisation techniques. The team was one of the first in the world to use these techniques on new GW4 Isambard supercomputing architectures,
The team subsequently corroborated simulation results through physical testing of prototypes in Hydro International’s hydraulics laboratory in Clevedon.

The outcome of the project was a new stacked tray design that improves grit removal performance and enables the production of more compact systems that can handle higher wastewater flows and requires less maintenance—an excellent example of combining academic research with commercial incentives to address real-world challenges.

Although the project was focused on improving technologies that will be applied to future iterations of the HeadCell® advanced grit removal system, the findings are fundamental to Hydro International’s core technologies, and will be applicable to other products that rely on the same hydrodynamic principles such as Downstream Defender® and First Defense®.

Following completion of the project, Innovate UK assessed the KTP and awarded it a Grade A, or “Outstanding”.