Design and Construction of an Aerated Accumulation Bioreactor for Solid Waste Treatment

Aerated accumulation bioreactors represent a promising alternative for the aerobic bioremediation of solid contaminated substrates. However, achieving homogeneous mixing and effective air distribution remains a key design challenge in solid-phase systems. This study presents the design and construction of a novel pilot-scale aerated bioreactor equipped with an angled-paddle agitation system, specifically developed to improve solid mixing and aeration. To evaluate the geometric configuration, a series of simulations were performed using the Discrete Element Method (DEM), with particle dynamics analyzed through the Lacey Mixing Index (LMI). Four paddle angles (0°, 15°, 45°, and 55°) were compared, with the 45° configuration achieving optimal performance, reaching LMI values above 0.95 in less than 15 s and maintaining high homogeneity at a filling volume of 70%. These results confirm that the paddle angle significantly influences mixing efficiency in granular media. While this work focuses on engineering design and DEM-based validation, future studies will include experimental trials to evaluate biodegradation kinetics. The proposed design offers a scalable and adaptable solution for ex situ bioremediation applications. This work reinforces the value of integrating DEM simulations early in the bioreactor development process and opens pathways for further optimization and implementation in real-world environmental remediation scenarios.