Development of dissolved air flotation technology from the first generation to the newest (third) one (DAF in turbulent flow conditions)
Authors: Kiuri H. J. 
Published: May 2018

This paper gives a brief description of the development of dissolved air flotation DAF (or so-called high pressure flotation) as an unit operation for removal of solids in water and wastewater treatment during the last 80 years up to this time. The first DAF-systems used in the water industry were the ADKA and Sveen-Pedersen ones from the 1920s. Some of these are still in use. The tanks in which the flotation phenomenon takes place in these systems are very shallow and narrow as well as rather long. The flow rate of water is some 2–3 m/h (at most less than 5 m/h only) and there is a very thin micro-bubble blanket below the water surface between the dry sludge blanket on that and the clarified water which flows almost horizontally below the bubble blanket toward the end of the tanks to be taken out there from near the bottom.

The second generation of DAF was introduced in the 1960s and these units are widely in use today. Their tanks are almost square ones having usually a little bit more length than bredth. They are rather deep, too. There is an under-flow wall in front of the back wall of the units having a narrow horizontal gap on the bottom of the tanks for letting out the clarified water from the flotation space. The flow rate of water is usually 5–7 m/h or at most less than 10 m/h. The direction of flow is 30–45° below the horizontal. There is a rather thick micro-bubble bed at the beginning of the tank below the dry sludge blanket. This bubble-bed becomes clearly thinner, when going toward the end of the tank. There are also round DAF tanks which are based on the same hydraulic principles as the rectangular ones presented above.

A special application of DAF called the flotation filter was invented at the very end of the 1960s. It is a combination of flotation and rapid sand filtration, both of those being placed in the same tank. Flotation takes place in the upper part of the tank and the filter has been placed in the lower part of it. The direction of water flow is now vertically down from the free surface of water in the tank toward the deep-bed filter. This controls the direction of flow in the flotation space of the tank above the filter bed. The flow rate of water in flotation filters may be 10–15 m/h, but the flow conditions are still laminar. It is the threat that the head-loss of filters would grow too rapidly which in practice is limiting the hydraulic flow rate of flotation filters in this area.

The third generation of DAF has been developed at the end of the 1990s. The operational idea is based on that of the flotation filter. The filter bed on the bottom of the tank has been replaced by a thin stiff plate with plenty of round orifices throughout the plate. This plate, having a very much lower flowing resistance than a sand filter can have, controls the vertical flow of water in the flotation space above the plate and distributes it evenly throughout the horizontal cross-section of the tank. The flotation tank is almost square seen from above and its depth is clearly more than the length and bredth of it. This kind of flotation unit can be operated with flow rates of water in the range 25–40 m/l. Even a flow rate of more than 60 m/h has been reported from this kind of DAF-units. There is no risk of clogging of the plate by suspended solids which could limit the flow rate.

This is to say that it is possible to operate DAF also in turbulent flow conditions. The depth of the micro-bubble bed below the surface of water can be 1.5–2.5 m. There actually is a continuously regenerated micro-bubble bed in the tank filtering water which is going through this bed. The lower surface of the micro-bubble bed is really a horizontal one a little bit above the plate controlling the flow in the flotation space. The clarified water below the micro-bubble bed is totally clear. It can be said that in this case the removal of suspended solids takes place much more by filtering water by a deep-bed micro-bubble filter than by attaching micro-bubbles onto solids, when both of these are mixed with each other in the inlet shaft of the flotation unit, because the retention time of water in the inlet shaft is very short indeed.