Multi-response optimization toward efficient and clean (co-)combustions of textile dyeing sludge and second-generation feedstock

Evaluating combustion kinetics and quantifying fuel-N conversion tendency of shoe manufacturing waste

Combustion is an effective and cost-efficient thermochemical conversion method for solid waste, showing promise for the resource utilization of shoe manufacturing waste (SMW). However, SMW is generally composed of different components, which can lead to unstable combustion and excessive pollutant emissions, especially NOx. To date, combustion characteristics, reaction mechanism and fuel nitrogen (fuel-N) conversion of different SMW components remain unclear. In this work, the combustion behavior of typical SMW components combustion was investigated using Thermogravimetric coupled with Fourier transform infrared spectrum (TG-FTIR). A simplified single-step reaction mechanism was proposed according to the temperature interval to estimate reaction mechanism of SMW. Additionally, the relationship between fuel-N conversion tendency and fuel properties was established. The results indicate that the values for the comprehensive combustion performance index (S) and flammability index (C) range from 1.65 to 0.44 and 3.98 to 1.37, respectively. This demonstrates the significant variability in combustion behavior among different SMW components. Cardboard, leather and sponge have higher values of S and C, suggesting a better ignition characteristic and a stable combustion process. During the combustion of SMW, nitrogen oxides (NO and N2O) are the main nitrogen-containing compounds in the flue gases, with NO being the major contributor, accounting for over 82.97 % of the nitrogen oxides. NO has a negative correlation with nitrogen content, but it is opposite for N2O, HCN and NH3. Furthermore, the conversion of NO, N2O and NH3 is proportional to logarithmic values of O/N, while its conversion to HCN is proportional to logarithmic values of VM/N. These findings facilitate the prediction of the fuel-N conversion of solid waste combustion. This work might shed light on combustion optimization and in-situ pollutant emission control in solid waste combustion.

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.

Microplastics in dyeing sludge: Whether do they affect sludge incineration?

Microplastics (MPs), as emerging contaminant detected in dyeing sludge (DS), inevitably affected the subsequent treatment and disposal of DS. However, the effect of MPs on the predominant disposal path (incineration) of DS remains far from explicit. This study used thermogravimetry-mass spectrometry (TG-MS) method to explore the effect of representative MPs, polyethylene terephthalate (PET) and polyvinyl chloride (PVC), on combustion characteristics, gas evolution and kinetics on DS combustion. Results showed that PET inhibited the whole combustion of DS by physical barrier. Relatively, PVC delayed the combustion of light volatile but promoted heavy volatile and char reaction due to HCl catalyst. Generally, MPs deteriorated the combustibility, burnout performance and combustion stability of DS. MPs aggravated HCl and gaseous N emissions. Noticeably, the interactions between DS and PVC accelerated the emissions of gaseous pollutants, especially under high dose condition. DAEM and FWO models could well describe the combustion kinetic of DS containing MPs. MPs led to an increase in activation energy of DS, namely, it deteriorated the combustion efficiency of DS. The combustion mechanisms could be divided into two stages: (1) diffusion (D₃) stage: melted MPs blocked the gas channels, (2) chemical reaction (F₃): the residual chars were thermally stable.

Oxy-fuel co-combustion dynamics of phytoremediation biomass and textile dyeing sludge: Gas-to-ash pollution abatement

The environmental pressures of major wastes in the circular economies can be abated leveraging the complementarity and optimal conditions of their co-combustion. The oxy-fuel co-combustion of phytoremediation biomass of Sedum alfredii Hance (SAH) and textile dyeing sludge (TDS) may be a promising choice for sustainable CO₂ capture and a waste-to-energy conversion. This study characterized and quantified their co-combustion performances, kinetics, and interactions as a function of blend ratio, atmosphere type, and temperature. With a focus on the characteristic elements of SAH (Ca, K, Zn, and Cd) and TDS (Al and S), changes in the mineral phases and ash melting and slagging trends of K₂O-Al₂O₃-SiO₂ and CaO-Al₂O₃-SiO₂ systems were quantified. The Zn and Cd residual rates of the co-combustion of 75% SAH and 25% TDS rose by 58.52% and 5.93%, respectively, in the oxy-fuel atmosphere at the 30% oxygen concentration, relative to the mono-combustion of SAH in the air atmosphere. The co-combustion in the oxy-fuel atmosphere at the 20% oxygen concentration delayed the release peaks of SO₂, C₂S, and H₂S, while the Ca-rich SAH captured S in TDS through the formation of CaSO₄. Our findings provide new and practical insights into the oxy-fuel co-combustion toward the enhanced co-circularity.

Efficiency, by-product valorization, and pollution control of co-pyrolysis of textile dyeing sludge and waste solid adsorbents: Their atmosphere, temperature, and blend ratio dependencies

This study aimed to quantify the co-pyrolytic synergistic effects of textile dyeing sludge (TDS) and waste biochar (WBC) for an optimal utilization of secondary resources and to mitigate environmental pollution and waste volume. TDS and WBC had a strong synergistic effect between 800 and 900 °C in the CO₂-assisted atmosphere. With the increased TDS fraction, NH₃ emission fell significantly regardless of the atmosphere type. The CO₂ atmosphere changed S in TDS char and released SO₂ in the range of 800-1000 °C. With the temperature rise, an unstable N structure turned into a more stable heterocyclic N structure in the CO₂ and N₂ atmospheres. Regardless of the atmosphere type and temperature, the C-containing functional groups in co-pyrolytic biochar existed mainly as C-C/C-H. In the CO₂ atmosphere, inorganic S, aliphatic S, and thiophene S in the co-pyrolytic biochar disappeared and became more stable sulfones. The co-pyrolysis inhibited the formation of S-containing compounds. The retention ability of the co-pyrolytic biochar peaked for most of the heavy metals in the N₂ atmosphere but was better for Pb and Zn in the CO₂ than N₂ atmosphere. Simultaneous optimization showed the co-pyrolysis of 10% TDS and 90% WBC at above 950 °C in the N₂-CO₂ or CO₂ atmosphere as the optimal operational settings combined.

Ash-to-emission pollution controls on co-combustion of textile dyeing sludge and waste tea

Given the globally increased waste stream of textile dyeing sludge (TDS), its co-combustion with agricultural residues appears as an environmentally and economically viable solution in a circular economy. This study aimed to quantify the migrations and chemical speciations of heavy metals in the bottom ashes and gas emissions of the co-combustion of TDS and waste tea (WT). The addition of WT increased the fixation rate of As from 66.70 to 83.33% and promoted the chemical speciation of As and Cd from the acid extractable state to the residue one. With the temperature rise to 1000 °C, the fixation rates of As, Cd, and Pb in the bottom ashes fell to 27.73, 8.38, and 15.40%, respectively. The chemical speciation perniciousness of Zn, Cu, Ni, Mn, Cr, Cd, and Pb declined with the increased temperature. The ash composition changed with the new appearances of NaAlSi₃O₈, CaFe₂O₄, NaFe(SO₄)₂, and MgCrO₄ at 1000 °C. The addition of WT increased CO₂ and NO_x but decreased SO₂ emissions in the range of 680-1000 °C. ANN-based joint optimization indicated that the co-combustion emitted SO₂ slightly less than did the TDS combustion. These results contribute to a better understanding of ash-to-emission pollution control for the co-combustion of TDS and WT.