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

Mobility and bio-accessibility of available phosphorus in sewage sludge: Influencing mechanism of hydrothermal pretreatment and incineration

Accurate assessment and enhancement of phosphorus (P) availability are critical for land application of sewage sludge and its thermal-treated products. By simulating different functioning pathways of P in soil, a novel multivariable scheme was developed to evaluate P availability from the perspective of mobility and bio-accessibility, then was applied to investigate the effects of hydrothermal pretreatment (HT), carbonaceous skeleton-assisted HT (CSkel-HT), and incineration on this topic. Sludge contained predominantly slow-release and microbial-available P (>50.0 % of total P). HT and incineration reduced available P through filtrate discharge, organic-P decomposition, and Fe/Al-P volatilization. Surprisingly, CSkel-HT addition promoted soluble Ca/MgHPO4 and thermal-stable Fe/AlPO4 formation under acidic conditions, which not only retained the slow-release and microbial-available P in hydrochar and ash, but also increased the rapid-available and plant-available P contents by 25.0 % and 300.0 %. Our scheme provided more informative insights than traditional single-index methods, and revealed the enhancing mechanism of CSkel-HT on P availability.

Intensified Enrichment and Leaching Strategy of Phosphorus in Sewage Sludge via Species-Targeted Conversion

Wet-chemical method for extracting phosphorus (P) from sludge incineration ash suffers from great P loss in the incineration and P-leaching stages due to the multidirectional migration of diversified P species. Existing single-process optimizations are difficult to meet the diverse and often conflicting needs of the two upstream and downstream processes to recover different P species. Herein, we developed a system-oriented strategy, HyperPhosⓅ, to synergistically address multiprocess requirements. It employs a specially designed one-pot pretreatment to create a unique reaction window for the most recoverable Fe/Al-P, achieving the targeted transformation of unstable P species into homogeneous Fe/Al-orthophosphate of 85.6% in proportion. These compounds exhibited remarkable thermal stability during incineration, with volatilization loss of only 60% of conventional technical route (Conv-Tech) even at 1000 °C. Subsequently, these parts of P were completely leached out using H2C2O4 or NaOH through redox reaction and chelating displacement, with the solvent concentration and the codissolution amounts of heavy metals less than half of the mean levels in the literature. Techno-economic analysis showed that HyperPhosⓅ obtained 1.1-2.4 times more P than Conv-Tech, while the unit cost was reduced by up to 49.5%. These findings provide new opportunities to close the P-cycle in a sustainable, economical, and environmentally friendly approach.

Enhanced phosphorus bioavailability and reduced water leachability in dairy manure through hydrothermal carbonization: effect of processing temperature and CaO additive

Dairy manure, a significant source of phosphorus (P), can potentially cause environmental risk due to P runoff when dairy manure is directly applied to cropland. Thus, there is an increasing interest in mitigating P loss from manure prior to land applications. This study aimed to investigate the potential of hydrochar produced by hydrothermal carbonization (HTC) for P recycling from dairy manure with and without the addition of CaO, focusing on the plant bioavailability, stabilization, and transformation of P in the resultant hydrochar. Hydrochar was prepared under different temperatures (180-240°C). The effect of CaO addition (0-10% of raw manure on dry wt. basis) was also evaluated at 220°C. Results showed that water-soluble P (WSP), a key indicator of P runoff loss, was significantly reduced in hydrochar, particularly with CaO addition. In addition, the plant available P in hydrochar increased with HTC temperature increase till 220°C, which accounted for ∼90% of total P content, then decreased with temperatures higher than 220°C. The addition of CaO slightly reduced plant bioavailability when compared to hydrochar produced at 220°C without additive. The P fractionation and speciation analyses indicated the transformation of P into Ca-associated apatite P. Hydrochar produced at 220°C with 10% CaO addition resulted in a high P recovery (∼85%) and a reduced runoff risk by 97%. The results demonstrate the efficacy of P recycling through hydrochar produced from dairy manure through HTC, which offers a sustainable approach to managing dairy waste while mitigating the potential environmental risks of P runoff.

Selective leaching and recovery of phosphorus from incinerated sewage sludge ash with CaO addition

Incinerated sewage sludge ash (ISSA) with high P2O5 content is a potential phosphorus resource that can replace the non-renewable phosphorus rocks. However, extracting phosphorus from ISSA using hydrometallurgical methods also dissolves a large amount of impurity metals into the leachate. Therefore, this study proposes a new method combining high-temperature reaction with CaO addition, selective leaching, and chemical precipitation for efficient and low-cost phosphorus recovery from ISSA. During thermal treatment at 1050 °C, the addition of CaO significantly influenced the types and amounts of phosphate mineral phases in ISSA. When 20 % CaO was added, the Al/Fe-phosphate phases were completely converted into acid-soluble Ca-phosphate phases, while Al and Fe were retained in acid-insoluble phases (e.g., Al- and Fe-containing oxides and silicates). Subsequently, by controlling the pH of acidic leachate (2.0 to 1.5), Ca-phosphate phases were selectively dissolved. At a pH of 1.5, better selective leaching was achieved, with a leaching efficiency of 94.71 % for P and less than 10 % for Al, Fe and Si. The XRF results showed that the majority of SiO2 (38.39 %), Al2O3 (33.26 %) remained in the post-leaching solid residue, which was expected to be further resource utilization. Without purification treatment to remove Al, Fe and Si, almost all phosphate ions were precipitated at pH = 8.5, with P recovery efficiency of 94.07 %. XRD results showed that the precipitate was mainly composed of HAP, with a P2O5 content of 37.51 % and low level of contaminants, thereby realizing the effective recovery of phosphorus from ISSA.

Combined effect of thermal hydrolysis process and low-temperature pyrolysis on the classification and bioavailability of phosphorus in sewage sludge

Existing phosphorus (P) resources are becoming increasingly scarce, so it is necessary to recover P from potential sources. This paper is based on thermal hydrolysis process (THP) at 140-180 °C, coupled with low-temperature pyrolysis at 300 °C, to study its effect on the recovery and conversion of P from sewage sludge. Most significant change was observed in apatite P, which increased from 3.43 ± 0.48 mg/g in raw sludge to 30.17 ± 1.17 mg/g in biochar (BTHP-180-4-300) during optimal process (THP condition: 180 °C, 4 h; pyrolysis condition: 300 °C). Reactions between phosphates and metal ions became more complete during this combined process. Unstable forms of P were converted into more stable forms, with transformations from Al-P and Fe-P toward Ca-P compounds like Ca3(PO4)2, Ca3Mg3(PO4)4, Ca2P2O7, and Ca(H2PO4)2, making P less degradable and more suitable as slow-release fertilizers. Additionally, P characteristics of actual THP in a sewage treatment plant were similar to those of laboratory THP.

Practical strategies of phosphorus reclamation from sewage sludge after different thermal processing: Insights into phosphorus transformation

In the context of circular economy and global shortage of phosphorus (P) fertilizer production, it is crucial to effectively recover P during the treatment and disposal of sewage sludge (SS). Although thermal treatment of SS has been widely applied, a targeted P reclamation route is not yet well established. This study has comprehensively investigated and compared the physicochemical properties of SS and solid residues (hydrochar (HC), biochar (BC), sewage sludge ash (SSA), hydrochar ash (HCA), and biochar ash (BCA)) after application of three typical thermal treatment techniques (i.e., hydrothermal carbonization (180‒240 °C), pyrolysis (400‒600 °C) and combustion (850 ℃). P speciation and transformation during thermal processes were extensively explored followed by a rational proposal of effective P reclamation routes. Specifically, thermal processing decomposed organic P and converted non-apatite P to apatite P. Orthophosphate-P was found to be the main species in all samples. Physicochemical properties of the resulting thermal-derived products were significantly affected by the thermal techniques applied, thereby determining their feasibility for different P reclamation purposes. In particular, ash is not recommended for agricultural use due to higher harmful metals content, while acid leaching can be an alternative solution to synthesize non-Fe-containing P products because of the lower co-dissolved Fe content in the leachate. HC and BC offer the option for synthesis of Fe containing products. Eventually, HC and BC demonstrate great potential for agriculture application, however, a comprehensive risk assessment should be conducted before their real-world applications.

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.