Phosphorus recovery from sewage sludge via incineration with chlorine-based additives

Optimizing iron removal from sewage sludge ash for enhanced phosphate fertilizer bioavailability

Sewage sludge derived fertilizer is a promising solution for phosphorus (P) recovery from biowaste, however, the inherent iron content in the sludge ash (SSA) impedes the P availability of the fused calcium magnesium phosphate fertilizer (FCMP). To achieve the goal of iron removal during the process, carbothermal reduction was adopted for the first time and the performance of carbon addition was systematically evaluated. Results showed that carbon addition at 4.50 % significantly increased the P availability from 9.50 % to 11.00 % and decreased the required amounts of calcium/magnesium. Moreover, ferrophosphate with 20.20 % P can be produced and the melting point of the system can be reduced by manipulating carbon addition. Finally, a process design was provided for the co-production of FCMP and ferrophosphate. This study highlights the addition of carbon to facilitate iron removal in SSA for the production of FCMP with enhanced bioavailability at a reduced energy consumption scenario.

Preparation of phosphorus containing products by co-incineration of sludge ash and calcium-based additives: Focusing one-step and multi-step method

Due to the irreplaceable nature of phosphorus (P) in biological growth and the shortage of P rock, it is necessary to recover P from waste, such as sludge ash. P-containing products were prepared using sludge ash and calcium-based additives (CaCO3 and eggshell). In addition, the effects of different incineration methods (one-step method (OSM) and multi-step method (MSM)), additive doses, and incineration temperature on the P content and species in the products were investigated. The results indicated that as the dose of calcium-based additives increased, total P (TP) content in P-containing products reduced, apatite P (AP) content increased, non-apatite P (NAIP) content declined, and P solubility in citric acid content decreased. The amount of AP increased, NAIP reduced, and P solubility in citric acid decreased as the incineration temperature climbed. Although P in P-containing products prepared by OSM and MSM changed in a similar way at different additive doses and temperatures, P-containing products prepared by MSM had at least a 6.1% increase in P solubility in citric acid. Compared with OSM, MSM could save 10% of calcium-based additives when reaching the maximum AP value. Additionally, pure materials were employed to investigate how P species changed during the incineration procedure. The advantage of the MSM-prepared product over the OSM-prepared product may be explained by the high concentration of Ca3(PO4)2 and low concentration of amorphous calcium bound P (Ca-P). Overall, MSM is an effective method to reduce the dose of calcium-based additives and increase the bioavailability of P in P-containing products.

Migration and transformation of phosphorus and toxic metals during sludge incineration with Ca additives

The recycling and utilization of phosphorus resources in sludge is becoming increasingly important. In this study, we compared the conversion of phosphorus and toxic metal passivation effects of different Ca additives under oxygen-rich combustion conditions and elucidated their specific mechanisms of action. The experimental results indicated that four Ca-based additives improved the recovery rate of total phosphorus, and promoted the generation of stable apatite phosphorus (AP). The effect of CaCl2 and CaO was greater than that of Ca(OH)2 and CaSO4. CaCl2 promoted the formation of Ca3(PO4)2 and Ca2P2O7, and CaSO4 improved the conversion of AlPO4 to Ca(H2PO4)2 with increasing temperature. The conversion capacity of CaO on non-apatite inorganic phosphorus to AP was greater than that of Ca(OH)2, and more CaH2P2O7, Ca(PO3)2, and Ca-Al-P minerals were found. Toxic metal percentages decreased after sludge incineration with CaCl2. Compared with CaO and Ca(OH)2, the toxic metal adsorption effect of CaSO4 was more significant. The influence of Ca additives on the conversion of Zn into stable components was as follows: CaCl2 > Ca(OH)2 > CaO > CaSO4. Ca additives reduced the toxic metal contamination level and ecological risk index values, and the order of toxic metal contamination levels was Ni > Zn > Cr > Cu > Mn. The experiment confirmed the conversion of phosphorus and the toxic metal passivation effect of Ca additives during oxy-fuel combustion of sludge, which is beneficial for its resource utilization.

The interaction of different chlorine-based additives with swine manure during pyrolysis: Effects on biochar properties and heavy metal volatilization

Poor properties and high concentrations of heavy metals are still major concerns of successful application of animal manure-derived biochar into the environment. This work thus proposed to add chlorine-based additives (Cl-additives, i.e., CaCl2, MgCl2, KCl, NaCl, and PVC, 50 g Cl/ kg) to improve biochar properties and enhance heavy metal volatilization during swine manure pyrolysis. The results showed that the addition of CaCl2 could improve the retention of carbon (C) by up to 13.1% during pyrolysis, whereas other Cl-additives had little effect on it. Moreover, CaCl2 could enhance the aromaticity of biochar, as indicated by lower H/C ratio than raw biochar. Pretreatment with CaCl2, MgCl2 and PVC reduced phosphorus (P) solubility but increased its bioavailability via the formation of chlorapatite (Ca5(PO4)3Cl). The CaCl2 was more effective for enhancing the volatilization efficiency of heavy metals than other Cl-additives, except for Pb that tended to react with the generated Ca5(PO4)3Cl to form more stable and less volatile Pb5(PO4)3Cl. However, high pyrolysis temperature (900℃) was essential for CaCl2 to simultaneously decrease the bioavailability of heavy metals. Our results indicated that co-pyrolysis of swine manure with CaCl2 is a promising strategy to increase C retention, P bioavailability, and volatilization of heavy metals, and, at higher temperature, reduce the bioavailability of biochar-born heavy metals.

Urban mining from biomass, brine, sewage sludge, phosphogypsum and e-waste for reducing the environmental pollution: Current status of availability, potential, and technologies with a focus on LCA and TEA

Rapid industrialization, improved standards of living, growing economies and ever-increasing population has led to the unprecedented exploitation of the finite and non-renewable resources of minerals in past years. It was observed that out of 100 BMT of raw materials processed annually only 10% is recycled back. This has resulted in a strenuous burden on natural or primary resources of minerals (such as ores) having limited availability. Moreover, severe environmental concerns have been raised by the huge piles of waste generated at landfill sites. To resolve these issues, 'Urban Mining' from waste or secondary resources in a Circular Economy' concept is the only sustainable solution. The objective of this review is to critically examine the availability, elemental composition, and the market potential of the selected secondary resources such as lignocellulosic/algal biomass, desalination water, sewage sludge, phosphogypsum, and e-waste for minerals sequestration. This review showed that, secondary resources have potential to partially replace the minerals required in different sectors such as macro and microelements in agriculture, rare earth elements (REEs) in electrical and electronics industry, metals in manufacturing sector and precious elements such as gold and platinum in ornamental industry. Further, inputs from the selected life cycle analysis (LCA) & techno economic analysis (TEA) were discussed which showed that although, urban mining has a potential to reduce the greenhouse gaseous (GHG) emissions in a sustainable manner however, process improvements through innovative, novel and cost-effective pathways are essentially required for its large-scale deployment at industrial scale in future.

The assessment of phosphorus recovery potential in sewage sludge incineration ashes - a case study

A sewage sludge incineration ash contains large amounts of phosphorus, which are considered as a novel anthropogenic waste-based substitute for phosphorus natural resources. Phosphorus is accumulated at most in phosphate minerals of whitlockite structure, that contain Fe, Ca, and Mg and in the matrix composed of Si, Al, Fe, Ca, P, Mg, K, Na in various proportions. The goal of this study was to estimate phosphorus recovery potential. A four-stage sequential extraction, following the modified Golterman procedure, was applied. Separation of four independent fractions enabled to understand better the manner of phosphorus occurrence in the studied ash. The results of the extraction indicated the greatest release of phosphorus combined with organic matter using sulfuric acid. The release was on average at the level of 64%. The chelating Na-EDTA compound indicated lower ability to extract phosphorus (at the level of 35%), and the highest ability to extract heavy metals and potentially toxic elements (As, Zn, Mo). The sequential extraction led to the total recovery of phosphorus of around 40-60.

CaO-assisted hydrothermal treatment combined with incineration of sewage sludge: Focusing on phosphorus (P) fractions, P-bioavailability, and heavy metals behaviors

Dewatering of sewage sludge (SS) was the prerequisite for saving its drying energy and sustaining its stable combustion. Hydrothermal treatment (HT) has been a promising technology for improving SS dewaterability with high energy efficiency. However, the knowledge of phosphorus (P) transformation and heavy metals (HMs) behaviors in the combined HT and incineration process was still lack. P fractions, P-bioavailability, HMs speciation, and their environmental risk in the ash samples from this combination process were evaluated and compared with those from the co-incineration of SS and CaO. The combination process was superior to the latter one in the light of P and HMs. CaO preferred to enhance the transformation of non-apatite inorganic phosphorus (NAIP) to apatite phosphorus (AP) initially with enriched P and increased P-bioavailability in the resultant ash samples. The combination process further reduced the values of risk assessment code and individual contamination factor with the increment of the stable F4 fraction in HMs. Significant reduction of potential ecological risk was observed with the lowest global risk index of 43.76 in the combination process. Optimum CaO addition of 6% was proposed in terms of P and HMs. The work here can provide theoretical references for the potential utilization of P from SS to mitigate the foreseeable shortage of P rocks.

Distinct responses of aerobic granular sludge sequencing batch reactors to nitrogen and phosphorus deficient conditions

The nutrients availability determines efficiency of biological treatment systems, along with the structure and metabolism of microbiota. Herein nutrients deficiencies on aerobic granular sludge were comparatively evaluated, treating wastewater with mass ratios of chemical oxygen demand : nitrogen : phosphorus being 200:20:4, 200:2:4, and 200:20:0.4 (deemed as nutrient-balanced, nitrogen-deficient, and phosphorus-deficient), respectively. Results revealed that both nitrogen and phosphorus deficiencies significantly raised the effluent qualities especially nitrogen removal. However, nitrogen deficiency aroused considerable growth of filamentous bacteria, while granules kept compact structure under phosphorus deficient condition. Extracellular polymeric substances (EPS) also varied in contents and structures in response to different wastewaters. Microbial community structure analysis demonstrated that nitrogen deficiency led to lower richness and higher diversity, while the reverse was observed under phosphorus deficient condition. Nitrogen deficiency mainly induced decrease of nitrifying bacteria, while similarly phosphorus deficiency led to loss of phosphorus accumulating organisms. Dramatic enrichment Candidatus_Competibacter and filamentous Thiothrix were found under nutrients deficiencies, in which the latter explained and indicated filamentous bulking potential especially under nitrogen limited condition. Bacterial metabolism patterns verified the functions of microbial community responding to nutrients via PICRUSt2 prediction mainly by up-regulating cell motility, and cellular processes and signaling. This study could aid understanding of long-term stability of aerobic granular sludge for low-strength wastewater treatment.

The effect of soil amendment derived from P-enhanced sludge pyrochar on ryegrass growth and soil microbial diversity

The application of pyrolyzed sewage sludge for land remediation is increasingly being considered as a technical solution to reuse nutrients in the sludge and mitigate the burden of sludge treatment. In this study, the enhancement effect of Ca-based additives, via phosphorus pyrolysis transformation promotion, was systematically investigated for the growth of ryegrass and soil microbial diversity. In the pot experiment, pyrochar-modified methods mainly changed the content of available phosphorus and organic matter in the soil and then affected ryegrass growth. Soils treated with pyrochar prepared with CaO and Ca(OH)₂ addition were dominated by phosphorus precipitation-capable Ramlibacter, while metal uptake-accelerating Massilia showed a high prevalence in the group treated with pristine sludge pyrochar. The results showed that the species composition of CaO and Ca(OH)₂ treated groups were similar, while the groups treated with Ca₃(PO₄)₂ and pristine sludge pyrochar exhibited similar compositional structures of microbial species. Furthermore, less than 3% of Pb accumulated in the shoots of the Ca-based additive-treated groups, but more than 35% of Pb was distributed in shoots treated with pristine sludge pyrochar. Therefore, the application of P-enhanced pyrochar adjusted by Ca-based additives to soil was beneficial to the growth of ryegrass and preventing metal transfer from soil to ryegrass. Based on both macroscopic and microscopic information, we summarized the promotion effect of P-enhanced pyrochar on ryegrass growth and soil physicochemical properties with the aim of designing a smart pyrochar for waste-to-resource applications.

Thermal treatment of sewage sludge: A comparative review of the conversion principle, recovery methods and bioavailability-predicting of phosphorus

Phosphorus is a nutrient that is essential to nature and human life and has attracted attention because of its very limited reserves. Dwindling phosphorus reserves and soaring prices have made the recovery of phosphorus from waste biosolids even more urgent. Waste activated sludge, as the final destination of most of the phosphorus in human domestic and industrial water, has been considered as a reliable source of phosphorus recovery. The thermal treatment method of sewage sludge is currently a relatively environmentally friendly disposal method, which mainly includes incineration, pyrolysis and hydrothermal carbonization. This paper reviews the methods for the recovery of different forms of phosphorus (wet chemical, thermochemical and electrodialysis) from solid products obtained from different sludge thermal treatment methods (incinerated sewage sludge ash, pyrolysis of sewage sludge char and hydrochar) and the bioavailability of the recovered phosphorus products. Incineration of sewage sludge is currently the most established and effective method for recovering phosphorus from the thermal treatment products of sewage sludge. One of the wet chemical methods has been applied on a commercial scale and is expected to be further developed for future industrial applications. Pyrolysis and hydrothermal carbonation still have many research gaps in this field. Based on their principles and laboratory performance, both of them have the potential to recover phosphorus and should be further explored.

Trace metal elements vaporization and phosphorus recovery during sewage sludge thermochemical treatment - A review

Phosphorus (P) plays essential roles in crops growth. Natural mineral sources of phosphate are non-renewable, overexploited and unevenly distributed worldwide, making P a strategic resource for agricultural systems. The search for sustainable ways to secure P supply for fertilizer production has therefore become a critical issue worldwide. Sewage sludge (SS) is an organic waste material considered as a key alternative source of P. Switzerland and the European Union are about to make it mandatory to recover P from SS or its treatment residues. Among the many technical options to achieve this objective, SS thermochemical treatments spiked with Cl-donors appear as a promising approach to recover P from SS and separate it from mineral pollutants such as trace metal elements (TME). The purpose of Cl-donor additives is to fix P within the mineral residues, possibly in bioavailable P species forms, while promoting TME vaporization by chlorination mechanisms. This review paper compares the various thermochemical treatments investigated worldwide over the past two decades. The influence of process conditions and Cl-donor nature is discussed. The presented results show that, except for nickel and chromium, most TME can be significantly vaporized during a high temperature treatment (over 900 °C) with Cl addition. In addition, the fixation rate and solubility of P is increased when a Cl-donor such as MgCl₂ is added.

Correlating phosphorus transformation with process water during hydrothermal carbonization of sewage sludge via experimental study and mathematical modelling

Recently, hydrothermal carbonization (HTC) based phosphorus (P) recovery from sewage sludge (SS) has attracted considerable interests worldwide. However, they concentrated on P transformation in the hydrochars, while ignored that the variations of process water (PW) might influence P transformation, since it exposed to water thoroughly during HTC. In this study, correlation of P transformation with PW were examined via experimental study and mathematical modelling. The results showed that statistical significance (p < 0.05) of HTC temperature and feedwater pH on NH₄⁺-N concentration in the PW was observed due to deamination and ring opening reactions of amino acids, confirming by their excellent correlation with R² = 0.988. NH₄⁺-N concentration dominated increasing PW pH, which stimulated the transformation of NAIP to AP. Associated model was developed with satisfactory R² = 0.938. Although P transformation during HTC was significantly influenced by HTC temperature and feedwater pH, supporting by their strong correlation with R² = 0.956, its transformation was PW pH dependent. Ultimately, detailed P transformation pathways during HTC was proposed with incorporation into the impact of PW. This work can provide new insights into HTC-based P transformation in the pristine SS.

Transformation of phosphorus by MgCl2 and CaCl2 during sewage sludge incineration

Phosphorus (P) recovery from sewage sludge (SS) have been regarded as an effective method of P recycling. The effects of incineration temperature, incineration time, and chlorine additives on the distribution of P speciation during sludge incineration were studied. Moreover, the reactions between model compounds AlPO4 and additives (MgCl2 and CaCl2) were investigated by thermogravimetric differential thermal analysis and X-ray diffraction measurements. The results demonstrated that the increase in temperature and time stimulated the volatilization of non-apatite inorganic phosphorus (NAIP) instead of apatite phosphorus (AP). MgCl2 and CaCl2 can greatly promote the conversion of NAIP to AP. Additionally, AlPO4 reacted with MgCl2 are incinerated at 500-600 °C to form Mg3(PO4)2, which is mainly due to the reaction of the intermediate product MgO and AlPO4. Reactions between AlPO4 and CaCl2 occurred at 700-750 °C and produced Ca2PO4Cl, which can be directly used with high bioavailability. These findings suggested that chlorine additives in the SS incineration process can obtain phosphorus-containing minerals with higher bioavailability to realize the resource utilization of P in sludge.

A green process for phosphorus recovery from spent LiFePO4 batteries by transformation of delithiated LiFePO4 crystal into NaFeS2

Recovery of high-content and valuable elements including phosphorus (P) is critical for recycling of spent LiFePO₄ battery, but P recovery is challengeable due to the poor solubility of lithium phosphate and iron phosphate. This study compared two strategies to recover P by adopting sulfide salt to induce P dissolution, i.e., recovery of P directly from LiFePO₄, and step-by-step recovery of Li then P. The results revealed that the second strategy was more efficient because of the higher recovering efficiency and selectivity. Accordingly, an acid-free process to recover P was successfully demonstrated. Li-recovery efficiency of 97.5 % was reached at a leaching time of 65 min, and nearly 100 % P-recovery efficiency was reached at 5 h. Mechanism analysis revealed that the transforming of delithiated LiFePO₄ crystal to NaFeS₂ was mainly responsible for P dissolution. Thermodynamic analysis and density functional theory calculation further proved the transformation reaction, and a stepwise-transformation mechanism was proposed. In addition, P was reclaimed in the form of soluble phosphate salts. The process is especially appealing due to its environmental and economic benefits for recycling spent LiFePO₄ batteries.