AbstractAn aeration process in an activated sludge plant is a continuous‐flow system. In this system, there is a steady input flow (flow from the primary clarifier or settling tank with some part from the secondary clarifier or secondary settling tank) and output flow connection to the secondary clarifier or settling tank. The experimental and numerical results obtained through batch systems can not be relied on and applied for the designing of a continuous aeration tank. In order to scale up laboratory results for field application, it is imperative to know the geometric parameters of a continuous system. Geometric parameters have a greater influence on the mass transfer process of surface aeration systems. The present work establishes the optimal geometric configuration of a continuous‐flow surface aeration system. It is found that the maintenance of these optimal geometric parameters systems result in maximum aeration efficiency. By maintaining the obtained optimal geometric parameters, further experiments are conducted in continuous‐flow surface aerators with three different sizes in order to develop design curves correlating the oxygen transfer coefficient and power number with the rotor speed. The design methodology to implement the presently developed optimal geometric parameters and correlation equations for field application is discussed.