Pyrolysis of wastewater sludge and composted organic fines from municipal solid waste: laboratory reactor characterisation and product distribution

Pyrolysis, a recovery solution to reduce landfilling of residual organic waste generated from mixed municipal waste

Despite policies to restrict the mixing of organic waste with other general waste and improve its separation at source, municipal solid waste still contains a high proportion of organic waste. The residual organic waste is generated as a by-product of the mechanical treatment of municipal solid waste (MSW) and is mainly disposed in landfills after composting. Its reuse and recovery status varies across European countries. Most countries restrict the use of biostabilised residual waste (BSRW) to landfill cover, whereas others have regulated it as marketable compost. Crucially, BSRW is set to lose its "recycled" status under the revised European Union waste framework, with probably tighter restrictions and increased costs imposed for the landfilling of organic waste. Our research aimed to investigate pyrolysis as an alternative technology to treat the 10-40 mm fraction of BSRW (representing 50% of BSRW generated). Pyrolysis at 700 °C was carried out and feedstock and pyrolysis products were characterized. Mass and energy balances showed that pyrolysis produced hot vapour/gas whose combustion may render the pyrolysis process energetically sustainable. Biochar comprises 30-50% of BRSW mass after removal of glass, metal and stones. Our results indicate that pyrolysis has the potential to create options for contributing to reduce the landfilling of BSRW; however, the presence of residual impurities may limit biochar applications.

Impact of temperature and residence time on sewage sludge pyrolysis for combined carbon sequestration and energy production

Environmental challenges related to sewage sludge call for urgent sustainable management of this resource. Sludge pyrolysis might be considered as a sustainable technology and is anticipated to support measures for mitigating climate change through carbon sequestration. The end products of the process have various applications, including the agricultural utilization of biochar, as well as the energy exploitation of bio-oil and syngas. In this research, sewage sludge was pyrolyzed at 500 °C, 600 °C, 750 °C, and 850 °C. At each temperature, pyrolysis was explored at 1hr, 2hrs, and 3hrs residence times. The ratio (H/Corg)at was tapped to imply organic carbon stability and carbon sequestration potential. Optimum operating conditions were achieved at 750 °C and 2hrs residence time. Produced biochar had (H/Corg)at ratio of 0.54, while nutrients' contents based on dry weight were 3.99%, 3.2%, and 0.6% for total nitrogen (TN), total phosphorus (TP), and total potassium (TK), respectively. Electrical conductivity of biochar was lesser than the feed sludge. Heavy metals in biochar aligned with the recommended values of the International Biochar Initiative. Heat content of condensable and non-condensable volatiles was sufficient to maintain the temperature of the furnace provided that PYREG process is considered. However, additional energy source is demanded for sludge drying.

Potential of biofuel production from leather solid wastes: Indian scenario

India is one among the major leather-producing countries in the world which shares close to one-fourth of the world's leather solid wastes and most of these wastes are not effectively utilized. These wastes are rich in protein and lipids that could be a potential feedstock for biofuel production, i.e., biogas, biodiesel, etc. Among the 150,000 tons of daily leather solid wastes in India, approximately 87,150 tons are shared by pre-tanning operations (i.e., raw trimmings, fleshing, and hair wastes) while the rest of the 62,850 tons are shared by tanning, post-tanning, and finishing operations (i.e., wet blue trimmings, chrome splits, shavings, buffing dust, crust trimming wastes). This review article shows that there is considerable bioenergy potential for the use of leather solid wastes as a green fuel. The biogas potential of leather solid wastes is estimated to be 40,532.9 m3/day whereas the biodiesel potential is estimated as 15,452.6 L/day. The bio-oil and bio-char potential of leather solid wastes is estimated to be 80,513.0 L/day and 45.8 tons/day, respectively. Several factors influence the biofuel process efficacy, which needs to be taken into consideration while setting up a biofuel recovery plant. The overall biofuel potential of leather solid wastes shows that this feedstock is an untapped resource for energy recovery to add commercial benefits to India's energy supply. Furthermore, in addition to the economic benefits for investors, the use of leather solid wastes for biofuel production will yield a positive environmental impact.

Products distribution and sulfur fixation during the pyrolysis of CaO conditioned textile dyeing sludge: Effects of pyrolysis temperature and heating rate

Textile dyeing sludge (TDS) is a typical industrial solid waste whose amount surged with the textile industry's development. Pyrolysis treatment is a promising technique for TDS to realize harmless disposal and resource reuse. However, the high content of organic compounds would cause sulfurous pollutants emission, reducing the economic feasibility during pyrolysis. This study aimed to fill the knowledge gaps about the thermal behavior, products distribution, kinetics, and sulfur transformation during TDS pyrolysis in 350-575 ℃ with the heating rate of 60, 600, and 6000 ℃/min, then investigate the sulfur fixation effect of CaO under representative conditions (350 ℃, 650 ℃ with 60 ℃/min, 6000 ℃/min). The primary decomposition stage of TDS is observed in 127-557 ℃, following the Avrami-Erofeev (n = 3) model, while the activation energy presents a convergent tendency with the increased heating rate. The pyrolysis temperature and heating rates impact the cracking of organic compounds, while a weakening effect is found for the sulfur distribution. CaO addition could efficiently realize sulfur fixation in char by absorbing sulfurous gas products, but SO₂ escape appeared with the increased CaO fraction. Pyrolysis condition at 650 ℃-60 ℃/min with 10 wt% CaO addition is recommended to achieve high sulfur retention, and the sulfur transformation mechanism in char during the TDS pyrolysis with and without CaO is proposed. Our findings provide novel and fundamental insights into the efficient disposal and pollution control during TDS pyrolysis.

Brewer’s Spent Grain Biochar: Grinding Method Matters

The present work is based on the principle of biomass waste valorization. Brewer’s spent grains (BSG) come from breweries as by-products. Their huge amount of production on an industrial scale should focus our attention on their valorization, which creates challenges as well as opportunities. One way to valorize BSG by-products is to convert them into biochar, a functional material with multiple potential applications. With an emphasis on sustainable development and the circular economy, in this work, we focused on a comparative study of the different mechanical processes of BSG grinding and their effect on the resulting biochar formed after pyrolysis. Home appliances such as blenders, coffee mills, and mortar and pestles were used for this purpose. FESEM images confirmed the successful creation of five different morphologies from the same BSG under the same pyrolysis conditions. Interestingly, a novel Chinese tea leaf egg-like biochar was also formed. It was found that a series of physical pretreatments of the biomass resulted in the reduced roughness of the biochar surface, i.e., they became smoother, thus negatively affecting the quality of the biochar. XRD revealed that the biomass physical treatments were also reflected in the crystallinity of some biochar. Via a Raman study, we witnessed the effect of mechanical pressure on the biomass for affecting the biochar features through pressure-induced modifications of the biomass’s internal structure. This induced enhanced biochar graphitization. This is a good example of the role of mechanochemistry. DSC revealed the thermochemical transformation of the five samples to be exothermic reactions. This study opens up an interesting possibility for the synthesis of biochar with controlled morphology, crystallinity, degree of graphitization, and heat capacity.

Investigation of Pyrolysis Behavior of Sewage Sludge by Thermogravimetric Analysis Coupled with Fourier Transform Infrared Spectrometry Using Different Heating Rates

In this study, pyrolysis of municipal sewage sludge samples from different sources including cattle and chicken manure as well as brook mud, was investigated using a thermogravimetric analysis coupled with a Fourier transform infrared spectrometer (TG-FTIR) at different heating rates (25, 50 and 100 °C/min). In order to determine the kinetic parameters, Arrhenius, model-free Kissinger–Akira–Sunose (KAS), as well as Friedman and Flynn–Wall–Ozawa (FWO) methods were compared. The thermogravimetric results revealed that pyrolysis involved different stages, and that the main decomposition reactions took place in the range of 200–600 °C. In this range, decomposition of biodegradable components (e.g., lipids and polysaccharides), proteins and carbohydrates occurred; meanwhile, there were samples (e.g., cattle manure, brook mud) in which the decomposition step could be observed even at temperatures above 700 °C. According to the Arrhenius method, the activation energies of the first decomposition stage were between 25.6 and 85.4 kJ/mol, while the activation energies of the second and third stages were in the ranges of 11.4–36.3 kJ/mol and 20.2–135 kJ/mol, respectively. The activation energies were also calculated by the KAS, Friedman and FWO methods, which were in the range of 100–300 kJ/mol for municipal sewage sludge or distillery sludge, and ranged between 9.6 and 240 kJ/mol for cattle manure, chicken manure and brook mud samples.

Slaughterhouse and poultry wastes: management practices, feedstocks for renewable energy production, and recovery of value added products

The slaughterhouse and poultry industry is possibly one of the fastest-growing sectors driven by the increasing demand in food availability. Subsequently, the wastes produced from the slaughterhouse and poultry industry are in huge quantities, which could be a promising resource for the recovery of value added products, and bioenergy production to minimize the dependence on fossil fuels. Furthermore, the wastes from slaughterhouses and poultry are a hub of pathogens that is capable of infecting humans and animals. This demands the emerging need for an effective and safe disposal method to reduce the spread of diseases following animal slaughtering. In light of that, the state of the production of slaughterhouse and poultry wastes was presented at first. Following this, the impact of solid waste exposure in terms of air, water, and soil pollution and the associated health challenges due to improper solid waste management practices were presented to highlight the importance of the topic. Secondly, the potency of these solid wastes and the various waste-to-energy technologies that have been employed for effective management and resource utilization of wastes generated from slaughterhouses and poultry were reviewed in detail. Finally, this review also highlights the opportunities and challenges associated with effective solid waste management, future requirements for the development of effective technologies for the recovery of value added products (like keratin, fibreboards), and biofuel production.

Application of Technological Processes to Create a Unitary Model for Energy Recovery from Municipal Waste

The subject matter of this paper is the functioning of a highly effective waste management system. Assumptions of the Energy Recovery Waste Processing (ERWP) model, being a universal solution for towns and regions irrespective of their population, are presented here. The result of simulations illustrating the energetic potential of municipal waste stored and processed in biological and physicochemical processes are also presented. Calculations were performed for the municipality of Koszalin (Poland), with a population of 106,000. Mixed household and commercial waste, organic waste, waste from selective collection and sewage sludge from a municipal wastewater treatment plant were considered in the waste mass balance. Empirical equations and unit coefficients describing the energetic efficiency of particular processes originating from the author’s own research work as well as from the results available from the scientific literature were used in the calculations. The developed ERWP model is based on the functioning of four objects constituting a comprehensive technical infrastructure, i.e., biological stabilisation in air condition (BSAC), mechanical treatment plant (MTP), cogeneration system plant (CSP) and gas production plant (GPP) where two independent modules operate, namely, dry/wet methane fermentation (DMF and WMF). Each day, this system generates highly energetic refuse-derived fuel (RDF) for combustion in amounts of 82.2 t for CSP and 127.3 t for GPP, generating 5519 m3 of gas/d. The value of the energy contained in such generated gas and in waste making up an alternative fuel is 1027.4 GJ, which is equivalent to 285.4 MWh. It should be noted that the creation of a waste management system based on the ERWP model assumptions fulfills the criteria of energetic recycling and allows for recovery of energy in the form of gas and heat equivalent to 79,917.6 MWh/a, i.e., 754 kWh/inhabitant/a.

Municipal sewage sludge energetic conversion as a tool for environmental sustainability: production of innovative biofuels and biochar

In this study, municipal sewage sludge (MSS) is converted simultaneously into renewable biofuels (bio-oil, syngas) and high value-added products (biochar) using a fixed bed pyrolyzer. This work examines the combined effect of two factors: final pyrolysis temperature (°C) and MSS moisture content (%) on pyrogenic product yields and characteristics. A centered composite experimental design (CCD) is established for pyrolysis process optimization by adopting the response surface methodology (RSM). The statistical results indicate that the optimal conditions considering all studied factors and responses are 550 °C as final pyrolysis temperature and 15% as MSS moisture content. In these optimal conditions, biofuels yield is around 48 wt%, whereas biochar yield is about 52 wt%. The pyrolysis products characterizations reveal that (i) pyrolytic oil has a complex molecular composition rich with n-alkanes, n-alkenes, carboxylic acids, and aromatic compounds; (ii) bio-oil presents a high-energy content (high heating value HHV around 30.6 MJ/kg); (iii) syngas mixture has a good calorific value (HHV up to 8 MJ/kg), which could be used as renewable energy vector or for pyrolysis reactor heating; and (iv) biochar residue has good aliphatic and oxygenated group contents favoring its application as biofertilizer. These findings suggest that MSS conversion into biofuels and biochar is an appropriate approach for MSS treatment. MSS-to-energy could be proposed as an element for circular economy concept due to its effectiveness in producing high value-added and sustainable products and reducing environmental problems linked to MSS disposal.

Sustainability prioritization of sewage sludge to energy scenarios with hybrid-data consideration: a fuzzy decision-making framework based on full consistency method and fusion ranking model

This work proposed a novel mathematical framework for the sustainability assessment of sewage sludge to energy (SStE) scenarios, by resorting to fuzzy multi-criteria decision-making (MCMD) methods. In which, an evaluation system including twelve criteria from four dimensions was introduced, while the fuzzy triangular number (TFN) was used to address the hybrid-data issue in the decision-making. More importantly, four fuzzy MCDM methods were used to make the following methodological contributions: (1) the fuzzy full consistency method (FUCOM) was extended into uncertain conditions to determine the weights easily and reliably, which preserves the consistency in ambiguous, subjective judgments; (2) a novel TFN-based fusion ranking model was developed by aggregating three fuzzy MCDM approaches, which not only takes the hybrid data as input information for decision-making (by combining the TFN) but also promotes the confidence in final prioritization (by reconciling different sequences). Four illustrative SStE scenarios were studied to test the feasibility of the model. Besides, the effectiveness and advantages of the model were verified by results comparison and discussion.

Slow pyrolysis of municipal solid waste (MSW): A review

In recent years, extensive studies have been carried out to improve our knowledge of the reactor operations and system performance in thermal pyrolysis of municipal solid wastes (MSW). However, the fundamentals of MSW pyrolysis and their engineering applications remain unsatisfactorily explored. This paper is a review of the pyrolysis of MSW and synergistic co-pyrolysis of the constituents of MSW with reference to pyrolytic performance, the distribution and energy content of the end products, and the mechanisms of the synergistic effects. The prospects for, and challenges of, the MSW pyrolysis process are provided. A MSW pyrolytic process with maximal energy recovery and minimal carbon footprint is proposed.

Integrating anaerobic digestion and pyrolysis for treating digestates derived from sewage sludge and fat wastes

The coupling of biological and thermal technologies allows for the complete conversion of wastes into energy and biochar eliminating the problem of sludge disposal. The valorisation of fatty residues as co-substrate in a mesophilic digester of a wastewater treatment plant was studied considering an integrated approach of co-digestion and pyrolysis. Four digested samples obtained from co-digestion of sewage sludge and butcher's fat waste were studied by thermogravimetric analysis. The activation energy corresponding to the sludge pyrolysis was calculated by a non-isothermal kinetic. Arrhenius activation energy was lower for the pyrolysis of a digested grease sample (92 kJ mol^-1 obtained by OFW and 86 kJ mol^-1 obtained by Vyazovkin) than for the pyrolysis of sewage sludge and its blends (164-190 kJ mol^-1 obtained by OFW and 162-190 kJ mol^-1 obtained by Vyazovkin). The analysis of the integrated approach of anaerobic co-digestion and pyrolysis of digestates demonstrated that the addition of 3% (w/v) of fat to the feeding sludge results in a 25% increase in the electricity obtained from biogas (if a combined heat and power unit is considered for biogas valorisation) and increasing the fat content to 15% allows for covering all thermal needs for drying of digestate and more than doubles (2.4 times) the electricity production when the scenario of digestion and pyrolysis is contemplated.

Investigation on pyrolysis and incineration of chrome-tanned solid waste from tanneries for effective treatment and disposal: an experimental study

Chrome-tanned leather solid wastes (leather finished trimmings (LFT) and chrome shavings (CS)) from tanneries were studied using pyrolysis and incineration. Detailed characterization of CS and LFT indicated higher calorific value of 15.77 MJ/kg and 19.97 MJ/kg respectively, which makes it suitable for thermal treatment. Thermal Gravimetric Analysis (TGA) of CS and LFT recorded a weight loss of 79.82% and 68.22% at 800 °C respectively. Energy-dispersive X-ray spectroscopy and scanning electron microscopy analysis for CS and LFT were also carried out. Pyrolysis of CS and LFT was carried out using a fixed bed-type pyrolysis unit at a temperature of 500 ± 10 °C for a reaction time of 30 min and three different by-products (bio-oil, biochar and pyrolytic gas) were obtained as a result of pyrolysis. From pyrolysis process, higher bio-oil yields of 52 wt.% and 49 wt.% from LFT and CS with calorific value of 28.0 and 27.8 MJ/kg respectively were obtained. The calorific values of the biochar obtained from LFT and CS were found to be 20.5 and 23.0 MJ/kg respectively. Incineration was carried out in the existing incineration facility of 150 kg/h capacity at a temperature of 1200 °C. The results of incineration process showed a higher weight reduction (93.0 wt.%) and higher concentration of gaseous emissions, revealing the need for off-gas treatment. Further, FT-IR spectra of residual ash from the incineration process revealed the occurrence of oxidation of trivalent chromium to its hexavalent form, which could be a potential raw material in the metallurgical/chemical industry for the synthesis of sodium chromate or ferrochrome alloy. Comparative experimental investigations of pyrolysis and incineration revealed that incineration could be a potential treatment and disposal option, in developing countries like India, for chrome-tanned leather solid wastes from tanneries, for producing heat energy and the residue with potential utilization viability in another industry paving a way towards circular economy.

Formation of highly graphitic char derived from phenolic resin carbonization by Ni-Zn-B alloy

The formation of highly graphitic phenolic resin chars (GPFCs) during catalytic carbonization at relatively low reaction temperature (1200-1600 °C) using novel Ni-Zn-B alloy catalyst with small amount of addition (5-15%) was systematically studied. Only two kinds of graphites (turbostratic graphite and ordered graphite) can be found in GPFCs after catalytic carbonization with Ni-Zn-B and their proportions were changed with reaction conditions. When Ni-Zn-B was involved at 1200-1600 °C, the phenolic resin char was fully transformed to be graphite, and ordered graphite content increased to 28.42% at 1400 °C, which was also almost twice of ordered graphite content in the char catalyzed by pure Ni. But the order graphite content would decrease due to sintering at higher reaction temperature. The addition of Zn and B can promote nickel-based alloy catalytic action by reducing melt point and accelerating graphitization respectively. It was also found that ordered graphite content could be used as a key evaluation parameter to directly reflect the quality of GPFCs based on detailed characteristics analysis. The model between three reaction conditions (reaction temperature, retention time, catalyst content) and ordered graphite content was built with artificial neural network (ANN), and the prediction accuracy of ANN was high up to 91.48%.

Distribution of Hg during sewage sludge and municipal solid waste Co-pyrolysis: Influence of multiple factors

Co-pyrolysis is a promising approach to recover energy from sewage sludge (SS) and municipal solid waste (MSW). Hg emission during this process has serious environmental risks. To reduce the environmental impact, orthogonal experiments on the blending ratio, heating rate, pyrolysis temperature, and residence time were conducted during SS and MSW co-pyrolysis. Variance analysis was used to determine the influence and synergetic effects of these factors. Multivariate nonlinear, neural network, random forest, and support vector machine models were used to simulate the Hg distribution based on four parameters, which were later optimized to optimize the Hg fixing ratio in pyrolysis char. The Hg was mainly distributed in the pyrolysis gas and char. The variance analysis results indicate that the blending ratio is the key factor influencing Hg distribution, and there is little synergetic effect among the four factors. Further experiments showed that a blending ratio of 87.5 SS wt% could enhance Hg fixation in char. The neural network model shows the best simulation performance with a mean relative error of 8.92%. The optimal parameters are a heating rate of 7 °C/min, pyrolysis temperature of 300 °C, and residence time of 10 min, resulting in a Hg fixing ratio of 25.68 wt% in pyrolysis char. The simulated Hg fixation characteristics correlate with the experimental results. This study provides insights into Hg distribution under various conditions during co-pyrolysis of SS and MSW. It is hoped that this work can contribute to the control of Hg during the waste treatment and utilization process.

Predicting the higher heating value of syngas pyrolyzed from sewage sludge using an artificial neural network

Sludge pyrolysis is a complex process including complicated reaction chemistry, phase transition, and transportation phenomena. To better evaluate the use of syngas, the monitoring and prediction of a higher heating value (HHV) is necessary. This study developed an artificial neural network (ANN) model to predict the HHV of syngas, with the process variables (i.e., sludge type, catalyst type, catalyst amount, pyrolysis temperature, and moisture content) as the inputs. In the first step, through optimizing various sets of parameters, a three-layer network including 8 input neurons, 15 hidden neurons, and 1 output neuron was established. Then, in the second step, an ANN model has been successfully used to predict the HHV of syngas, with a fitting correlation coefficient of 0.97 and a root mean square error (MSE) value of 14.62. The relative influence of input variables showed that the pyrolysis temperature and moisture content were the determining factors that affected the HHV of syngas. The results of optimization experiments showed that when temperature was 895 °C and the moisture content was 45.63 wt%, the highest HHV can be obtained as 438.22 kcal/m³-N. Moreover, the ANN model showed a higher prediction accuracy than other models like multiple linear regression and principal component regression. The model developed in this work may be used to predict the HHV of syngas using conventional operational parameters measured from in situ experiments, thus further providing predictive information for the use of syngas as energy and fuel.