Continuous reaction crystallization of struvite from phosphate(V) solutions containing calcium ions

Evaluating the opportunities for mainstream P-recovery in anaerobic/anoxic/aerobic systems

Mainstream P-recovery can help wastewater treatment plants (WWTPs) to effectively maintain good enhanced biological phosphorus removal (EBPR) while helping to recover P. In this study, a pilot-scale anaerobic-anoxic-aerobic (A2O) process was operated for simultaneous COD/N/P removal and P-recovery under different operational conditions. The operation with conventional extraction of waste activated sludge (WAS) from the aerobic reactor was compared to the mainstream P-recovery strategy of WAS extraction from the anaerobic reactor. Successful nutrient removal was obtained for both scenarios, but the anaerobic WAS extraction results improved polyphosphate accumulating organisms (PAOs) activity by increasing almost 27 % P concentration in the anaerobic reactor. WAS fermentation was also evaluated, showing that anaerobic WAS required only 3 days to reach a high P concentration, while the aerobic WAS fermentation required up to 7 days. The fermentation process increased the amount of soluble P available for precipitation from 24.4 % up to 51.6 % in the fermented anaerobic WAS scenario. Results obtained by precipitation modelling of these streams showed the limitations for struvite precipitation due to Ca2+ interference and Mg2+ and NH4+ as limiting species. The optimum precipitation scenario showed that P-recovery could reach up to 51 % of the input P, being 90 % struvite.

A review of struvite crystallization for nutrient source recovery from wastewater

Nutrient recovery from wastewater not only reduces the nutrient load on water resources but also alleviates the environmental problems in aquatic ecosystems, which is a solution to achieve a sustainable society. Besides, struvite crystallization technology is considered a potential nutrient recovery technology because the precipitate obtained can be reused as a slow-release fertilizer. This review presents the basic properties of struvite and the theory of the basic crystallization process. In addition, the possible influencing variables of the struvite crystallization process on the recovery efficiency and product purity are also examined in detail. Then, the advanced auxiliary technologies for facilitating the struvite crystallization process are systematically discussed. Moreover, the economic and environmental benefits of the struvite crystallization process for nutrient recovery are introduced. Finally, the shortcomings and inadequacies of struvite crystallization technology are presented, and future research prospects are provided. This work serves as the foundation for the future use of struvite crystallization technology to recover nutrients in response to the increasingly serious environmental problems and resource depletion.

Phosphorus biorecovery from wastewater contaminated with multiple nitrogen species by a bacterial consortium

Recovering finite and non-substitutable phosphorus from liquid waste streams through bio-mediated techniques has attracted increasing interest, but current approaches are incredibly dependent on ammonium. Herein, a process to recover phosphorus from wastewater under multiple nitrogen species conditions was developed. This study compared the effects of nitrogen species on the recovery of phosphorus resources by a bacterial consortium. It found that the consortium could not only efficiently utilize ammonium to enable phosphorus recovery but also utilize nitrate via dissimilatory nitrate reduction to ammonium (DNRA) to recover phosphorus. The characteristics of the generated phosphorus-bearing minerals, including magnesium phosphate and struvite, were evaluated. Furthermore, nitrogen loading positively influenced the stability of the bacterial community structure. The genus Acinetobacter was dominant under nitrate and ammonium conditions, with a relatively stable abundance of 89.01% and 88.54%, respectively. The finding may provide new insights into nutrient biorecovery from phosphorus-containing wastewater contaminated with multiple nitrogen species.

A comparison of struvite precipitation thermodynamics and kinetics modelling techniques

Solution thermodynamics and kinetic modelling applied to struvite crystallisation-precipitation were reviewed from diverse references to determine proximity between predicted and cited experimental measurements. These simulations show the expected variability range of struvite saturation calculation when only limited solution compositional information is given, showing acceptable agreement between predicted and experimental struvite mass. This work also compares results from struvite crystallisation kinetic studies on liquid phase species depletion, crystallisation induction time, primary nucleation, secondary nucleation, crystal growth, and crystal aggregation. Large inconsistencies between reported kinetics were observed in many scenarios. Variations in species depletion models highlighted that they are only suitably applied to the specific system from which they were regressed. Spontaneous primary nucleation was predicted to occur in the range of SI = 0.237-0.8. Predicted primary nucleation rates vary over at least 10 orders of magnitude (depending on supersaturation) because of uncertainties in interfacial tension and maximum achievable nucleation rate. Secondary nucleation rates are more agreeable, varying over approximately two orders of magnitude. Growth rates varied over five orders of magnitude due to variations in experimental conditions. Aggregation rates are not thoroughly examined enough to make any inferences.

Size-dependent growth kinetics of struvite crystals in wastewater with calcium ions

Kinetic parameters describing continuous reaction crystallization of struvite from aqueous solutions containing also calcium ions (from 100 to 2000 mg Ca2+/kg) were estimated. Test results were compared with kinetic data of struvite manufactured from real cattle liquid manure. Kinetic model for ideal MSMPR (Mixed Suspension Mixed Product Removal) crystallizer was used assuming dependence of crystal growth rate G on its size L (size-dependent growth, SDG MSMPR model). Based on nonlinear regression and statistical analysis, one from within five considered G(L) models was selected – Rojkowski exponential (RE) model – rendering the experimental population density distributions the best. It was concluded, that calcium ions influenced all components of struvite manufacturing process disadvantageously. A rise of Ca2+ concentration in a feed from 100 to 2000 mg/kg increased nucleation rate ca. 160-time, whereas growth rate of nuclei up to macroscopic size G0 decreased more than 10-time. Linear (larger) crystal growth rate G¥ was nearly two-times smaller: 1.71·10–8 m/s (100 mg Ca2+/kg) – 9.10·10–9 m/s (2000 mg Ca2+/kg). Resulting in a product with deteriorated quality. Mean size of the crystals decreased nearly two-times (to 18.4 μm), non-homogeneity within product population enlarged and calcium fraction in the product increased. The product, beside struvite MgNH4PO4·6H2O, also contained hydrated amorphous calcium phosphate(V) Ca3(PO4)2·nH2O (ACP). It was observed, that 5-times smaller concentration of phosphate(V) ions in a feed and magnesium ions excess in relation to phosphate(V) and ammonium ions (1.2 : 1 : 1) influenced all kinetic parameters of continuous struvite reaction crystallization advantageously.

Recovery of phosphates(V) from wastewaters of different chemical composition

Phosphate(V) ions were recovered from wastewaters of different chemical compositions in a continuous reaction crystallization of struvite. Two real wastewaters were represented by an effluent sample from the phosphorus mineral fertilizer industry and by liquid manure derived from a cattle-breeding farm. Two other wastewaters were prepared under laboratory conditions. Impurities present in the wastewaters caused the precipitation of solid products of distinctly different quality. The mean size of struvite crystals varied from ca. 18 to ca. 40 μm. Homogeneity within their populations, quantified by the coefficient of variation CV, varied from satisfactory (CV ca. 75%) to unfavorable (CV ca. 100%), which resulted in the elongation of necessary filtration time. Calcium ions in wastewater precipitated as amorphous hydrated calcium phosphates ACP. Their content in the products varied from 33.4 up to 73.1 mass %. Also 28.32 – 32.74 mass % of P2O5, 6.35 – 14.12 mass % of MgO and 4.35 – 16.94 mass % of CaO were confirmed in the products, together with hydroxides of some metals and salts of other impurities. Based on the chemical composition of the products derived from the investigated wastewaters, their application in agriculture as valuable mineral fertilizers is recommended.

Phosphorus recovery through struvite crystallisation: Recent developments in the understanding of operational factors

Phosphorus is an essential element for life and is predicted to deplete within the next 100 years. Struvite crystallization is a potential phosphorus recovery technique to mitigate this problem by producing a slow release fertilizer. However, complex wastewater composition and a large number of process variables result in process uncertainties, making the process difficult to predict and control. This paper reviews the research progress on struvite crystallization fundamentals to address this challenge. The influence of manipulated variables (e.g. seed material, magnesium dosage and pH) and sources of variation on phosphorus removal efficiency (e.g. organics and heavy metal concentration) and product purity were investigated. Recently developed models to describe, control and optimize those variables were also discussed. This review helps to identify potential challenges in different wastewater streams and provide valuable information for future phosphorus recovery unit design. It therefore paves the way for commercialization of struvite crystallization in the future.

Phosphorous recovery through struvite crystallization: Challenges for future design

Phosphorous (P) is an essential element for living organisms and is predicted to be depleted within the next 100 years. Across the world, significant phosphorous losses due to its low utilization efficiency become one of the main reasons for water pollution. Struvite crystallization has been found to be a promising recovery technique to mitigate these problems, as the recovered precipitate can be used as a slow release fertilizer or raw material for chemical industry. Although this technique has been widely investigated over the past two decades, there are currently few real applications in industry. This paper addresses this issue by reviewing key aspects relevant to process design to pave the way for future application. It will help to narrow down struvite process design options and thus reduce the voluminous calculations for a detailed analysis. Struvite process development, research trend, product application and process economics are reviewed and a conceptual process design is provided. This analysis provides comprehensive information that is essential for future industrial struvite crystallization process design.

Concurrent hydrogen production and phosphorus recovery in dual chamber microbial electrolysis cell

Concurrent hydrogen (H₂) production and phosphorus (P) recovery were investigated in dual chamber microbial electrolysis cells (MECs). The aim of the study was to explore and understand the influence of applied voltage and influent COD concentration on concurrent H₂ production and P recovery in MEC. P was efficiently precipitated at the cathode chamber and the precipitated crystals were verified as struvite, using X-ray diffraction and scanning electron microscopy analysis. The maximum P precipitation efficiency achieved by the MEC was 95%, and the maximum H₂ production rate was 0.28m³-H₂/m³-d. Response surface methodology showed that applied voltage had a great influence on H₂ production and P recovery, while influent COD concentration had a significant effect on P recovery only. The overall energy recovery in the MEC was low and ranged from 25±1 to 37±1.7%. These results confirmed MECs capability for concurrent H₂ production and P recovery.

Chemical Species of Phosphorus and Zinc in Water-Dispersible Colloids from Swine Manure Compost

The release of phosphorus (P) and zinc (Zn) from swine manure compost and from soils applied with swine manure compost can be accelerated by colloidal particles. This study investigated the concentrations and chemical species of P and Zn in water-dispersible colloids (WDCs) collected from swine manure compost by using X-ray absorption fine structure (XAFS) spectroscopy. A filtration and ultracentrifugation process was used to separate and collect WDCs (20-1000 nm) from the bulk swine manure compost (<2 mm). The swine manure compost contained 2.7 g kg WDC, in which P (140 g kg) was highly concentrated and Zn concentrations were greater than in the bulk compost (1.45 g kg). Phosphorus K-edge X-ray absorption near-edge structure (XANES) spectroscopy determined the presence of struvite (NHMgPO·6HO) as a major P species (74%), followed by tricalcium phosphate as a secondary component (26%). In the WDC fraction, struvite was not found, but tricalcium phosphate (56%) occurred as a primary component. Zinc K-edge XAFS spectroscopy determined hopeite [Zn(PO)·4HO, 59%] and to a lesser extent smithsonite (ZnCO, 24%) and Zn adsorbed on ferrihydrite (17%). In the WDC fraction, hopeite (44%) and organically bound Zn (35%) were predominant. Our results demonstrate the notable difference in the concentration and chemical species of P and Zn between the WDC and bulk fractions of swine manure compost.

Phosphorus recovery as struvite from farm, municipal and industrial waste: Feedstock suitability, methods and pre-treatments

Global population growth requires intensification of agriculture, for which a sustainable supply of phosphorus (P) is essential. Since natural P reserves are diminishing, recovering P from wastes and residues is an increasingly attractive prospect, particularly as technical and economic potential in the area is growing. In addition to providing phosphorus for agricultural use, precipitation of P from waste residues and effluents lessens their nutrient loading prior to disposal. This paper critically reviews published methods for P recovery from waste streams (municipal, farm and industrial) with emphasis on struvite (MgNH4PO4·6H2O) crystallisation, including pre-treatments to maximise recovery. Based on compositional parameters of a range of wastes, a Feedstock Suitability Index (FSI) was developed as a guide to inform researchers and operators of the relative potential for struvite production from each waste.

Struvite recovery from solution containing phosphate(V) and sulphate(VI) ions

The research results concerning the application of magnesium and ammonium ions for continuous removal of phosphate(V) ions from solution containing 1.0 or 0.20 mass% of PO43– and from 0.10 to 0.50 mass% of SO42– are presented. A continuous struvite MgNH4PO4 × 6H2O reaction crystallization process was carried out both under stoichiometric conditions and using 20% excess of magnesium ions. The research was conducted in a DT MSMPR type crystallizer with internal circulation of suspension driven by a propeller stirrer, in constant temperature 298 K. The pH varied from 9 to 11 and mean residence time of suspension in a crystallizer τ varied from 900 to 3600 s. It was concluded, that sulphate(VI) ions influenced product quality disadvantageously. Depending on process parameter combinations struvite crystals of mean size from ca. 18 to ca. 44 μm and of moderate homogeneity: CV 7–95% were produced. Presence of sulphate(VI) ions favored crystallization of struvite as prismatic crystals, but tubular forms were also identified. The best shaped struvite crystals were produced at relatively low concentration of sulphate(VI) ions, pH 9 and for mean residence time of suspension in a crystallizer elongated up to 3600 s.

Phosphates (V) recovery from phosphorus mineral fertilizers industry wastewater by continuous struvite reaction crystallization process

Continuous DT MSMPR (Draft Tube Mixed Suspension Mixed Product Removal) crystallizer was provided with typical wastewater from phosphorus mineral fertilizers industry (pH < 4, 0.445 mass % of PO4(3-), inorganic impurities presence), dissolved substrates (magnesium and ammonium chlorides) and solution alkalising the environment of struvite MgNH4PO4·6H2O reaction crystallization process. Research ran in constant temperature 298 K assuming stoichiometric proportions of substrates or 20% excess of magnesium ions. Influence of pH (8.5-10) and mean residence time (900-3600 s) on product size distribution, its chemical composition, crystals shape, size-homogeneity and process kinetics was identified. Crystals of mean size ca. 25-37 μm and homogeneity CV 70-83% were produced. The largest crystals, of acceptable homogeneity, were produced using 20% excess of magnesium ions, pH 9 and mean residence time 3600 s. Under these conditions nucleation rate did not exceed 9 × 10(7) 1/(s m(3)) according to SIG (Size Independent Growth) MSMPR kinetic model. Linear crystal growth rate was 4.27 × 10(-9) m/s. Excess of magnesium ions influenced struvite reaction crystallization process yield advantageously. Concentration of phosphate(V) ions decreased from 0.445 to 9.2 × 10(-4) mass %. This can be regarded as a very good process result. In product crystals, besides main component - struvite, all impurities from wastewater were detected analytically.

Optimization of struvite precipitation in synthetic biologically treated swine wastewater--determination of the optimal process parameters

A sustainable way to recover phosphorus (P) in swine wastewater involves a preliminary step of P dissolution followed by the separation of particulate organic matter. The next two steps are firstly the precipitation of struvite crystals done by adding a crystallization reagent (magnesia) and secondly the filtration of the crystals. A design of experiments with five process parameters was set up to optimize the size of the struvite crystals in a synthetic swine wastewater. More than 90% of P was recovered as large crystals of struvite in optimal conditions which were: low Mg:Ca ratio (2.25:1), the leading parameter, high N:P ratio (3:1), moderate stirring rate (between 45 and 90 rpm) and low temperature (below 20 °C).These results were obtained despite the presence of a large amount of calcium and using a cheap reactant (MgO). The composition of the precipitates was identified by Raman analysis and solid dissolution. Results showed that amorphous calcium phosphate (ACP) co-precipitated with struvite and that carbonates were incorporated with solid fractions.

Struvite-based fertilizer and its physical and chemical properties

This study describes a method to formulate struvite fine powder into pellets that are easy to spread on agricultural land. To evaluate the quality of produced pellets, some chemical and physical properties commonly measured for fertilizers were tested. The findings indicated that the salt index and heavy metal content ofstruvite pellets were significantly lower than those of commercial NPK fertilizers. In addition, the percentage of nutrient released from struvite pellets after 105 days was in the range of 9.6-23.2, 8.4-26.7 and 11.3-32.6% for nitrogen, phosphorous and magnesium, respectively, which is considerably lower than that of commercial NPK fertilizer. Among different formulations between struvite crystals and binders, starch and bentonite were the most efficient in agglomerating struvite powder, leading to an increase in the crush strength to over the recommended limit of >2.5 kgf for fertilizer hardness.