Moving Bed Biofilm Reactors (MBBRs) can efficiently treat wastewater by incorporating suspended biocarriers that provide attachment surfaces for active microorganisms. The performance of MBBRs for wastewater treatment is, among other factors, contingent upon the characteristics of the surface area of the biocarriers. Thus, novel biocarrier topology designs can potentially increase MBBR performance in a significant manner. The goal of this work is to assess the performance of 3-D-printed biofilter media biocarriers with varying surface area designs for use in nitrifying MBBRs for wastewater treatment. Mathematical models, rendering, and 3D printing were used to design and fabricate gyroid-shaped biocarriers with a high degree of complexity at three different levels of specific surface area (SSA), generally providing greater specific surface areas than currently available commercial designs. The biocarriers were inoculated with a nitrifying bacteria community, and tested in a series of batch reactors for ammonia conversion to nitrate, in three different experimental configurations: constant fill ratio, constant total surface area, and constant biocarrier media count. Results showed that large and medium SSA gyroid biocarriers delivered the best ammonia conversion performance of all designs, and significantly better than that of a standard commercial design. The percentage of ammonia nitrogen conversion at 8 hours for the best performing biocarrier design was: 99.33% (large SSA gyroid, constant fill ratio), 94.74% (medium SSA gyroid, constant total surface area), and 92.73% (large SSA gyroid, constant biocarrier media count). Additionally, it is shown that the ammonia conversion performance was correlated to the specific surface area of the biocarrier, with the greatest rates of ammonia conversion (99.33%) and nitrate production (2.7 mg/L) for manufactured gyroid biocarriers with a specific surface area greater than 1980.5 m²/m³. The results suggest that the performance of commercial MBBRs for wastewater treatment can be greatly improved by manipulation of media design through topology optimization.

Decoupled aquaponic systems are gaining popularity as a way to manage water quality in aquaponic systems to suit plant and fish growth independently. Aquaponic systems are known to be deficient in several plant-essential elements, which can be affected by solution pH to either increase or decrease available nutrients. To determine the effect of pH in a decoupled aquaponic system, a study was conducted using aquaculture effluent from tilapia culture tanks at four pH treatments: 5.0, 5.8, 6.5, and 7.0, used to irrigate a cucumber crop. Growth and yield parameters, nutrient content of the irrigation water, and nutrients incorporated into the plant tissue were collected over two growing seasons. pH did not have a practical effect on growth rate, internode length or yield over the two growing seasons. Availability and uptake of several nutrients were affected by pH, but there was no overarching effect that would necessitate its use in commercial systems. Nutrient concentrations in the aquaculture effluent would be considered low compared to hydroponic solutions; however, elemental analysis of leaf tissues was within the recommended ranges. Research into other nutrient sources provided by the system (i.e., solid particles carried with the irrigation water) would provide further information into the nutrient dynamics of this system.

Purpose: The purpose of this paper is to elucidate the effect of part thickness and build orientation upon the type and magnitude of distortion in material jetting processes. Design/methodology/approach: Specimens with high (10:1) aspect ratio were printed in two orientations (XY and YX) and three thickness values (1, 3 and 6 mm) and scanned with a white-light profilometer to quantify distortion. Findings: The results of this paper indicate that 1-mm thick specimens always distorted following a wavy edge type, while thicker specimens (3- and 6-mm) always distorted following a reverse coil set. The factor thickness, when measured with the indices height of the highest peak (H) and profile radius (R), was shown to be statistically significant, with 3-mm specimens experiencing distortions of 57 and 51 per cent, respectively, more severe than those in 6-mm specimens. The thickness effect is attributed to the percentage of build layers that receive maximum energy exposure (61-72 per cent in 1-mm, 87-91 per cent in 3-mm and 93-95 per cent in 6-mm specimens). With respect to the thinner 1-mm specimens, the factor orientation was found to be statistically significant with distortion 114 per cent less severe in the YX orientation when measured by the H index. Originality/value: This paper provides the first known description of build orientation and part thickness effects on dimensional distortion as a pervasive consequence of the curing process in photopolymerization and explores one of the most common defects encountered in additive manufacturing. In addition to the characterization of the type and magnitude of distortion, the contributions of this paper also include establishing the foundation for design guidelines aiming at minimizing distortion in material jetting.