Rheological measurements as a tool for monitoring the performance of high pressure and high temperature treatment of sewage sludge

Comprehensive analysis of the relationship between yield stress and dewatering performance in sludge conditioning: Insights from various treatment methods

Understanding the relationship between sludge yield stress (σy) and dewatering performance is essential for optimizing sludge conditioning processes. This study systematically investigates the effects of various conditioning methods-including thermal hydrolysis (TH), freezing/thawing (FT), anaerobic digestion (AD), polyaluminum chloride (PAC), polyacrylamide (PAM), and Fenton treatment (Fenton)-on sludge yield stress and its correlation with dewatering efficiency. Using linear regression, partial least squares regression (PLSR), and correlation heatmap analyses, we reveal significant variations in the correlation between σy and dewatering indexes, including moisture content (Mc), capillary suction time (CST), and bound water proportion (Wb/Wt), depending on the conditioning method and intensity. Under FT and PAM conditioning, σy shows a strong negative linear correlation with dewatering performance, with Pearson's r values exceeding -0.880, indicating that a decrease in σy corresponds to improved dewatering efficiency. Conversely, AD conditioning exhibits a positive linear correlation, with r values up to 0.993, suggesting that an increase in σy correlates with reduced dewatering efficiency. For TH, PAC, and Fenton treatments, the correlation between σy and dewatering metrics is highly sensitive to changes in treatment intensity. In the PLSR analysis, the VIP values, which quantify the importance of each predictor variable, indicate that Wb/Wt in TH conditioning (VIP = 1.649) and CST in PAC (VIP = 1.309) and Fenton (VIP = 1.299) conditioning strongly influence σy. This study highlights the significant impact of conditioning methods and intensities on the correlation between σy and dewatering performance. While σy provides valuable insights as a predictive indicator, its predictive power is limited in more complex conditioning scenarios. Therefore, optimizing conditioning intensity and incorporating multiple rheological parameters are essential for achieving superior sludge dewatering outcomes.

Rheological properties of thermally treated and digested sludge: Implications for energy requirements of pumps and agitators

Understanding sludge rheology and optimizing equipment performance is crucial for energy efficiency in wastewater treatment plants (WWTPs). This study examined sludge rheology after thermal hydrolysis pre-treatment (THP) at 60, 80, and 120 °C for 2 h, followed by anaerobic digestion (AD) at 37 °C for 20 days, and assessed impacts on pump and agitator performance. Post-treatment, sludge showed reduced viscosity and improved flowability, indicated by changes in Herschel-Bulkley parameters, enhancing pump and agitator efficiency, particularly at 120 °C. These rheological improvements were correlated to the solubilization of sludge components after THP and solids reduction after AD, highlighting the interconnectedness of rheology and treatment outcomes. Despite high heat demands, an energy balance showed that THP scenarios, especially at 120 °C, had lower energy requirements for pumps and agitators, leading to energy savings without increased heat consumption. These findings underscore the influence of rheological changes in improving energy efficiency in WWTPs.

Yield stress Measurement of municipal sludge: A comprehensive evaluation of testing methods and concentration effects using a rotational rheometer

Accurate prediction and measurement of yield stress are crucial for optimizing sludge treatment and disposal. However, the differences and applicability of various methods for measuring yield stress are subjects of ongoing debate. Meanwhile, literature on measuring sludge yield stress is limited to low solid concentrations (TS <10%), understanding and studying the yield stress of medium to high solid concentration sludge is crucial due to increasingly stringent standards for sludge treatment and disposal. So, this study employed a rotational rheometer to measure sludge yield stress across a wide range of TS (4-50%) using steady shear, dynamic oscillatory shear, and transient shear. The study derived significant conclusions by comparing and summarizing the applicability and limitations of each testing method: Dynamic oscillatory shear methods, including G'-σ curve method, γ-σ curve method, and G**γc method can measure sludge yield stress ranging from 4% to 40% TS, while other methods are restricted to low or limited solid concentrations; The G' = G″ method, utilizing the intersection of G' and G″ curves, consistently yields the highest value for yield stress when 4%≤ TS ≤ 12%; The rotational rheometer cannot measure sludge yield stress when the solid concentration exceeds 40% TS; The relationship between sludge yield stress and solid concentration is stronger as a power-law for TS ≤ 25%, transitioning to linear for higher concentrations (28%≤ TS <40%). This study systematically explores the applicability and limitations of various measurement methods for characterizing sludge yield stress across a wide range of solid concentrations, providing valuable guidance for scientific measurement and highlighting challenging research issues.

Understanding the Influence of Diverse Non-Volatile Media on Rheological Properties of Thermophilic Biological Sludge and Evaluation of Its Thixotropic Behaviour

In this study, the rheological properties of thermophilic biological sludge (TBS) have been investigated evaluating the influence of non-volatile solids (NVS). Calcium carbonate, sand, and sodium bentonite were separately added to the sludge to evaluate the effect of concentration and type of NVS. Results show that TBS consistency coefficient significantly enhanced increasing sodium bentonite concentration. On the contrary, calcium carbonate and sand showed relatively small influence on the rheological properties of TBS. Thixotropic behaviour of TBS has also been investigated and is more pronounced at higher shear rate (1000 s−1). Double exponential fitting model was the best choice to represent thixotropic behaviour in case of low (100 s−1) and high shear rate (1000 s−1), while a single-exponential model represents the best option in case of medium shear rate (400 s−1).

Viscous and filamentous bulking in activated sludge: Rheological and hydrodynamic modelling based on experimental data

Although achieving good activated sludge settleability is a key requirement for meeting effluent quality criteria, wastewater treatment plants often face undesired floc structure changes. Filamentous bulking has widely been studied, however, viscous sludge formation much less investigated so far. Our main goal was to find relationship between sludge floc structure and related rheological properties, moreover, to estimate pressure loss in pipe networks through hydrodynamic modelling of the non-Newtonian flows in case of well settling (ideal-like), viscous and filamentous sludge. Severe viscous and filamentous kinds of bulking were generated separately in continuous-flow lab-scale systems initially seeded with the same reference (ideal-like) biomass and the entire evolution of viscous and filamentous bulking was monitored. The results suggested correlation between the rheological properties and the floc structure transformations, and showed the most appropriate fit for the Herschel-Bulkley model (vs. Power-law and Bingham). Validated computational fluid dynamics studies estimated the pipe pressure loss in a wide Reynolds number range for the initial well settling (reference) and the final viscous and filamentous sludge as well. A practical standard modelling protocol was developed for improving energy efficiency of sludge pumping in different floc structure scenarios.

Obtaining high-value nitrogen-containing carbon nanosheets with ultrahigh surface area from waste sludge for energy storage and wastewater treatment

Recovering high value-added resources from waste activated sludge (WAS) is a potential way for the sustainable wastewater treatment. In this study, hydrothermal treatment at 180 °C was used to simultaneously improve sludge dewaterability and recover sludge organic matters (SOMs). The recovered SOMs were subsequently employed as precursors to prepare nitrogen-doped porous carbon nanosheets via a facile stepwise synthesis method. The as-prepared optimal carbon (AP-SOM₈₀₀) was characterized with an ultrahigh specific surface area (3473 m²/g), appropriate porosity (1.77 cm³/g), and abundant heteroatoms (1.47% N and 7.44% O). AP-SOM₈₀₀ exhibited a high specific capacitance (409 F/g at 0.25 A/g), low resistance (0.52 Ω), and superior cyclic stability (only 9.09% loss after 10,000 cycles) in 6 M KOH aqueous electrolyte. Furthermore, AP-SOM₈₀₀ demonstrated an extraordinary adsorption capacity (1528 mg/g for methyl orange (MO) and 1265 mg/g for tetracycline (TC)) that can be maintained (˃ 1200 mg/g) over a wide range of pH conditions. Specifically, 80.97% of MO and 66.67% of TC were rapidly absorbed through AP-SOM₈₀₀ within 10 min, and 90.27% of MO and 81.24% of TC were eventually removed from wastewater after 60 min. The adsorption processes fit closely with the pseudo-second-order kinetic (R² > 0.999) and Langmuir models (R² > 0.914), revealing that the adsorption processes were dominated by a monolayer chemical adsorption reaction. This study suggests that high value-added materials can be obtained from the WAS through improving and extending the traditional sludge treatment processes, which will enrich the technical options available for future sustainable sludge treatment and disposal.

Mechanisms, status, and challenges of thermal hydrolysis and advanced thermal hydrolysis processes in sewage sludge treatment

Sewage sludge management has garnered interest in both academia and industry due to the challenges of overpopulation and its potential as a bioenergy source. Thermal hydrolysis is a promising technology for sludge pre-treatment prior to anaerobic digestion to enhance biogas production. However, the technology is facing two main problems; the dark colour of sludge can affect UV disinfection and the formation of methanogenesis inhibitors such as free ammonia and refractory compounds have a significant impact on methane production in anaerobic digestion processes. Advanced thermal hydrolysis, which is an oxidative thermal hydrolysis process, has been introduced to overcome these challenges. This study provides a comprehensive review of the mechanisms and reactions which occur during the hydrothermal hydrolysis and advanced thermal hydrolysis processes. Technical and implementation challenges of both technologies are discussed. Additionally, the prospects of the technologies are assessed through their technology readiness levels. An assessment of the relevant literature is also provided to illuminate the aspects in which research gaps exist and areas where additional studies could be performed.

Effect of high-temperature thermal hydrolysis on rheological properties and dewaterability of sludge

The disposal processes like dewatering and anaerobic digestion (AD) are commonly utilized to reduce the volume of sludge and recover energy. Thermal hydrolysis process is widely used as a pretreatment for sludge AD, which can change rheological properties and dehydration of sludge irreversibly. The experiment was designed to evaluate the effect of high-temperature thermal hydrolysis (120, 130, 145, 160 and 170°C) for 60 min on sludge rheological properties, as well as its dewaterability. Rheological tests were performed at (20 ± 0.1)°C with a HAAKE Viscotester 550 Rotary Viscometer. Both raw and thermal hydrolysis sludge has a considerable reduction on apparent viscosity and yield stress, but a somewhat increase in thixotropy. With the increase of temperature, the sludge flow behaviour index n increases linearly, while the consistency coefficient k follows the law of linear decline, showing that thermal hydrolysis can weaken the non-Newtonian fluid properties and then improve sludge fluidity. The dewaterability increases linearly with the temperature. Besides, the dewaterability of high-temperature thermal hydrolysis processes sludge was always significantly better than raw sludge as its mud cake has a much larger solid content. Notably, the increase in flow performance index n and the decrease of thixotropy kinetic coefficient K caused by thermal hydrolysis are all linear with the enhancement of dewaterability, which demonstrates that rheological indicators can be a new tool to evaluate the dewaterability of sludge.

Mechanistic insights into the effects of biopolymer conversion on macroscopic physical properties of waste activated sludge during hydrothermal treatment: Importance of the Maillard reaction

In this study, the molecular transformation of sludge biopolymers during hydrothermal treatment with the temperature ranging from 25 °C to 200 °C was examined and was seen to significantly affect the macrophysical properties (dewaterability and rheological property) of sludge. The results showed that the sludge dewaterability and flow ability under high shear stress deteriorated by a hydrothermal process at 25 °C to 120 °C, but the deterioration alleviated above the temperature threshold of 120 °C. The consistence of changes in sludge dewaterability and rheological property in HT process was mainly attributed to the variation in gel properties of soluble biopolymer. Two-stage changes in biopolymer transformation were identified, beginning with a solubilization stage from 25 °C to 120 °C in which a biopolymer with a gel-like network structure was released into liquid phase, creating flow resistance under high shear stress such that sludge dewaterability deteriorated. The second stage was identified as a conversion stage (120 °C-200 °C) in which proteins and polysaccharides hydrolyzed and experienced a Maillard reaction, leading to the degradation of the biopolymer network structure. The newly formed recalcitrant Maillard products showed weak flow response to high shear stress, allowing for an improvement in sludge dewaterability. The pathways of a Maillard reaction were identified via gas chromatography-mass spectrometer (GC-MS), ¹H nuclear magnetic resonance spectroscopy (¹H NMR) and two-dimensional correlation spectral analysis (2D-COS) of Fourier-transform infrared spectrometer (FTIR), etc. Three-dimensional excitation-emission matrix (3D-EEM) proved to be an applicable method for tracking Maillard reaction in sludge hydrothermal process due to the distinctive fluorescence characteristics of Maillard products. This study further clarifies the obscure process of sludge hydrothermal treatment and will help improve the accuracy of subsequent research.

Rheology improvement in an osmotic membrane bioreactor for waste sludge anaerobic digestion and the implication on agitation energy consumption

Sludge rheology is an essential factor for anaerobic digestion (AD) processes to control the agitation energy consumption. In this study, the sludge rheology was characterized for an osmotic membrane bioreactor and a conventional sludge anaerobic digestion reactor as the solid content being increased from 3.5-3.7% to 7.5-7.7%. The flow curves were fitted using different rheological models and the mechanism was discussed. The sludge from the osmotic membrane bioreactor exhibited obviously better rheological properties than that of the conventional reactor at a solid content of 7.5-7.7%. Larger particles induced by less negative zeta potential and higher extracellular polymeric substances, together with the higher conductivity resulted by reverse salt flux in the osmotic membrane bioreactor, improved the sludge rheology due to reduced interactions between particles. As a result, the agitation energy consumption of the osmotic membrane bioreactor can save up to 34-39% compared with the conventional one at total solid content of 7.5-7.7%.

Rheological characterization of thermal hydrolysed waste activated sludge

Rheological properties are important in the design and operation of sludge-handling process. Despite this, the rheology of sludge in thermal hydrolysis processes (TH) is not well described. In-situ measurements were performed to characterize the flow behaviour of various concentrations (7-13 wt%) of waste activated sludge (WAS) at TH conditions. Equations were presented for predicting in-situ rheological parameters (high-shear viscosity, η_∞,i, consistency index, k_i, and yield stress, σ_c,i) under various treatment conditions, which are useful for design of process units. The equations enable convenient estimation of in-situ properties based on ambient rheological measurements. Results suggested that the proportion of sludge solubilization and its rate were unaffected by varying sludge concentration. Thermally treated sludge still exhibited gel-like, viscoelastic characteristics similar to untreated sludge; however, the storage (G') and loss (G") moduli decreased with higher treatment temperatures. Frequency and creep responses were described by a fractional derivatives Kelvin-Voigt (FKV) model, which showed increasing viscous characteristics of treated sludge. These equations can be utilised in CFD models. Results obtained from oscillatory measurements can also approximate steady-shear behaviour by comparing dynamic viscosity, η'(ω), and steady-shear viscosity, η(γ̇), whose values were very similar. This enables convenient estimation of steady-shear behaviour of sludge from oscillatory measurements, which is found to be a non-destructive technique for measuring flow behaviour of highly concentrated sludge. Yield stress can also be predicted from the product of modified Cox-Merz shift factors and storage modulus (G'). Practical engineering implications of the rheological observations were discussed.

Influence of CeO2 nanoparticles on viscoelastic properties of sludge: Role of extracellular polymeric substances

Cerium oxide nanoparticles (CeO₂ NPs) affected the production of extracellular polymeric substances (EPSs), and thus might bring challenges for sludge pumping and mixing. In the present study, we investigated the rheological behavior of sludge before and after extraction of different EPSs fractions under various CeO₂ NPs concentrations. It was found that the removal of loosely bound EPSs (LB-EPSs) could affect the shear stress (τ) and apparent viscosity (η), and the changes were dependent on CeO₂ NPs concentrations. The removal of tightly bound EPSs (TB-EPSs) either with or without the addition of CeO₂ NPs significantly decreased the yield stress (τ_y) and the limiting viscosity (η_∞). Furthermore, the dynamic (strain, frequency and time) sweep measurements proved that the storage modulus (G') decreased after the extraction of TB-EPSs, indicating the weakened elastic and solid-like properties. The fluctuated content of polysaccharide in LB-EPSs and the increased amount of protein in TB-EPSs were likely to contribute to the variation of viscoelastic behaviors after the removal of LB-EPSs and TB-EPSs, respectively. In addition, the decreased rheological properties of sludge was also related to the increased zeta potential, decreased particle size and the removal of key organic matters of (10⁴-10⁶ Da) with the extraction of stratified EPSs. These results were significant to take advantages of the rheological properties for sludge treatment in the presence of NPs.

Investigation of the rheological behavior of activated sludge in response to CeO2 nanoparticles and potential mechanism

With the rapid development of CeO₂ nanoparticles (NPs), the released CeO₂ NPs entering into wastewater treatment plants might bring the challenges for sludge pumping and mixing. In this study, we firstly elucidated the rheological behavior of 4.0 wt% sludge at various concentrations of CeO₂ NPs. With the increase of CeO₂ NPs to 5 mg/L, the shear stress at any given shear rate was reduced and the limiting viscosity was also decreased, indicating the sludge became more flowability. The dynamic sweep tests further demonstrated the decreased elastic behavior and weakened internal structure in response to low concentrations of CeO₂ NPs (≤ 5 mg/L). However, 20 mg/L CeO₂ NPs had negative effects on the rheological evolution of sludge, namely, better solid-like property and higher elastic structure. These results were mainly attributed to the combination of the decreased β-D-glucopyranose polysaccharides which support the rigid structure of sludge and the dramatically increased protein content (especially in 20 mg/L CeO₂ NPs). These results can potentially provide novel information for the efficient design of sludge treatment when coped with CeO₂ NPs. Graphical abstract ᅟ.