Hazardous elements flow during pyrolysis of oily sludge

Energy recoveries and heavy metal migration behaviors of different oily sludges treated by pyrolysis versus solvent extraction

The pyrolysis and trace element mitigation characteristics are investigated by contrast to solvent extraction for four oily sludges, including storage tank bottom sediment (OS-1), scum from a wastewater separator (OS-2), white-clay-adsorbed waste oil (OS-3), and settlings from wastewater treatment (OS-4). Slow pyrolysis at 700 °C generated a single oil phase for OS-1 and separate oil and aqueous phases for OS-2, OS-3 and OS-4. Up to 73.0-88.3 % of the total energy were recovered from OS-1, OS-2 and OS-3 in the oil phase with 19.9-77.1 % oil yield; however, the oil phase from OS-4 accounted for only 13.3 % of the total energy, while the aqueous product accounted for 68.0 % of the total energy. Quantification of 16 trace elements revealed that OS-2 and OS-4 had much higher contents of Cu/Zn/As/Se/Cd/Pb and Ni/Cu/Zn/Se/Cd contents than the average crustal abundances, respectively. Correlations between evaporation and extraction rates indicated that the mitigation behaviors of trace elements were related to their occurrence modes in different oily sludges. Except for Cd, As and Se, all other trace elements were enriched in the pyrolysis residues of the oily sludges. Ni in the pyrolysis residue of OS-4 posed a moderate potential ecological risk.

Role of municipal solid waste incineration fly ash components in co-pyrolysis of oily sludge: Pyrolysis products and catalytic mechanism

The co-pyrolysis of oily sludge (OS) and municipal solid waste incineration fly ash (IFA) is a promising strategy for sustainable waste management. This study delves into the distinct catalytic roles of individual IFA components during co-pyrolysis and assesses their impact on the inherent Fe species in OS, highlighting their contributions to overall catalytic activity. Notably, in comparison to IFA, CaCl2 and KCl significantly enhance pyrolysis oil upcycling, while IFA components collectively exhibit a positive catalytic effect on pyrolysis gas and coke production. Ca(OH)2 notably boosts H2 yield by 137.16 %. Alkali chlorides facilitate gaseous hydrocarbon formation and convert oxygen-containing compounds to CO and CO2 which are subsequently consumed and absorbed by CaO and Ca(OH)2. CaCl2 and KCl promote heavy compound decomposition and alkane aromatization, reducing coke formation and increasing light aromatic production. Conversely, NaCl increases alkane proportions. However, CaSO4 and CaCO3 hinder catalytic reactions, promoting carbon conversion to coke. Importantly, IFA compounds aid the dispersion of inherent Fe-based species from OS on char surface, enhancing in-situ catalytic pyrolysis. Additionally, the augmented H2 production accelerates the reduction of Fe-based species. The findings expand waste utilization possibilities and provide insights for co-processing solid wastes.

Mitigating ash-related alkali and heavy metals emissions in rotary kiln through oxygen-carrier-aided combustion of waste

Rotary kiln (RK) incineration technology gains prominence in waste management, aiming to reduce pollution, recover energy, and minimize waste. Oxygen-carrier (OC)-aided incineration of waste in the RK demonstrates notable benefits by enhancing oxygen distribution uniformity and facilitating fuel conversion. However, the effects of OC on ash-related alkali and heavy metals during waste incineration in the RK remain unknown. In this study, manganese ore and ilmenite as OCs are introduced into RK during waste combustion, focusing on their effects on the bottom ashes and the behavior of alkali and heavy metals. Results show that manganese ore exhibits a decreasing reactivity due to oxygen depletion during the conversion from Mn2O3 to Mn3O4, while ilmenite maintains good reactivity due to sustained enrichment of Fe2O3 on the particles even after multiple cycles in RK. The porous structure on the surface of OCs particles verifies the cyclic reaction involving oxidation by air and reduction by fuel as OCs move between the active and passive layers of the bed. The porous OCs particles offer abundant adsorption sites for K from the gaseous phase, with surface-deposited K migrating into the particles and enhancing the OCs' capacity for K adsorption. Adding OCs promotes the formation of stable, less volatile compounds of heavy metals (As, Cr, Pb, and Zn) and enhances their retention in bottom ash while ensuring the leaching toxicity remains below Chinese national standard limits. This study enhances the understanding of OCs in incineration, guiding vital references for waste management practices and environmental sustainability.

Comparative study by microwave pyrolysis and conventional pyrolysis of pharmaceutical sludge: Resourceful disposal and antibiotic adsorption

Compared with conventional pyrolysis, microwave pyrolysis has superior heat transfer performance and promotes the decomposition of organic matter. The paper focuses on the harmless treatment and resource utilization of pharmaceutical sludge (PS) by microwave heating and conventional heating methods. The experimental results showed that the conventional pyrolysis gas is dominated by CO2, CO and H2. For microwave pyrolysis gas, the "microwave effect" promoted secondary cracking of volatile fractions and increases the content of CH4, CxHy, H2 and CO through condensation, aromatization, and dehydrogenation. Conventional pyrolysis oils contained the highest percentage of oxygenated compounds. However, high-temperature microwave radiation accelerated the cleavage of polar oxygenated molecular bonds and long-chain hydrocarbons, thereby increasing the aromatics content of pyrolysis oils. The solid residues obtained from microwave pyrolysis is highly graphitized and porous, with a surface area of 146.2 m2/g. Furthermore, the solid residue was rich in pyridine-N and pyrrole-N that could be utilized for adsorption and catalysis. The MA-600 removes up to 99% of tetracycline (TC) in 6 h. It was also found that the adsorption process of TC by the two pyrolysis residues was consistent with the proposed secondary and Freundlich models.

In-depth insight into the effects of intrinsic calcium compounds on the pyrolysis of hazardous petrochemical sludge

To understand the potential effects of intrinsic calcium compounds on sludge pyrolysis, the pyrolysis behavior of petrochemical sludge (PS), calcium carbonate blend PS (CaPS), and decalcified PS (DePS) were investigated using thermogravimetric analysis (TGA) and in-situ Fourier-transform infrared spectroscopy coupled with pyrolysis-gas chromatography and mass spectrometry (Py-GC/MS). The TGA results indicated that decalcification increased and decreased the energy barriers of PS decomposition in ranges 200-350 °C and 350-600 °C, respectively. In contrast, copyrolysis with CaCO₃ decreased the activation energy (E) of the pseudoreaction phase 2 (PH2) and altered the mechanism model. Meanwhile, during copyrolysis, char deposition and interaction hindered CaCO₃ decomposition. The two-dimensional correlation spectroscopy results, on the other hand, showed that the reaction priority of O-containing groups and CH- vibration of methyl groups were affected by both decalcification and CaCO₃ copyrolysis. The Py-GC/MS results indicated that the three sludges mainly released hydrocarbons, N-containing organics, alcohols, aldehydes, and acids. During pyrolysis, CaCO₃ also played a neutralization role, which reduced the release of pyrolytic acidic products. In addition, the increase of the pyrolysis temperature increased the hydrocarbon content. This research will guide the industrial application of sludge pyrolysis.

Biochar-Assisted Catalytic Pyrolysis of Oily Sludge to Attain Harmless Disposal and Residue Utilization for Soil Reclamation

Pyrolysis of oily sludge (OS) is a feasible technology to match the principle of reduction and recycling; however, it is difficult to confirm the feasible environmental destination and meet the corresponding requirements. Therefore, an integrated strategy of biochar-assisted catalytic pyrolysis (BCP) of OS and residue utilization for soil reclamation is investigated in this study. During the catalytic pyrolysis process, biochar as a catalyst intensifies the removal of recalcitrant petroleum hydrocarbons at the expense of liquid product yield. Concurrently, biochar as an adsorbent can inhibit the release of micromolecular gaseous pollutants (e.g. HCN, H₂S, and HCl) and stabilize heavy metals. Due to the assistance of biochar, pyrolysis reactions of OS are more likely to occur and require a lower temperature to achieve the same situation. During the soil reclamation process, the obtained residue as a soil amendment can not only provide a carbon source and mineral nutrients but can also improve the abundance and diversity of microbial communities. Thus, it facilitates the plant germination and the secondary removal of petroleum hydrocarbons. The integrated strategy of BCP of OS and residue utilization for soil reclamation is a promising management strategy, which is expected to realize the coordinated and benign disposal of more than one waste.

The removal of organic impurities from industrial waste salt by pyrolysis

The presence of organic impurities hinders the resource utilization of industrial waste salt (IWS). In this study, pyrolysis treatment was chosen to remove these organic impurities. The optimal process parameters for the pyrolysis of organic impurities were as follows: a temperature of 500 °C and a holding time of 20 min. Under these optimal conditions, the total organic carbon (TOC) removal rate was 96.32%, inducing a decrease in the TOC mass fraction from 1.88 to 0.08%. Fourier transform infrared spectroscopy (FTIR) results obtained during this process showed that prolonging the pyrolysis time (10-70 min) for IWS resulted in a gradual decrease in the relative content of characteristic functional group, such as C-O in ether groups, and the disappearance of functional group, such as benzophenone carbonyl group and ester carbonyl. Organic impurities can release gas-containing compounds that destroy the initially smooth IWS surface, and the resulting particles with rough and irregular shapes fuse into large or lumpy particles during the pyrolysis process. GC‒MS results clearly showed that the number of different semivolatile organic compounds in the IWS was reduced from 35 to 19 as a result of the pyrolysis process. Correspondingly, organic impurities with molecular formulas containing 5-10 carbon atoms converted into compounds containing 6-20 carbon atoms. These findings provide theoretical support for IWS resource utilization.

Environmental Risk Analysis Based on Characterization of Ground Oily Sludge

Oily sludge is recognized as hazardous waste. To reduce the potential danger and harmful factors of oily sludge, it is very important to analyze its environmental risk. In this paper, the characterization of oily sludge from Shengli Oilfield in China was tested experimentally, including the composition content, particle size, microscopic morphology, heavy metal content, organic composition, inorganic composition, and thermogravimetric analysis, which were used to analyze environmental risks. The results show that the oil content of oily sludge is as high as 10.3%, which will cause serious pollution. It is calculated that China can recover 772.5 million liters of oil and reduce 553.9 million kg of carbon emissions compared with incineration in one year, if the oily sludge can be managed effectively. The content of heavy metals such as Ba, Zn, Cr, As, Ni, Se, Be, and Hg in oily sludge exceeds the standard. It will restrain the self-healing ability of soil, pollute groundwater, and endanger animals and plants. The organic matter of oily sludge is concentrated in C₁₁ to C₂₉. It contains a large amount of benzene series and polycyclic benzene hydrocarbons, which can lead to cancer in the human body. Inorganic substances in oily sludge are mixed with some additives, which can not only reduce the toxicity of heavy metals, but also be used as building materials. The median particle size D₅₀ of oily sludge is 0.91 μm, and it spreads all over the narrow pores. Generally, it needs to be treated under high temperature conditions, which will cause secondary pollution to the environment. The research content of this paper provides a theoretical reference for the management of oily sludge.

Trend in Research on Characterization, Environmental Impacts and Treatment of Oily Sludge: A Systematic Review

Oily sludge is a hazardous material generated from the petroleum industry that has attracted increasing research interest. Although several review articles have dealt with specific subtopics focusing on the treatment of oily sludge based on selected references, no attempt has been made to demonstrate the research trend of oily sludge comprehensively and quantitatively. This study conducted a systematic review to analyze and evaluate all oily sludge-related journal articles retrieved from the Web of Science database. The results show that an increase in oily sludge-related research did not take place until recent years and the distribution of the researchers is geographically out of balance. Most oily sludge-related articles focused on treatment for harmfulness reduction or valorization with limited coverage of formation, characterization, and environmental impact assessment of oily sludge. Pyrolytic treatment has attracted increasing research attention in recent years. So far, the research findings have been largely based on laboratory-scale experiments with insufficient consideration of the cost-effectiveness of the proposed treatment methods. Although many methods have been proposed, few alone could satisfactorily achieve cost-effective treatment goals. To enable sustainable management of oily sludge on a global scale, efforts need to be made to fund more research projects, especially in the major oil-producing countries. Pilot-scale experiments using readily available and affordable materials should be encouraged for practical purposes. This will allow a sensible cost-benefit analysis of a proposed method/procedure for oily sludge treatment. To improve the treatment performance, combined methods are more desirable. To inform the smart selection of methods for the treatment of different oily sludge types, it is suggested to develop universally accepted evaluation systems for characterization and environmental risk of oily sludge.

Integrated system of anaerobic digestion and pyrolysis for valorization of agricultural and food waste towards circular bioeconomy: Review

Agricultural and food waste have become major issue affecting the environment and climate owing to growing population. However, such wastes have potential to produce renewable fuels which will help to meet energy demands. Numerous valorization pathways like anaerobic digestion, pyrolysis, composting and landfilling have been employed for treating such wastes. However, it requires integrated system that could utilize waste and promote circular bioeconomy. This review explores integration of anaerobic digestion and pyrolysis for treating agricultural and food waste. Proposed system examines the production of biochar and pyro-oil by pyrolysis of digestate. The use of this biochar for stabilizing anaerobic digestion process, biogas purification and soil amendment will promote the circular bioeconomy. Kinetic models and framework of techno-economic analysis of system were discussed and knowledge gaps have been identified for future research. This system will provide sustainable approach and offer carbon capture and storage in form of biochar in soil.

Pyrolysis of food waste and food waste solid digestate: A comparative investigation

The effects of anaerobic digestion (AD) on pyrolysis were elaborated by comparing the pyrolysis performance of food waste (FW) and food waste solid digestate (FWSD). The pyrolysis mechanisms of FW and FWSD were revealed by experimental and kinetic analysis. The properties and potential applications of pyrolytic products from FW and FWSD were discussed. The results showed that part of organic matters of FW were consumed during AD, which altered the pyrolysis performance of FWSD. The pyrolytic gas from FW had better quality due to its higher lower heating value (LHV) (20.52 kJ/Nm³). The pyrolytic oil and biochar derived from FWSD showed better qualities as oil fuel and carbon-based absorbent. Pyrolysis of FWSD produced less nitrogen-containing pollutants (NCPs) indicated that AD coupled with pyrolysis is more environmental-friendly to treat FW. This study provides potential approach and theoretical guidance for the treatment and resource utilization of FW and FWSD.

Products distribution and pollutants releasing characteristics during pyrolysis of waste tires under different thermal process

Pyrolysis has been widely utilized to achieve resource recovery of waste tires by attaining oil and carbon black. However, due to the stacking effect of fixed bed, the heat and mass transfer is insufficient during the pyrolysis process of waste tires. Additionally, the harmful N/S/Cl pollutants and heavy metals are inevitable that has been ignored. This paper systematically studied the effect of promoting heat and mass transfer on the oil quality and pollutant releasing characteristics during the pyrolysis of waste tires. A fixed bed pyrolizer with multifunction was innovatively designed to conduct fast pyrolysis by equipping an intermittent feeder and slow pyrolysis by equipping an agitator. Fast pyrolysis with feeding step by step and slow pyrolysis with stirring could promote the heat and mass transfer, which was firstly researched in lab-scale reactor. The experimental results demonstrated that slow pyrolysis with stirring was recommended with the target of acquiring pyrolytic oil. Promoting heat and mass transfer could improve the quality of oil and increase the retaining proportion of S in char during both fast and slow pyrolysis. The combustion of pyrolysis oil and gas generated more dioxins (0.6 ng/g_wt) than the total dioxins in pyrolytic gas and oil (0.06 ng/g_wt).

Pyrolysis Behaviors and Residue Properties of Iron-Rich Rolling Sludge from Steel Smelting

Iron-rich rolling sludge (FeRS) represents a kind of typical solid waste produced in the iron and steel industry, containing a certain amount of oil and large amounts of iron-dominant minerals. Pyrolysis under anaerobic environment can effectively eliminate organics at high temperatures without oxidation of Fe. This paper firstly investigated comprehensively the pyrolysis characteristics of FeRS. The degradation of organics in FeRS mainly occurred before 400 °C. The activation energy for pyrolysis of FeRS was extremely low, ca. 5.44 kJ/mol. The effects of pyrolytic temperature, atmosphere, heating rate, and stirring on pyrolysis characteristics were conducted. Commonly, the yield of solid residues maintained around 85 wt.%, with approximately 13 wt.% oil and 2 wt.% gas. Due to the low yield of oil and gas, their further utilization remains difficult despite CO₂ introduction which could upgrade their quality. The solid residues after pyrolysis exhibited porous properties with co-existence of micropores and mesopores. Combined with the high content of zero-valent iron, magnetic property, hydrophobic characteristic, and low density, the solid residues could be further utilized for water pollution control and soil remediation. Moreover, the solid residues were suitable for sintering to recover valuable iron resources. However, the solid residues also contained certain heavy metals, such as Cd, Cr, Cu, Ni, Pb, and Zn, which might cause secondary pollution during their utilization. In particular, the toxic Cr possessed high content, which should be treated with detoxification and removal. This paper provides fundamental information for pyrolysis of FeRS and utilization of solid residues.

Products distribution and hazardous elements migration during pyrolysis of oily sludge from the oil refining process

Oily sludge is a hazardous waste due to the enrichment of nitrogen, sulfur, PAHs, and heavy metals. In this work, an oily sludge from oil refining factory was pyrolyzed at various temperatures of 250-850 °C in a fixed bed reactor focusing on product distribution and migration of hazardous compounds of PAHs, sulfur, nitrogen-containing compounds, and heavy metals. The mechanism of PAHs formation and migration of nitrogen, sulfur, heavy metals were elucidated by comprehensive analysis of the solid, liquid, and gas products. The distribution and risk analysis of heavy metals were also conducted. The pyrolytic products distribution was markedly affected by pyrolysis temperatures. A maximum oil yield was observed at 500 °C, which can further crack into gas due to secondary reaction. The pyrolytic gas was enriched in the order of CO₂ > CO > CH₄ > H₂. At lower temperatures, CO₂ was largely generated due to the elimination of oxygen-containing functional groups, while H₂ was mainly formed above 450 °C due to the recombination reaction. Higher temperatures promoted more N-/S-containing compounds into tar and gas phases. The N-/S-containing compounds mainly included NH₃, HCN, H₂S, SO₂, COS in the gas phase and amines, indoles, pyridines, nitriles, thiophenes in liquid phase. PAHs with 2-ring to 5-ring were mainly generated due to the secondary reaction at higher temperatures. Moreover, Pyrolysis caused the accumulation of heavy metals in chars. Cd presented a high potential risk while the other heavy metals in chars presented a low risk.

Steam Pyrolysis of Oil Sludge for Energy-Valuable Products

Experimental studies of the steam pyrolysis of oil sludge were performed using a flow-type pilot plant with 300 kg/h capacity (raw material) to obtain energy-valuable products, such as liquid hydrocarbons (30.4 wt%), semi-coke (39.6 wt%), non-condensable gas-phase compounds (26.5 wt%), and bitumen (3.5 wt%). The pyrolysis process was conducted at a temperature of 650 ° C and with a steam flow rate of 150 kg/h. Liquid hydrocarbons were considered a target product. Comprehensive studies of their physicochemical characteristics, atomization process, droplet ignition, and combustion were carried out. The studied sample had physicochemical characteristics similar to traditional fuel oil (calorific value—42.6 MJ/kg, sulfur content—0.8 wt%). The jet spraying angle was 25° in view of the improved rheological properties of the test sample, with a homogeneous jet structure and a predominant droplet diameter of no more than 0.4 mm. The flame combustion process was accompanied by the formation of microexplosions, the frequency and intensity of which depended on the temperature of the air (Tg = 450–700 °C). This study, in view of its applied nature, is of interest in the design of new installations and technological systems for hydrocarbon pyrolysis.

The dosage-effect of biochar on anaerobic digestion under the suppression of oily sludge: Performance variation, microbial community succession and potential detoxification mechanisms

This study investigated the dosage-effect of biochar on the suppressed mesophilic digestion of oily sludge (OS) containing naphthalene (recalcitrant compound) and starch (easily bioavailable substrate). Methanogenesis was inhibited in control with OS, where biomethane yield (63.33 mL/gVS) was obviously lower than theoretical yield (260.55 mL/gVS). With adding optimal dose of biochar (0.60 g/gVS OS), the highest CH₄ yield (138.41 mL/gVS) was 2.19 times of control. Meanwhile, the efficiencies of hydrolysis, acidogenesis and acetogenesis were significantly enhanced. However, excessive biochar (4.80 g/gVS OS) caused negative effects with methanogenic efficiency diminished by 32.5% and lag phase prolonged by 5.72 h. Dissolved organic matter (DOM) analysis showed that humic acid-like and fulvic acid-like components percentages of fluorescence regional integration were decreased because of the adsorption of biochar. In addition, biochar mediating interspecies electron transfer selectively enriched electroactive fermentation bacteria (Clostridium and Bacteroides) and acetoclastic Methanosaeta, which was responsible for promoting mesophilic digestion performance. The functional genes related to metabolism and environmental information processing were potentially activated by biochar. Above results indicate that moderate biochar application may mitigate the bio-toxicity suppression of OS, which help to provide a promising pathway for reinforcing oily wastes bio-treatment.

Enhanced Separation of Oil and Solids in Oily Sludge by Froth Flotation at Normal Temperature

Oily sludge (OS) contains a large number of hazardous materials, and froth flotation can achieve oil recovery and non-hazardous disposal of OS simultaneously. The influence of flotation parameters on OS treatment and the flotation mechanism were studied. OS samples were taken from Shengli Oilfield in May 2017 (OSS) and May 2020 (OST), respectively. Results showed that Na2SiO3 was the suitable flotation reagent treating OSS and OST, which could reduce the viscosity between oil and solids. Increasing flotation time, impeller speed and the ratio of liquid to OS could enhance the pulp shear effect, facilitate the formation of bubble and reduce pulp viscosity, respectively. Under the optimized parameters, the oil content of OST residue could be reduced to 1.2%, and that of OSS could be reduced to 0.6% because of OSS with low heavy oil components and wide solid particle size distribution. Orthogonal experimental results showed that the impeller speed was the most significant factor of all parameters for OSS and OST, and it could produce shear force to decrease the intensity of C-H bonds and destabilize the OS. The oil content of residue could be reduced effectively in the temperature range of 24–45 °C under the action of high impeller speed.

Functional Group Characteristics and Pyrolysis/Combustion Performance of Karamay OS Based on FT-IR and TG-DTG Analyses

Proximate analysis, ultimate analysis, Fourier-transform infrared spectroscopy (FT-IR), and thermogravimetry-differential thermal analysis characterization were carried out on oily sludge (OS) samples OS1-OS5, from Karamay, Xinjiang, China. The Coast-Redfern model (CRm) was used to simulate the pyrolysis and combustion kinetics of oily samples. The results showed that the peak area percentage of benzene ring trisubstitution of OS5, in the range of 700-900 cm^-1, is close to 75%, corresponding to its high volatile content. Based on the kinetic analysis by the CRm, it is found that the fitting degree of the five samples is better when the reaction order is selected as n = 2, with R ² close to 1.00 and 2RT/E to 0. Among them, the S _N and D _W of OS5 are 17.8 × 10^-10%² min^-2 °C^-3 and 0.10899 × 10^-5% min^-1 °C^-2, respectively, higher than those of other samples, indicating a good combustion performance.

Pyrolysis characteristics and kinetics analysis of oil sludge with CaO additive

In the process of exploitation, transportation and refining of high-sulfur crude oil, a large number of oil sludge (OS) with high sulfur content is produced. Pyrolysis has been proved to be an effective method for OS disposal, but for solid waste with high sulfur content, lots of sulfur-containing gases will be released during thermal disposal. The addition of calcium oxide in pyrolysis process is an economical and effective way to capture sulfur-containing gases. In order to understand the pyrolysis process of OS with CaO, a thermogravimetric analyser was used to conduct pyrolysis experiments of OS with different Ca/S molar ratios (0, 1, 2 and 3) at different heating rates (10°C/min, 20°C/min, 30°C/min and 40°C/min). The results showed that with the increase of CaO addition the derivative thermogravimetric curves showed a gentle trend. In addition, new weight loss peaks were occurred at 700-900°C and after 1100°C, which were the decomposition of calcium carbonate and calcium sulfate, respectively. The kinetic parameters were solved by Friedman, FWO, and Starink methods, and the results were similar, with an average activation energies (E) value of 214 kJ/mol. The change trend of the activation energy was followed by an increase and then a decrease corresponding to the change of energy demand for the reaction. The calculated average values of ΔH, ΔG and ΔS were about 207, 447 and -0.3250 kJ/mol, respectively. When the conversion rate was 0.5, the thermodynamic parameters reached their maximum values.