Common Problems of Disc Diffusers in Use, and How Can They Be Solved?

 Introduction

Disc diffusers are widely used in municipal, food wastewater treatment fields. They can achieve oxygen dissolution, pollutant degradation, or reaction acceleration through efficient gas-liquid mass transfer. However, during long-term operation, due to changes in factors such as water quality, operating parameters, and material aging, these diffusers may face various problems, resulting in low efficiency. This article will discuss with you the signs of these common problems and how we should deal with them.


What is a Disc Diffuser?

A disc diffuser is a disc-shaped device that uniformly disperses gases (such as oxygen, ozone) into a liquid (water) through a microporous membrane. Its main structure includes an elastic membrane, a support skeleton, and a gas distribution pipeline. The material of the membrane is mostly corrosion-resistant silicone rubber, EPDM rubber, or ceramic composite material. The disc structure gives it a larger contact surface with water, and it evenly diffuses the air bubbles output from the pipeline system.

 

 

The Working Principle of Disc Diffusers

The working process can be divided into three stages:

1. Gas Input: The gas enters the diffuser cavity through the gas supply pipeline and is evenly distributed on the surface of the membrane.

2. Microporous Diffusion: Under the action of gas pressure, the micropores on the elastic membrane expand. The gas is released into the liquid in the form of tiny bubbles.

3. Gas-liquid Mixing: A large number of bubbles rise rapidly in the liquid, fully contacting and mixing with the water, promoting oxygen dissolution or chemical reactions.

  


Problems and Solutions During the Use of Disc Diffusers

Problem 1: Uneven Diffusion or Abnormal Bubble Size

 Signs: At this time, the dissolved oxygen concentration in the aeration tank fluctuates greatly, and there are obviously larger or fewer bubbles in local areas.

 Solutions: Uneven diffusion is usually caused by the blockage of the micropores on the surface of the diffuser, unstable gas pressure, or the aging of the membrane. We can remove the scaling or biofilm on the surface of the membrane through low-pressure water backflushing or chemical cleaning (such as soaking in citric acid), and adjust the gas pressure within the design range of the equipment (0.1-0.3 bar). However, if the elasticity of the membrane fails or the pore structure is damaged, a new membrane needs to be replaced in a timely manner.

 

Problem 2: membrane Rupture

 Signs: During operation, we may observe that gas escapes from the edge or interface of the diffuser, forming large bubbles or directly escaping to the liquid surface. Sometimes, the liquid will also flow back into the gas supply pipeline through the membrane.

 Solutions: membrane rupture may be caused by mechanical damage, chemical corrosion of the sewage, and long-term operation under overpressure. We need to immediately shut off the gas source and disassemble the membrane of the diffuser. If the membrane is only slightly damaged, it can be repaired with special glue. If it is seriously damaged, a new membrane assembly needs to be replaced. In addition, in chemical sewage treatment plants, we prefer to use EPDM or PTFE membrane membranes because they are resistant to chemical corrosion.

 

Problem 3: Sudden Increase in Energy Consumption

 Signs: At this time, the load of the fan continues to increase, the power consumption keeps rising, and the system pressure gauge shows that the pressure drop is significantly higher than the initial value.

 Solutions: This situation is generally caused by blockage in the pipeline or uneven gas distribution in the pipeline. What we can do is to check whether the gas filter, valve, and pipeline are blocked, especially to clean the scaling at the elbows and tees. If multiple groups of diffusers in your aeration tank are used in parallel, you should also adjust the opening of the branch valve to make the gas volume of each unit balanced.

 

Problem 4: The Membrane Fails Quickly

 Signs: The new membrane shows hardening, cracking, or pore size deformation within less than half a year of use.

 Solutions: The accelerated aging of the diffuser membrane may be due to ozone oxidation, high temperature, or frequent pressure shocks. We must select the membrane material according to the characteristics of the medium. For example, in an ozone environment, use oxidation-resistant silicone rubber, and for high-temperature liquids, use ceramic composite membranes. Secondly, we can also install a pressure relief valve in the gas supply pipeline to avoid sudden pressure changes impacting the membrane, and use soft start control when starting and stopping the fan.


 

Conclusion

The operating status of disc diffusers determines whether the water treatment system is efficient and energy-saving. Through measures such as regular cleaning, pressure adjustment, and material selection, we can extend the lifespan of the diffusers and reduce the failure rate.

As a professional water treatment supplier in the industry, AquaSust will provide users with more durable disc diffusers through innovative technologies and customized designs. Contact us now to get a reliable disc diffuser design solution!

 

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