Effects of co-processing sewage sludge in cement kiln on NOx, NH3 and PAHs emissions

The influence of organic components in sludge on selective non-catalytic reduction denitrification

Collaborative disposal of sludge has been applied extensively in cement industry kilns, but the influence of organic components in sludge on the selective non-catalytic reduction (SNCR) denitrification is still in highly demanding. This paper focuses the influence of ethanol, n-octane, benzene, and acetone on the SNCR denitrification, and the influence of ethanol are analyzed on SNCR denitrification under different flue gas condition. The result showed that the presence of organic components reduces the reaction temperature of SNCR. When the temperature of SNCR reaction is at 750 ~ 800 ℃, the denitrification rate of four organic components is ethanol > benzene > n-octane > acetone. The optimum denitrification rate on SNCR can reach as high as 90.377% when the reaction condition is the NH3/NO is 1; the ethanol concentration is 1000 ppm; O2 concentration is 2%; and temperature is 750 ℃. The presence of carbon dioxide inhibits the denitrification reaction. With the increase of temperature, the influence of SO2 on the denitrification reaction first increases and then decreases. In this paper, the influence of organic components in sludge on SNCR denitrification will be analyzed, which provides a theoretical basis for the selection of sludge dosing method for cement kiln collaborative disposal.

Structural Equation Model of Factors Influencing the Selection of Industrial Waste Disposal Service in Cement Kilns

Industrial waste disposal in a cement kiln is an operation that includes waste disposal as well as the conversion of waste into renewable energy, which is a cement industry in many countries. This research studied business factors related to the intention to use co-processing industrial waste disposal service in cement kilns by surveying the data with questionnaires from 1251 customers nationwide. The objectives of this research were to study the relationship of business factors by using structural equation modeling to analyze factors influencing the selection of industrial waste disposal service in cement kilns. The study results found that customer attitude towards the following factors, including perceived ease of use, perceived usefulness, disposal price, service provider location, promotion, people, and a service provider’s infrastructure, influenced intention to use the service. The variables that customers gave importance to were the industrial waste disposal with zero wastes to landfill and the use of industrial waste relevant to the circular economy by using the industrial waste, which has a quality of renewable fuel in cement kiln as the renewable fuel of the cement furnace. According to the research results, service providers in cement kilns can potentially plan service strategies to achieve sustainability for further business operations in a highly competitive market.

Emissions of BTEXs, NMHC, PAHs, and PCDD/Fs from Co-processing of Oil-based Drilling Cuttings in Brick Kilns

Oil-based drilling cuttings (OBDC) produced from shale gas development is a hazardous waste that have high calorific values and should be disposed of properly. Burning bricks with OBDC is a promising co-disposal method; however, organic pollutants emitted during this process have not received sufficient attention. In this study, the composition and combustion characteristics of OBDC were determined, and the emissions of typical organic pollutants when burning bricks with the addition of OBDC were investigated; these included benzene series compounds (BTEXs), non-methane total hydrocarbons (NMHC), polycyclic aromatic hydrocarbons (PAHs), and polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans (PCDD/Fs). The results showed that OBDC comprised large amounts of alkanes and aromatic hydrocarbons, and combusted mainly in the temperature range of 145-450 °C with an ignition temperature of 145 °C. The co-processing 10% OBDC increased the concentrations of toluene, NMHC, and PAHs in the flue gases by ∼1000%, ∼500%, and 200%, respectively, compared to the control experiment; however, their emission concentrations were within the limits set by the Integrated emission standards of air pollutants of Chongqing. It is worth noting that 26.443 ng/Nm³ PCDD/Fs with a total toxicity of 0.709 ng I-TEQ/Nm³ was generated from the co-processing 10% OBDC, which was ascribed to the high content of chlorine and aromatic hydrocarbons in the OBDC-promoted PCDD/Fs formed during the burning and cooling processes. Though PCDD/Fs in flue gas exceeded the 0.5 ng I-TEQ/Nm³ limit prescribed in the Pollution control standard for hazardous wastes incineration of China, the realistic emission of PCDD/Fs is expected to meet with this emission limit after desulfurization treatment as PCDD/Fs can be absorbed by gypsum. It is recommended that a lower amount of OBDC is added to reduce PCDD/F formation at the source and to take more efficient air pollution control system in order to reach a stricter emission limit of 0.1 ng I-TEQ/Nm³ in EU and USA. Cycling flue gas may also be an effective method to reduce other organic pollutants. Under these conditions, co-processing OBDC in brick kilns can be achieved without serious environmental pollution, making it a potential method for disposal and utilization.

Emission, dispersion, and potential risk of volatile organic and odorous compounds in the exhaust gas from two sludge thermal drying processes

Emissions of odorous and volatile organic compounds (VOCs) were investigated between two sludge drying methods. A total of 37 chemical compounds were identified and quantified from the off-gases from sludge drying by indirect drying method. The total number of VOCs detected ranged from 3.45 × 10^-3 to 4.53 mg/m³, which includes benzene series, volatile organic sulfur, and nitrogenous organic compounds. High emissions were found in the exhaust gas released from drying workshop that used direct drying method. Sulfur dioxide, aromatics, and chlorinated compounds were dominant. Based on the olfactory effect analysis and cancer risk assessment, the main odor-causing gaseous pollutants were methyl mercaptan and methyl sulfide (for indirect sludge drying process) and SO₂ (for direct sludge drying process), while the dominant carcinogens were benzene, carbon tetrachloride, chloroform, and methylene. This study provides new insights into the emission characteristics, olfactory effects, and cancer risks of VOCs and odorous compounds in the exhaust gas from thermal sludge drying processes.

Dual role of O2 concentration on the reducing gases produced and NO reduction during sewage sludge combustion in pilot scale cement precalciner

The reducing gases produced and NO reduction by sewage sludge combustion were investigated in a self-made cement precalciner. The dual role of O₂ concentration (0-5 vol%) in the production characteristics of reducing gases and the reduction efficiency of NO were evaluated experimentally. TG-FTIR analysis demonstrated that the key reducing gaseous species produced by sewage sludge combustion were HCN, NH₃, CO, and CH₄. And experiments demonstrated that O₂ concentration had pronounced effects on NH₃ distribution, the maximum production rate was obtained at an O₂ concentration of 3 vol%. Meanwhile, the reducing gases NH₃ and CO were the key species for NO reduction in the cement precalciner, and the reduction efficiency of NO, when reduced by NH₃, increased with an increase in O₂ concentration, while the reduction performance of NO by CO was limited by O₂ concentration. Therefore, O₂ concentration greatly influences NO reduction efficiency by sewage sludge combustion; the maximum NO reduction efficiency was 61.67% at an O₂ concentration of 3 vol%. The difference in NO reduction by sewage sludge combustion under different O₂ concentrations was primarily attributed to NH₃ production rate and NO reduction by NH₃ and CO, which is greatly affected by O₂ concentration. Sewage sludge combustion can result in NO reduction in the cement kiln flue gas and resource utilisation of sewage sludge.

Removal and transformation of unconventional air pollutants in flue gas in the cement kiln-end facilities

To understand the removal and transformation behaviors of unconventional air pollutants (polycyclic aromatic hydrocarbons, heavy metals and carbonyl compounds) in the flue gas in cement kiln-end facilities, including SP boiler, a slide stream SCR-DeNO_x system, raw mill and baghouse filter, the gas and particle matter samples at the inlets and outlets of each kiln-end installation were collected and the contents of the unconventional air pollutants were measured. The results showed that the concentrations of the polycyclic aromatic hydrocarbons (PAHs) in particulate and gas-phase, heavy metals in the particulate matter were 17.5 μg m^-3, 48.7 μg m^-3 and 3113.1 μg m^-3 at the inlet of the SP boiler, and decreased to 0.6 μg m^-3, 17.7 μg m^-3 and 39.7 μg m^-3, respectively, while the concentrations of carbonyl compounds in gas-phase increased from 1988.5 μg m^-3 to 2844.5 μg m^-3 after flue gas successively passed through the kiln-end facilities. The cooling of flue gas and the precipitation of coarse particulate matter in the SP boiler resulted in a significant decrease of PAHs concentration in both gas-phase and particulate-phase, as well as the heavy metal concentration in the particulate-phase, while the SP boiler hardly had any influence on the removal and transformation of carbonyl compounds. Grinding and heat exchange in the raw mill accelerated the volatilization of compounds with the low boiling point in the raw meal, which increased concentrations of gas-phase PAHs and carbonyl compounds. When flue gas passed through the baghouse filter, almost all particulate-phase PAHs, heavy metals and most of the gas-phase PAHs, were removed while the carbonyl compounds concentration maintained unchanged. Furthermore, some portion of gas-phase PAHs and carbonyl compounds were removed by the SCR-DeNO_x system.

Emission and migration of PCDD/Fs and major air pollutants from co-processing of sewage sludge in brick kiln

The annual output of sewage in China is increasing rapidly and continues to grow, so there is an urgent need for a treatment other than landfills. Among various treatment methods, brick production coprocessing of sewage sludge is technically and economically advantageous. The emission characteristics of typical brick kiln coprocessing of sewage sludge with an annual production of 60 million bricks were studied. The major air pollutants and PCDD/Fs in gas and soil were determined. Particulate matter and SO₂ contributed most before treatment, with concentrations of (1.017 ± 0.089) × 10⁴ mg/Nm³ and (2.770 ± 0.251) × 10³ mg/Nm³, respectively. After cleaning, the average emitted concentrations of major air pollutants were permissive and homogeneous: 58.13 ± 5.51 mg/Nm³ for NO_x, 30.15 ± 9.12 mg/Nm³ for HCl, 28.63 ± 14.33 mg/Nm³ for SO₂, 23.76 ± 3.31 mg/Nm³ for particulate matter, and 356.8 ± 99.1 for odor. The PCDD/Fs in the exhaust gas and ambient air showed similar distributions and fingerprint characteristics. The annual emission amounts of the PCDD/Fs were 0.265 g/year and 0.0393 g TEQ/year. Moreover, correlation analysis indicated that PCDD/Fs were most relevant to HCl, and particulate matter might be important to SO₂ and fluoride. Further relativity studies showed that the brick kiln was a source of PCDD/Fs but not a main source of major air pollutants to the surrounding environment. All the above pollutants from the brick kiln were permissive with relevant national standards. The results could help with pollution inventories for the brick and tile industry and sewage sludge disposal process.

A Framework for Sustainable Planning and Decision-Making on Resource Recovery from Wastewater: Showcase for São Paulo Megacity

Currently, it is important to develop strategic frameworks to support the selection of sustainable resource recovery solutions. This study applies a new framework for planning, implementation, and assessment of resource recovery strategies for a full-scale wastewater treatment plant (WWTP) in São Paulo megacity. The framework comprises several steps based on case study-specific data and information from current literature. Data were collected from various sources: a survey with a wastewater treatment utility, national and regional databases, and review of local regulations and international literature. Treatment configuration, wastewater and by-products composition, potential demand (for water, energy, and phosphorus), stakeholder identification, and local legislation were thoroughly discussed regarding decision-making on resource recovery. Scenario analysis was used to explore suitable nutrient and energy recovery measures based on indicators. Biogas recovery and sewage sludge composting showed more favorable conditions due to similar experiences in the area and robust legislation. The proposed framework is a simplified tool, and its application can support managers to get information on resource recovery and how to plan such initiatives in easier ways to facilitate wiser decision-making, and better operation and management. The results on framework use and refinement can guide potential applications in other contexts and stimulate public policy formulation and further research.

Simultaneous removal of bioaerosols, odors and volatile organic compounds from a wastewater treatment plant by a full-scale integrated reactor

Biological control of odors and bioaerosols in wastewater treatment plants (WWTPs) have gained more attention in recent years. The simultaneous removal of odors, volatile organic compounds (VOCs) and bioaerosols in each unit of a full-scale integrated-reactor (FIR) in a sludge dewatering room was investigated. The average removal efficiencies (REs) of odors, VOCs and bioaerosols were recorded as 98.5 %, 94.7 % and 86.4 %, respectively, at an inlet flow rate of 5760 m3/h. The RE of each unit decreased, and the activated carbon adsorption zone (AZ) played a more important role as the inlet flow rate increased. The REs of hydrophilic compounds were higher than those of hydrophobic compounds. For bioaerosols, roughly 35 % of airborne heterotrophic bacteria (HB) was removed in the low-pH zone (LPZ) while over 30 % of total fungi (TF) was removed in the neutral-pH zone (NPZ). Most bioaerosols removed by the biofilter (BF) had a particle size larger than 4.7 μm while bioaerosols with small particle size were apt to be adsorbed by AZ. The microbial community in the BF changed significantly at different units. Health risks were found to be associated with H2S rather than with bioaerosols at the FIR outlet.

Study on the influencing factors of removal of NOX from cement kiln flue gas by sewage sludge as a denitration agent

Experimental study on the influencing factors of using sewage sludge as a denitration agent for cement industry was carried out on a self-made laboratory-scale fluid-bed reactor. Results indicate that sludge combustion at 900 °C shows an ideal NO_X (the sum of NO and NO₂) removal activity under simulated working conditions of cement precalciner. The optimal removal efficiency of NO_X can reach 70.36 ± 3.59% in the presence of cement raw meal (CRM) at a sludge particle size range of 0.18-0.25 mm and the sludge dosage of 0.75 g/min. Besides, the NO_X removal efficiency increases to 76.94 ± 5.02% in the absence of CRM, indicating that cement raw meal inhibits the NO_X removal. This phenomenon may be attributed to the fact that CRM has promotion effect on NH₃ produced and obvious inhibitory effect on CO produced; while NH₃ and CO play a leading role in NO_X reduction, the combined effect leads to the decrease of NO_X removal. Moreover, the relationship between the composition of CRM on the inhibition of NO_X removal is MgO < CaCO₃ < CRM < Al₂O₃ <Fe₂O₃. Meanwhile, the effect of additive variety on the sludge denitration activity indicates that urea significantly promotes the NO_X removal, which is attributed to the decomposition of urea to form NH₃. The stability experiment shows that sludge denitration efficiency remains stable above 70% in the presence of CRM and can reach over 80% when adding appropriate urea. This method can realize the removal of NO_X in the cement kiln flue gas and the resource utilization of sludge. It is a promising method for sludge disposal.

Cement plant emissions and health effects in the general population: a systematic review

Adverse health effects of cement plant exposure have been found in occupational contexts but are less defined for the general population living near plants. We aimed to summarize the evidence on the health effects of people exposed to ambient air pollution by cement plants. A systematic review using Embase, PubMed and Web of Science was performed. We included only non-occupational studies with a comparison group that focused on adverse health outcomes and biomarkers of internal dose or subclinical effect associated with cement plant exposure. Selection of articles was performed by two authors independently. Of 1491 articles identified by the initial search, 24 were included: 17 of them were included in the analysis of adverse health outcomes and 9 in the analysis of biomarkers of internal dose or subclinical effects. The studies were very heterogeneous in study design, measure of cement plant exposure, outcome detection, measure of association and adjustment for confounding. Almost all the studies found positive associations between cement plant exposure and respiratory diseases and symptoms. An excess risk of cancer incidence and mortality in both children and adults mainly concerning respiratory tract cancers was also reported in some studies. Higher values of heavy metals and of a biomarker of renal toxicity were found in the exposed compared to unexposed populations. In conclusion, there is some evidence for a possible role of cement plant exposure on health adverse effects, although many studies had serious or critical risk of bias and overall level of certainty was low.

Mechanistic study on NO reduction by sludge reburning in a pilot scale cement precalciner with different CO2 concentrations

The reducing gases of CO and NH₃ produced by sludge reburning make a major contribution to NO reduction.

Sulfur dioxide and o-xylene co-treatment in biofilter: Performance, bacterial populations and bioaerosols emissions

Sulfur dioxide (SO₂) and benzene homologs are frequently present in the off-gas during the process of sewage sludge drying. A laboratory scale biofilter was set up to co-treat SO₂ and o-xylene in the present study. SO₂ and o-xylene could be removed simultaneously in a single biofilter. Their concentration ratio in the inlet stream influenced the removal efficiencies. It is worth noting that the removal of SO₂ could be enhanced when low concentrations of o-xylene were introduced into the biofilter. Pseudomonas sp., Paenibacillus sp., and Bacillus sp. were the main functional bacteria groups in the biofilter. Sulfur-oxidizing bacteria (SOB) and o-xylene-degrading bacteria (XB) thrived in the biofilter and their counts as well as their growth rate increased with the increase in amount of SO₂ and o-xylene supplied. The microbial populations differed in counts and species due to the properties and components of the compounds being treated in the biofilter. The presence of mixed substrates enhanced the diversity of the microbial population. During the treatment process, bioaerosols including potentially pathogenic bacteria, e.g., Acinetobacter lwoffii and Aeromonas sp., were emitted from the biofilter. Further investigation is needed to focus on the potential hazards caused by the bioaerosols emitted from waste gas treatment bioreactors.

Migration and transformation of sulfur in the municipal sewage sludge during disposal in cement kiln

The aim of this work was to investigate the migration and transformation of sulfur in the municipal sewage sludge during disposal in cement kiln, and better understand the emission of the sulfur related pollutants in this process. In consideration of the temperature conditions in the practical operation, municipal sewage sludge was pre-dried at 105 °C, and then dried at 210, 260 and 310 °C, co-combusted with cement raw mill at 800, 900 and 1000 °C, and 1350, 1400 and 1450 °C respectively in the laboratory. X-ray photoelectron spectroscopy (XPS) was used to determine the S2p spectral lines of the municipal sewage sludge treated in the different process. Besides, The Thermal Analysis-Thermogravimetry (DTA-TG), Back Scattered Electron (BSE) and Energy Dispersive Spectrometer (EDS) were also employed to explore the mechanism of sulfur subsistence at 1450 °C. The results indicate that sulfide, thiophene, sulfone and sulfate are mainly sulfur compound in the municipal sewage sludge dried at 105 °C. Sulfoxide, a new sulfur compound, appears after it is further dried at 210 °C. The relative contents of sulfide and thiophene are continuously declined as the drying temperature increases due to their evaporation, decomposition and transformation in this process. The transformation of sulfide and thiophene makes the relative contents of sulfoxide and sulfate accordingly increased. However, the relative content of sulfone experiences an elevating-lowering process while the dry temperature elevated from 210 to 310 °C. This case is related to its evaporation and decomposition, as well as its production for the transformation of sulfide and thiophene. In the co-combustion process, sulfide, thiophene and sulfone are entirely vanished for their evaporation, decomposition and transformation. Sulfone is still contained at 800 °C, but when the temperature unceasingly rises, it is completely decomposed or evaporated and sulfate is the only sulfur compound. The microstructures left by the gas release are also observed in the mixtures sintered at 1450 °C, however sulfate still exists even at 1450 °C. The BSE and EDS results show that the melt phase is the important contribution to the appearance of sulfate at the high temperature. These results will sever as a theoretically reference for the pollution control of the sulfur related pollutants in the disposal process of the municipal sewage sludge in cement kiln.

Effects of Co-Processing Sewage Sludge in the Cement Kiln on PAHs, Heavy Metals Emissions and the Surrounding Environment

To understand the effects of co-processing sewage sludge in the cement kiln on non-criterion pollutants emissions and its surrounding environment, the flue gas from a cement kiln stack, ambient air and soil from the background/downwind sites were collected in the cement plant. Polycyclic aromatic hydrocarbons (PAHs) and heavy metals of the samples were analyzed. The results show that PAHs in flue gas mainly exist in the gas phase and the low molecular weight PAHs are the predominant congener. The co-processing sewage sludge results in the increase in PAHs and heavy metals emissions, especially high molecular weight PAHs and low-volatile heavy metals such as Cd and Pb in the particle phase, while it does not change their compositions and distribution patterns significantly. The concentrations and their distributions of the PAHs and heavy metals between the emissions and ambient air have a positive correlation and the co-processing sewage sludge results in the increase of PAHs and heavy metals concentrations in the ambient air. The PAHs concentration level and their distribution in soil are proportional to those in the particle phase of flue gas, and the co-processing sewage sludge can accelerate the accumulation of the PAHs and heavy metals in the surrounding soil, especially high/middle molecular weight PAHs and low-volatile heavy metals.