Reusability of recovered iron coagulant from primary municipal sludge and its impact on chemically enhanced primary treatment

Iron Recycle-Driven Organic Capture and Sidestream Anaerobic Membrane Bioreactor for Revolutionizing Bioenergy Generation in Municipal Wastewater Treatment

The practicality of intensifying organic matter capture for bioenergy recovery to achieve energy-neutral municipal wastewater treatment is hindered by the lack of sustainable methods. This study developed innovative processes integrating iron recycle-driven organic capture with a sidestream anaerobic membrane bioreactor (AnMBR). Iron-assisted chemically enhanced primary treatment achieved elemental redirection with 75.2% of chemical oxygen demand (COD), 20.2% of nitrogen, and 97.4% of phosphorus captured into the sidestream process as iron-enhanced primary sludge (Fe-PS). A stable and efficient biomethanation of Fe-PS was obtained in AnMBR with a high methane yield of 224 mL/g COD. Consequently, 64.1% of the COD in Fe-PS and 48.2% of the COD in municipal wastewater were converted into bioenergy. The acidification of anaerobically digested sludge at pH = 2 achieved a high iron release efficiency of 96.1% and a sludge reduction of 29.3% in total suspended solids. Ultimately, 87.4% of iron was recycled for coagulant reuse, resulting in a theoretical 70% reduction in chemical costs. The novel system evaluation exhibited a 75.2% improvement in bioenergy recovery and an 83.3% enhancement in net energy compared to the conventional system (primary sedimentation and anaerobic digestion). This self-reliant and novel process can be applied in municipal wastewater treatment to advance energy neutrality at a lower cost.

Green industry work: production of FeCl3 from iron and steel industry waste (mill scale) and its use in wastewater treatment

Mill scale (MS) is considered to be a significant metallurgical waste, but there is no economical method yet to utilize its metal content. In this study, which covers various processes in several stages, the solution of iron in MS, which is the Iron and Steel Industry (I&SI) waste, as FeCl3 (MS-FeCl3) in the thermoreactor in the presence of HCl, was investigated. In the next step, the conditions for using this solution as a coagulant in the treatment of I&SI wastewater were investigated using the jar test. The results of the treated water sample were compared by chemical oxygen demand (COD), total suspended solids (TSS), color, and turbidity analyses using commercial aluminum sulfate (Al2(SO4)3) and FeCl3 (C-FeCl3). Additionally, heavy metal analyses were conducted, and the treatment performance of three coagulants was presented. Accordingly, while 2.0 mg/L anionic polyelectrolyte was consumed at a dosage of 4.05 mg/L Al2(SO4)3 at pH 7.0, 0.25 mg/L anionic polyelectrolyte was consumed at a dosage of 1.29 mg/L at pH 5.0 in the C-FeCl3 and MS-FeCl3 studies. Also, Fe, Cr, Mn, Ni, Zn, Cd, Hg, and Pb removal efficiencies were over 93.56% for all three coagulant usage cases. The results showed that the wastewater treatment performance of MS-FeCl3 by the recycling of MS, which is an I&SI waste, was at the same level as C-FeCl3. Thus, thanks to recycling, waste scale can be used as an alternative to commercial products for green production.

Phosphorus release and recovery by reductive dissolution of chemically precipitated phosphorus from simulated wastewater

Chemically mediated recovery of phosphorous (P) as vivianite from the sludges generated by chemical phosphorus removal (CPR) is a potential means of enhancing sustainability of wastewater treatment. This study marks an initial attempt to explore direct P release and recovery from lab synthetic Fe-P sludge via reductive dissolution using ascorbic acid (AA) under acidic conditions. The effects of AA/Fe molar ratio, age of Fe-P sludge and pH were examined to find the optimum conditions for Fe-P reductive solubilization and vivianite precipitation. The performance of the reductive, chelating, and acidic effects of AA toward Fe-P sludge were evaluated by comparison with hydroxylamine (reducing agent), oxalic acid (chelating agent), and inorganic acids (pH effect) including HNO3, HCl, and H2SO4. Full solubilization of Fe-P sludge and reduction of Fe3+ were observed at pH values 3 and 4 for two Fe/AA molar ratios of 1:2 and 1:4. Sludge age (up to 11 days) did not affect the reductive solubilization of Fe-P with AA addition. The reductive dissolution of Fe-P sludge with hydroxylamine was negligible, while both P (95 ± 2%) and Fe3+ (90 ± 1%) were solubilized through non-reductive dissolution by oxalic acid treatment at an Fe/oxalic acid molar ratio 1:2 and a pH 3. With sludge treatment with inorganic acids at pH 3, P and Fe release was very low (<10%) compared to AA and oxalic acid treatment. After full solubilization of Fe-P sludge by AA treatment at pH 3 it was possible to recover the phosphorus and iron as vivianite by simple pH adjustment to pH 7; P and Fe recoveries of 88 ± 2% and 90 ± 1% respectively were achieved in this manner. XRD analysis, Fe/P molar ratio measurements, and magnetic attraction confirmed vivianite formation. PHREEQC modeling showed a reasonable agreement with the measured release of P and Fe from Fe-P sludge and vivianite formation.

Evaluation of combined thermo-chemical processes for the treatment of landfill leachate using virgin and recovered FeCl3 coagulants

Sludge resulting from treatment of municipal waste landfill leachate contains suitable cationic substances such as Fe-based recovered coagulants which, if not recovered, can cause environmental problems. The present study aimed to maximise coagulant recoverability and investigate its potential reuse for the treatment of municipal waste landfill leachate. The study focused on establishing (i) the effect of mineral acids on leaching of Fe, (ii) the % of maximum recovery of Fe coagulant, (iii) the impact of ultrasound on recovery, and (iv) effectiveness of recovered coagulant when reused in coagulation-flocculation treatment of landfill leachate. Sulfuric acid outran hydrochloric acid in performance, with the acid leaching process leading to the recovery of 70.12% of Fe (acid concentration = 3.80 M, solid-to-liquid ratio = 8%, and heating time = 5 h). Subsequently, a developed acid leaching process was tested, which results showed that the highest rate of Fe recovery occurred without ultrasound treatment, meaning the use of it could reduce the recovery rate due to the increase in the iron (III) oxide-hydroxide [Fe(OH)3] sedimentation. Comparative experiments were undertaken with the recovered and virgin coagulants. These revealed that Fe-based recovered coagulant led to the 60.21% and 91.40% removal of COD and total suspended solid respectively, while the values of the COD and total suspended solid removal with the virgin FeCl3 were 7.66% and 6.42% lower than that of Fe under optimal conditions (dosage = 9.38 g/L, pH = 8.94, settling time = 52.9 min). The present study established that Fe recovered could be exploited as an eco-friendly coagulant to replace FeCl3 in the landfill leachate treatment.

A review of iron use and recycling in municipal wastewater treatment plants and a novel applicable integrated process

Chemical methods are expected to play an increasingly important role in carbon-neutral municipal wastewater treatment plants. This paper briefly summarises the enhancement effects of using iron salts in wastewater and sludge treatment processes. The costs and environmental concerns associated with the widespread use of iron salts have also been highlighted. Fortunately, the iron recovery from iron-rich sludge provides an opportunity to solve these problems. Existing iron recovery methods, including direct acidification and thermal treatment, are summarised and show that acidification treatment of FeS digestate from the anaerobic digestion-sulfate reduction process can increase the iron and sulphur recycling efficiency. Therefore, a novel applicable integrated process based on iron use and recycling is proposed, and it reduces the iron salts dosage to 4.2 mg/L and sludge amount by 80%. Current experimental research and economic analysis of iron recycling show that this process has broad application prospects in resource recovery and sludge reduction.

Reuse of lime sludge from immediate one-step lime precipitation process as a coagulant (aid) in slaughterhouse wastewater treatment

The circularity of wastewater treatment subproducts is on the worldwide agenda. In this way, this work aims to evaluate alternatives for the reuse of sludge from slaughterhouse wastewater treatment. Wetted sludges produced in the immediate one-step lime precipitation process were applied directly or first calcined, as a coagulant or coagulant aid, in the absence or presence of Ca(OH)₂, to slaughterhouse wastewaters with different characteristics. For the best sludge reuse, successive reuses of the sludge were carried out and the characteristics of treated slaughterhouse wastewater were evaluated after each reuse. Results showed a great similarity between slaughterhouse and treated slaughterhouse wastewaters using wetted and calcined sludges as a coagulant for highly contaminated slaughterhouse wastewater. In addition, a great similarity was also observed between the calcined and the wetted sludges, both as a coagulant aid, for all the slaughterhouse wastewaters tested. However, the latter consumed more hydrated lime, more volume of sludge sedimented, and higher concentrations phosphorus and organic matter in the treated wastewater. Calcined sludge as a coagulant aid guaranteed the best slaughterhouse wastewater quality for almost of the tested paramenters (≥94% for absorbances at 254 nm and 410 nm, E. coli, turbidity, and phosphorus, chemical oxygen demand between 3 and 91%, and total Kjeldahl nitrogen between 3 and 62%) independently of the wastewater characteristics. Calcined sludge as a coagulant aid can be three times reused for the tested parameters and slaughterhouse wastewater characteristics without significantly decreasing the quality. The successive sludge reused saves the hydrated lime dose applied (up to 28.4%) and the sedimented sludge volume (up to 24.7%), and can be a solution to stabilize sludge due to the pH increase (sludge pH = 12).

Realizable wastewater treatment process for carbon neutrality and energy sustainability: A review

Despite a quick shift of global goals toward carbon-neutral infrastructure, activated sludge based conventional systems inhibit the Green New Deal. Here, a municipal wastewater treatment plant (MWWTP) for carbon neutrality and energy sustainability is suggested and discussed based on realizable technical aspects. Organics have been recovered using variously enhanced primary treatment techniques, thereby reducing oxygen demand for the oxidation of organics and maximizing biogas production in biological processes. Meanwhile, ammonium in organic-separated wastewater is bio-electrochemically oxidized to N₂ and reduced to H₂ under completely anaerobic conditions, resulting in the minimization of energy requirements and waste sludge production, which are the main problems in activated sludge based conventional processes. The anaerobic digestion process converts concentrated primary sludge to biomethane, and H₂ gas recovered from nitrogen upgrades the biomethane quality by reducing carbon dioxide in biogas. Based on these results, MWWTPs can be simplified and improved with high process and energy efficiencies.

Towards an Energy Self-Sufficient Resource Recovery Facility by Improving Energy and Economic Balance of a Municipal WWTP with Chemically Enhanced Primary Treatment

The recent trend of turning wastewater treatment plants (WWTPs) into energy self-sufficient resource recovery facilities has led to a constant search for solutions that fit into that concept. One of them is chemically enhanced primary treatment (CEPT), which provides an opportunity to increase biogas production and to significantly reduce the amount of sludge for final disposal. Laboratory, pilot, and full-scale trials were conducted for the coagulation and sedimentation of primary sludge (PS) with iron sulphate (PIX). Energy and economic balance calculations were conducted based on the obtained results. Experimental trials indicated that CEPT contributed to an increase in biogas production by 21% and to a decrease in sludge volume for final disposal by 12% weight. Furthermore, the application of CEPT may lead to a decreased energy demand for aeration by 8%. The removal of nitrogen in an autotrophic manner in the side stream leads to a further reduction in energy consumption in WWTP (up to 20%). In consequence, the modeling results showed that it would be possible to increase the energy self-sufficiency for WWTP up to 93% if CEPT is applied or even higher (up to 96%) if, additionally, nitrogen removal in the side stream is implemented. It was concluded that CEPT would reduce the operating cost by over 650,000 EUR/year for WWTP at 1,000,000 people equivalent, with a municipal wastewater input of 105,000 m3/d.

Determination on inhibition effects of coagulants used in wastewater treatment plants on anaerobic digester

Domestic wastewaters causing pollution contain inorganic and/or organic materials. When the domestic wastewater outflows to the receiving waters, it causes physical, chemical, and biological pollution in them, and deteriorates the ecological balance of those waters. In the treatment of wastewater, various treatment methods are available depending on the pollution strength of the wastewater. Besides mechanical and biological methods, wastewater treatment with physicochemical methods is still one of the most effective and economical options. Particularly in wastewater with a high concentration of suspended solids, this method is very successful, and obtaining high suspended solids removal efficiencies is very possible. In this study, the effects of the use of coagulant and coagulant aid to be used in a treatment plant where domestic wastewater treatment is carried out are determined to increase the treatment efficiency of a biological treatment that comes later in the stages of the treatment. The effluent of the pre-settling tank may contain a lot of suspended solids. This presence of excess suspended solids decreases the efficiency at other levels of treatment and causes energy loss. In the experiments, the standard jar and inhibition tests are done as a method. As a result of the conducted studies, it is determined that the FeCl₃, Synthetic coagulant LP 526, FeClSO_4, and the combination of anionic polyelectrolyte yield the best results in the removal of the parameters of chemical oxygen demand (COD), total suspended solids (TSS), and volatile suspended solids (VSS). While FeCl₃, APE 65, APE 85, Synthetic coagulant LP 526, and FeClSO₄ did not show any inhibition effect in the sludge, APE 67, CPE 84, and (Al₂(SO₄)₃ are found to cause inhibition in the sludge.

Fate of micropollutants in chemically enhanced primary treatment using recovered coagulants

In this study, the fate of several micropollutants (MPs) in wastewater due to coagulation using both fresh and recovered aluminum and iron coagulants was determined. 18 MPs from different groups such as antibiotics, food additives, and surfactants were selected and spiked into the primary influent collected from a local wastewater plant. The distribution of MPs in the recovered coagulant and treated effluent after coagulation was determined for both fresh and recycled coagulants. The distribution of MPs in wastewater and the removal during coagulation were compound specific; MPs with log K_ow < 2.5 were predominantly present in the effluent after coagulation, while MPs with log K_ow > 2.5 were sorbed on the coagulated sludge. The distribution ratio (K_d) of all the MPs (diclofenac, clarithromycin, etc.) with log K_ow > 2.5 was determined along with their extent of accumulation in sludge due to the recycling of coagulants. Compounds such as sulfamethoxazole, erythromycin and sulfathiazole, showed low removal during coagulation. The tetracycline group of compounds showed possible chelation with iron and aluminum. Only <10% of the initially spiked MPs with log K_ow > 2.5 was being recycled with the recovered coagulant, thus alleviating the concern of accumulation of the MPs during recycle of the coagulants.

Revisiting Chemically Enhanced Primary Treatment of Wastewater: A Review

Chemically enhanced primary treatment (CEPT) is a process that uses coagulant and/or flocculant chemicals to remove suspended solids, organic carbon, and nutrients from wastewater. Although it is not a new technology, it has received much attention in recent years due to its increased treatment capacity and related benefits compared to the conventional primary treatment process. CEPT involves both physical and chemical processes. Alum and iron salts are the commonly used coagulants in CEPT. Several types of anionic, cationic, and uncharged polymers are used as flocculants, where poly aluminum chloride (PACL) and polyacrylamide (PAM) are the widely used ones. Some of the coagulants and flocculants used may have inhibitory and/or toxicity effects on downstream treatment and recovery processes. There has been an increasing amount of work on the treatment of wastewaters from various sources using CEPT. These wastewaters can range from municipal/domestic wastewater, combined sewer overflow, landfill leachate, cattle manure digestate to wastewaters from textile industry, pulp and paper mill, slaughterhouse, milk processing plant, tannery and others. In recent cases, CEPT is employed to enhance carbon redirection for recovery and substantially reduce the organic load to secondary treatment processes. CEPTs can remove between 43.1–95.6% of COD, 70.0–99.5% suspended solids, and 40.0–99.3% of phosphate depending on the characteristics of wastewater treated and type of coagulants and/or flocculants used. This article reviews the application, chemicals used so far, removal efficiencies, challenges, and environmental impacts of CEPT.