Heuristic optimization of a continuous flow point-of-use UV-LED disinfection reactor using computational fluid dynamics.

Alternative disinfection sources such as ultraviolet light (UV) are being pursued to inactivate pathogenic microorganisms such as Cryptosporidium and Giardia, while simultaneously reducing the risk of exposure to carcinogenic disinfection by-products (DBPs) in drinking water. UV-LEDs offer a UV disinfecting source that do not contain mercury, have the potential for long lifetimes, are robust, and have a high degree of design flexibility. However, the increased flexibility in design options will add a substantial level of complexity when developing a UV-LED reactor, particularly with regards to reactor shape, size, spatial orientation of light, and germicidal emission wavelength. Anticipating that LEDs are the future of UV disinfection, new methods are needed for designing such reactors. In this research study, the evaluation of a new design paradigm using a point-of-use UV-LED disinfection reactor has been performed. ModeFrontier, a numerical optimization platform, was coupled with COMSOL Multi-physics, a computational fluid dynamics (CFD) software package, to generate an optimized UV-LED continuous flow reactor. Three optimality conditions were considered: 1) single objective analysis minimizing input supply power while achieving at least (2.0) log10 inactivation of Escherichia coli ATCC 11229; and 2) two multi-objective analyses (one of which maximized the log10 inactivation of E. coli ATCC 11229 and minimized the supply power). All tests were completed at a flow rate of 109 mL/min and 92% UVT (measured at 254 nm). The numerical solution for the first objective was validated experimentally using biodosimetry. The optimal design predictions displayed good agreement with the experimental data and contained several non-intuitive features, particularly with the UV-LED spatial arrangement, where the lights were unevenly populated throughout the reactor. The optimal designs may not have been developed from experienced designers due to the increased degrees of freedom offered by using UV-LEDs. The results of this study revealed that the coupled optimization routine with CFD was effective at significantly decreasing the engineer's design decision space and finding a potentially near-optimal UV-LED reactor solution.