Production of technical grade phosphoric acid from incinerator sewage sludge ash (ISSA)

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.

Ashes from challenging fuels in the circular economy

In line with the objectives of the circular economy, the conversion of waste streams to useful and valuable side streams is a central goal. Ash represents one of the main industrial side-products, and using ashes in other than the present landfilling applications is, therefore, a high priority. This paper reviews the properties and utilization of ashes of different biomass power plants and waste incinerations, with a focus on the past decade. Possibilities for ash utilization are of uttermost importance in terms of circular economy and disposal of landfills. However, considering its applicability, ash originating from the heat treatment of chemically complex fuels, such as biomass and waste poses several challenges such as high heavy metal content and the presence of toxic and/or corrosive species. Furthermore, the physical properties of the ash might limit its usability. Nevertheless, numerous studies addressing the utilization possibilities of challenging ash in various applications have been carried out over the past decade. This review, with over 300 references, surveys the field of research, focusing on the utilization of biomass and municipal solid waste (MSW) ashes. Also, metal and phosphorus recovery from different ashes is addressed. It can be concluded that the key beneficial properties of the ash types addressed in this review are based on their i) alkaline nature suitable for neutralization reactions, ii) high adsorption capabilities to be used in CO2 capture and waste treatment, and iii) large surface area and appropriate chemical composition for the catalyst industry. Especially, ashes rich in Al2O3 and SiO2 have proven to be promising alternative catalysts in various industrial processes and as precursors for synthetic zeolites.

Molecular transformation pathway and bioavailability of organic phosphorus in sewage sludge under vermicomposting

Phosphorus reclamation from sewage sludge is essential for sustainable phosphorus management, as large quantities of phosphorus afflux into wastewater treatment plants and are finally enriched in sewage sludge via phosphorus removal technologies. Meanwhile, vermicomposting is a cost-effective biotechnique for sludge stabilization. This work unveiled the molecular transformation pathway and bioavailability of organic phosphorus (OP) in sludge under vermicomposting with solution 31P NMR, FT-ICR MS and enzymatic hydrolysis assay. In conclusion, vermicomposting transformed OP in two stages. In stage I (day 0 to 14), macromolecule CHONP such as phospholipids, phosphoproteins and nucleic acid were decomposed into orthophosphate and high bioavailability OP including flavin mononucleotide, flavin mononucleotide hydrate and N6-isopentenyladenosine 5'-monophosphate under the action of earthworm intestinal flora. This resulted in the bioavailability of OP reaching a maximum of 13.58 mg/L on day 14. In stage II (day 14 to 28), the enzyme in vermicompost began to dominate the transformation of OP. Under the catalysis of phosphate, high bioavailability orthophosphate monoester was decomposed into orthophosphate. Nitrogen-containing aromatic OP polymerization produced humic acid-like OP under the catalysis of ligase. And phytic acid-like OP were produced under the catalysis of transferase. These led to the OP bioavailability decreasing to 5.60 mg/L on day 28. This work provides a new perspective on sludge phosphorus recovery and use.

Phosphate recovery from sludge-incinerated ash by adsorption with hydrotalcite synthesized by metals in the ash

Selective adsorption of phosphorus (P) from the acidic leachate of sludge-incinerated ash (SIA) becomes more attractive due to avoiding removing heavy metals. Especially, layered double hydroxides (LDHs) as an anion adsorbent could be applied into this area owing to their good capacity on P-adsorption and low cost on preparation. Interestingly, SIA contains more aluminum (Al) and iron (Fe) needed to be removed prior to P-recovery, and removed Al and Fe could be utilized to synthesize LDHs, like Mg/Al-LDH and Mg/Fe-LDH. With this study, Mg/Al-LDH-r and Mg/Fe-LDH-r were economically synthesized with Al and Fe removed from SIA, which were similar in their chemical structures to commercial LDHs. The synthesized LDHs had a high P-adsorption capacity, up to 95.0%. The maximal phosphate capacity of the recovered LDHs (Mg/Al-LDH-r and Mg/Fe-LDH-r) was 239.0 and 199.8 mg P/g LDHs, respectively. "NaOH + desalinated brine" as a new desorption solution could achieve a desorption ratio at about 80%, which could reduce the liquid-solid ratio by at least 60%, greatly decreasing the desorption cost. Pot trials demonstrated that the desorbed and precipitated CaP could promote the growth of maize as well as a commercial P-fertilizer. Furthermore, the adsorbed phosphate by LDHs could be directly used as a slow-released P-fertilizer and also improve the pH value of acidic soil, completely deleting the desorption process.

Recovery of Phosphorus and Metals from the Ash of Sewage Sludge, Municipal Solid Waste, or Wood Biomass: A Review and Proposals for Further Use

This review provides an overview of methods to extract valuable resources from the ash fractions of sewage sludge, municipal solid waste, and wood biomass combustion. The resources addressed here include critical raw materials, such as phosphorus, base and precious metals, and rare earth elements for which it is increasingly important to tap into secondary sources in addition to the mining of primary raw materials. The extraction technologies prioritized in this review are based on recycled acids or excess renewable energy to achieve an optimum environmental profile for the extracted resources and provide benefits in the form of local industrial symbioses. The extraction methods cover all scarce and valuable chemical elements contained in the ashes above certain concentration limits. Another important part of this review is defining potential applications for the mineral residues remaining after extraction. Therefore, the aim of this review is to combine the knowledge of resource extraction technology from ashes with possible applications of mineral residues in construction and related sectors to fully close material cycle loops.

Phosphorus recovery from sewage sludge ash (SSA): An integrated technical, environmental and economic assessment of wet-chemical and thermochemical methods

Incineration is a promising disposal method for sewage sludge (SS), enriching more than 90% of phosphorus (P) in the influent into the powdered product, sewage sludge ash (SSA), which is convenient for further P recovery. Due to insufficient bioavailable P and enriched heavy metals (HMs) in SSA, it is limited to be used directly as fertilizer. Hence, this paper provides an overview of P transformation in SS incineration, characterization of SSA components, and wet-chemical and thermochemical processes for P recovery with a comprehensive technical, economic, and environmental assessment. P extraction and purification is an important technical step to achieve P recovery from SSA, where the key to all technologies is how to achieve efficient separation of P and HMs at a low economic and environmental cost. It can be clear seen from the review that the economics of P recovery from SSA are often weak due to many factors. For example, the cost of wet-chemical methods is approximately 5∼6 €/kg P, while the cost of recovering P by thermochemical methods is about 2∼3 €/kg P, which is slightly higher than the current P fertilizer (1 €/kg P). So, for now, legislation is significant for promoting P recovery from SSA. In this regard, the relevant experience in Europe is worth learning from countries that have not yet carried out P recovery from SSA, and to develop appropriate policies and legislation according to their own national conditions.

The Utilization of Recycled Sewage Sludge Ash as a Supplementary Cementitious Material in Mortar: A Review

The output of sewage sludge has been increasing in recent years in China. Traditional treatment methods, such as incineration and landfilling, cannot meet the requirement of sustainability in various industries. As one of the efficient recycling methods for sewage sludge, previous studies have proven that sewage sludge ash (SSA) can be used as a supplementary cementitious material to partly replace cement in mortar or concrete. To understand the performance of SSA comprehensively, which contributes to its better utilization, this study reviews the basic properties of SSA and the effect of SSA on the performance of mortar. Firstly, the basic properties of SSA, such as chemical composition, heavy metal content, activity, and microstructure, are investigated. Then, the effects of SSA on the workability, setting time, and mechanical properties of mortar are reviewed. The results show that the particle size distribution of SSA is in the range of 2.5–250 μm. SSA contains active oxides such as SiO2, Al2O3, Fe2O3, and CaO, which are similar to fly ash, indicating that SSA has potential pozzolanic properties. The leaching concentration of SSA is much lower than the required values in the relevant specifications, leading to an allowable environment influence. The incorporation of SSA has a negative impact on the workability, setting time, water absorption, compressive strength, and flexural strength of the mortar. The 90-day compressive strength of the SSA mortar is 71.72–98.6% of the cement mortar, when the replacement ratio of SSA is in the range of 10–30%. However, performance can be improved by increasing the grinding time or adding an admixture. The drying shrinkage and capillary water absorption of SSA mortar are higher than those of normal mortar, which is mainly related to an increase of porosity. In conclusion, it is proven that SSA can be used to partly replace cement in mortar with appropriate properties. Source and production process have a great influence on the basic properties of SSA, leading to varied, even opposite, effects on the mechanical properties and durability of mortar. In the future, the selected raw materials and a standard preparation method should be proposed for promoting the application of SSA.

A review on the integration of mainstream P-recovery strategies with enhanced biological phosphorus removal

Phosphorus (P), an essential nutrient for all organisms, urgently needs to be recovered due to the increasing demand and scarcity of this natural resource. Recovering P from wastewater is a feasible and promising way widely studied nowadays due to the need to remove P in wastewater treatment plants (WWTPs). When enhanced biological P removal (EBPR) is implemented, an innovative option is to recover P from the supernatant streams obtained in the mainstream water line, and then combine it with liquor-crystallisation recovery processes, being the final recovered product struvite, vivianite or hydroxyapatite. The basic idea of these mainstream P-recovery strategies is to take advantage of the ability of polyphosphate accumulating organisms (PAO) to increase P concentration under anaerobic conditions when some carbon source is available. This work shows the mainstream P-recovery technologies reported so far, both in continuous and sequenced batch reactors (SBR) based configurations. The amount of extraction, as a key parameter to balance the recovery efficiency and the maintenance of the EBPR of the system, should be the first design criterion. The maximum value of P-recovery efficiency for long-term operation with an adequate extraction ratio would be around 60%. Other relevant factors (e.g. COD/P ratio of the influent, need for an additional carbon source) and operational parameters (e.g. aeration, SRT, HRT) are also reported and discussed.

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.

Purification of recovered phosphoric acid by extracting aluminium with di-2-ethylhexyl phosphoric acid

The extraction of aluminium from dilute phosphoric acid with di-2-ethylhexyl phosphoric acid (DEHPA) was optimized using response surface methodology. The optimization was based on the experimental three-level central composite face-centred design (CCF) and was conducted on real-life samples. The three variables included were pH, extractant concentration and aqueous to organic phase ratio (AO). Under the optimized conditions (pH 2.5, 0.6 M DEHPA and AO ratio 1:2), extraction efficiency of 99% for aluminium in four extraction stages is achieved. The purified phosphoric acid solution can then be utilized by the fertilizing industry. Stripping tests for organic phase loaded with aluminium were conducted with sulphuric acid. Extremely high stripping efficiency was obtained with 0.9 M sulphuric acid resulting in the recovery rate of 88% in one stage. After stripping, the aluminium sulphate solution can be reused as a precipitation agent for phosphorus in the wastewater treatment process.

Assessment of a simple and replicable procedure for selective phosphorus recovery from sewage sludge ashes by wet chemical extraction and precipitation

The selective phosphorus recovery by wet chemical extraction and precipitation was assessed at the laboratory scale aiming at identifying a simple and replicable procedure that could be effectively applied to different types of sewage sludge ashes. The experimental work was performed on five samples of sewage sludge ashes, of which three were obtained from muffle-furnace incineration and two from full-scale mono-incineration plants. A single-step extraction procedure has been investigated by applying different operating conditions (type of leaching acid, liquid-to-solid ratio, contact time). Experimental results indicated that phosphorus recovery efficiency varied between 54 and 92% with limited co-dissolution of metals and metalloids, except for arsenic. Operating conditions, sewage sludge ashes characteristics and phosphorus removal processes in the wastewater treatment plant were the main factors affecting phosphorus recovery efficiency. The application of optimal operating conditions (0.2 M sulfuric acid, liquid-to-solid ratio of 20 and contact time of 2 h) resulted in phosphorus recovery from 76 to 92% on four samples. Subsequently, precipitation of phosphorus from acidic leachate was carried out by lime dosing. After filtering and drying, the recovered products presented a P₂O₅ content between 11.5 and 36.7% dry weight, with a fraction of soluble phosphorus between 75 and 91%, a good percentage for application as fertilizer or animal feed. Since few undesired elements (i.e., As, Cu and Zn) exceeded the limits for fertilizer application (exception was represented by Ni and Pb, which were present at low concentration), an additional purification step may be required. Overall, experimental results highlighted the influence of process parameters on phosphorus recovery.

Assessment of Ecotoxicity of Incinerated Sewage Sludge Ash (ISSA)

Combustion in fluidised bed boilers is one of the most commonly used methods of treatment of municipal sewage sludge. Fly ash (FA) and air pollution control (APC) residues are the solid by-products generated by flue gas treatment. There are significant differences in the chemical composition of these wastes. FA is composed of mainly SiO2, P2O5, CaO and metals such as Zn, Ti, Cu, Cr, Pb and Ni. APC residues mainly contain SO3 and Na2O. The leachability tests that were carried out indicate that these wastes display very low leachability of heavy metals (for example leachability of Pb was equal 0.0004 mg·dm−3 in both wastes, leachability of Cd was equal 0.0012 mg·dm−3 in FA an 0.00004 mg·dm−3 in APC). On the other hand, very high sulphate concentrations (49,375 mg·dm−3) were found in water extract for the APC residues. In order to determine the toxicity of these wastes for plants, pot experiments with different additions of waste to the soil were carried out (on Lepidium sativum and Sinapis alba). Tests based on seeds germinations (on Lepidium sativum) in water extracts from waste (in different concentrations) were also performed. The results obtained indicate the very high toxicity of APC residues. Complete inhibition of germination and growth of the test plants was found for all concentrations of the tested waste in water extract and for all additions of waste to the soil in pot experiments. Seed germination tests on water extracts from FA did not show any toxicity of this waste. Pot tests with FA showed their toxicity only with a high (30%) addition in soil.

Phosphorus Recovery from Sewage Sludge Using Acidithiobacilli

Sewage sludge contains a significant amount of phosphorus (P), which could be recycled to address the global demand for this non-renewable, important plant nutrient. The P in sludge can be solubilized and recovered so that it can be recycled when needed. This study investigated the P solubilization from sewage sludge using Acidithiobacillus thiooxidans and Acidithiobacillus ferrooxidans. The experiment was conducted by mixing 10 mL of sewage sludge with 90 mL of different water/liquid medium/inoculum and incubated at 30 °C. The experiment was conducted in three semi-continuous phases by replacing 10% of the mixed incubated medium with fresh sewage sludge. In addition, 10 g/L elemental sulfur (S) was supplemented into the medium in the third phase. The pH of the A. thiooxidans and A. ferrooxidans treated sludge solutions was between 2.2 and 6.3 until day 42. In phase 3, after supplementing with S, the pH of A. thiooxidans treated sludge was reduced to 0.9, which solubilized and extracted 92% of P. We found that acidithiobacilli supplemented with S can be used to treat sludge, i.e., achieve hygienization, removal of heavy metals, and solubilization and recovery of P.

Extraction and Purification of Phosphorus from the Ashes of Incinerated Biological Sewage Sludge

Phosphorus depletion represents a significant problem. Ash of incinerated biological sewage sludge (BSS) contains P, but the presence of heavy metals (e.g., Fe and Al) is the main issue. Based on chemical characterization by SEM-EDS, ED-XRF and ICP-OES techniques, the characteristics and P content of bottom ash (BA) and fly ash (FA) of incinerated BSS were very similar. On BA, P extraction carried out in counter- current with an S:L ratio of 1:10 and H2SO4 0.5 M led to better extraction yields than those of a similar test with H2SO4 1 M and an S:L ratio of 1:5 (93% vs. 86%). Comparing yields with H2SO4 0.5 M (S:L ratio of 1:10), the counter-current method gave better results than those of the crossflow method (93% vs. 83.9%), also improving the performance obtained with HCl in crossflow (93% vs. 89.3%). The results suggest that the purification of the acid extract from heavy metals with pH variation was impractical due to metal precipitation as phosphates. Extraction with H2SO4 and subsequent treatment with isoamyl alcohol represented the best option to extract and purify P, leading to 81% extraction yields of P with low amounts of metals.

Alkaline modification of the acid residue of incinerated sewage sludge ash after phosphorus recovery for heavy metal removal from aqueous solutions

Enriched in phosphorus, sewage sludge ash has been extensively studied and applied as a secondary source for phosphorus recovery. Wet extraction, especially acid washing, is one of the most feasible methods to recover phosphorus from the ash due to its ease of operation, high efficiency and low cost. However, the management of the resultant acid residue was seldom addressed. In this study, special focus was paid to the reuse and recycling of the acid residue by an alkaline activation method. Its adsorption performance towards four different heavy metals in aqueous solutions was evaluated by batch and fixed-bed column adsorption experiments. The obtained material showed a high BET specific area (98.29 m²/g) and a total pore volume (0.114 cm³/g), and effectively removed Cd(II), Cu(II), Pb(II) and Zn(II) from aqueous solutions with the maximum adsorption capacity of around 26.8, 22.2, 53.3 and 13.5 mg/g respectively. It could be loaded in a fixed-bed column to continuously remove heavy metals especially for Pb(II). The proposed method to recycle the acid residue makes the wet extraction methods designing to recover phosphorus from incinerated sewage sludge complete without the generation of waste, which contributes to circular economy and a sustainable future.

To incinerate or not? - Effects of incineration on the concentrations of heavy metals and leaching efficiency of post-precipitated sewage sludge (RAVITA™)

The major element and heavy metal concentrations of post-precipitated sewage sludge (PPS) and its ash residue (PPA) were determined using microwave digestion followed by inductively coupled plasma optical emission spectrometry (ICP-OES) and mass spectrometry (ICP-MS). To the best of our knowledge, this has not been previously done. In both PPS and PPA the heavy metal concentrations were clearly below the average concentrations than those encountered in sewage sludge in Europe. The leaching efficiency of the metal (Al/ Fe) used as a precipitation agent from post-precipitated sludge and its ash residue with phosphoric acid was also investigated with previously optimized leaching conditions. Tests resulted in leaching efficiencies for Al of 85 ± 1% and 99.5 ± 0.7% for PPS and PPA, respectively which were produced with aluminum as precipitation agent for phosphorus. Sludge, which was produced using iron as a precipitation agent, had a leaching efficiency of Fe 36.6 ± 0.9% and 68.0 ± 1.1%, for PPS and PPA, respectively. The leaching efficiency for P was 94 ± 3% and 96 ± 5% for Al-PPA and Fe-PPA, respectively.

The Ecological Risk Assessment and the Chemical Speciation of Heavy Metals in Ash after the Incineration of Municipal Sewage Sludge

Popular incineration of sewage sludge results in the increase in heavy metals content in ash. The knowledge of the total content of heavy metals in sewage sludge ash does not demonstrate a potential hazard. The toxicity of heavy metals in great measure depends on the form of their occurrence. The prevailing norms do not require the ecological risk assessment of the environmental burden with heavy metals for the choice of the method of the utilization of sewage sludge ash. The paper presents the research results on the mobility of heavy metals in sewage sludge ash after its incineration. The geo-accumulation index (IGAI), the potential ecological risk index (PERI) and the risk assessment code (RAC) were used for the evaluation of the potential soil contamination with heavy metals. The authors also suggested a new formula, which took into consideration more factors influencing the risk of the contamination of a water-soil environment with heavy metals—the water and soil environment risk index (WSERI). The calculated indices for sewage sludge ash indicate the risk of soil contamination with heavy metals.

Closing the phosphorus cycle: Multi-criteria techno-economic optimization of phosphorus extraction from wastewater treatment sludge ash

The presence of heavy metals in concentrations above legal limit values is one of the main obstacles preventing closure of the phosphorus (P) cycle through directly applying wastewater treatment sludge ash as a fertilizer. Therefore, an alternative procedure is proposed to recover the valuable P from the sludge ash via wet chemical extraction. This comprehensive study uses several inorganic and organic acids, chelating agents and an alkaline solution to establish optimal and cost-effective conditions for wet P extraction from sludge ash. The optimization takes into account co-extraction of the following heavy metals: Cd, Cr, Cu, Ni, Pb and Zn. Design of experiments results show extraction liquid concentration, liquid/solid ratio and contact time all affect P and heavy metal extraction efficiency, both individually and through interaction. In addition, type of extraction liquid and pH at the end of the extraction procedure also affect P and heavy metal extraction efficiency. Combining results of XRD and SEM-EDX analysis with extraction data shows that at a pH <2, both Ca- and Al-phosphates in the ash dissolve easily. However, at slightly higher pH only Ca-phosphates dissolve well and at alkaline pH only Al-phosphates. The best trade-off between high P extraction, low heavy metal co-extraction and low operational costs is obtained with H₂SO₄ (0.5 N, 10 ml/g, 120 min) and oxalic acid (0.5 N, 12.8 ml/g, 120 min). H₂SO₄ outperforms the other extraction liquids in terms of extraction liquid costs per kg P extracted, whereas extraction with oxalic acid results in the lowest heavy metal co-extraction, thus reducing the downstream processing costs. None of the extraction liquids considered is appropriate for heavy metal removal prior to P extraction due to loss of P and insufficient heavy metal removal.

Understanding the mobility of potential nutrients in rock mining by-products: An opportunity for more sustainable agriculture and mining

The increase in demand for highly soluble fertilizers brings a global sustainability concern. Alternative sources for traditional fertilization are therefore needed. Rock powder use has been proposed as an alternative approach to soil remineralization. However, research on the agricultural potential of minerals and rocks as alternative sources of nutrients is limited to changes in soil chemical attributes or effects on crop yield. In this work, we report an experimental study addressing the dissolution of two silicate rock-derived powders (andesite and dacite) that were produced during mining activities in Southern Brazil. The rock powders were exposed to Milli-Q water at pH (7.4-8.8) range, in solutions of 0.1 mol L^-1 citric acid at pH range 2.1-3.3, and Milli-Q water acidified with 0.5 mol l^-1 acetic acid (pH 5-5.8), in a continuous mechanical rotatory shaker at room temperature. Dissolution kinetics were determined as a function of reaction times at 24 to 5760 h, and solution pH. Based on this kinetics, dissolution rates were determined for the individual powders and compared to expected values for aluminosilicates. Based on this comparison, it was shown that the application of andesite and dacite rock-derived powder to replace high soluble fertilizers is feasible due to high dissolution rates of their minerals. The average andesite dissolution rates in Milli-Q water, in citric acid solution, and in Milli-Q water acidified with acetic acid were 2.1 × 10^-5, 1.92 × 10^-1 and 6.3 × 10^-4 mmol cm^-2 s^-1, respectively for Ca, being 183%, 22.6%, and 69.2% higher than for the dacite rock. This make andesite rock a potential substitute for carbonate-based liming. In contrast, the average dacite dissolution rates in Milli-Q water, in citric acid solution, and in Milli-Q water acidified with acetic acid were 1.05 × 10-5, 7.22 × 10^-5, and 3.72 × 10^-5 mmol cm^-2 s^-1, respectively for K, being 72.0%, 61.4%, and 73.6% higher than the andesite rock. This highlights its potential use as a K source for agriculture to replace highly soluble K-fertilizers.

Recycling of iron and titanium resources from early tailings: From fundamental work to industrial application

The comprehensive recovery of iron and titanium resources from early tailings were systematically attempted from fundamental work to industrial application. Geochemical characterization of the tailings was first conducted, followed by the iron recovery and titanium recovery. Iron recovery was mainly achieved through a series of magnetic separation, and titanium recovery was on the combination of magnetic pre-concentration and flotation separation. Special for titanium recovery, different pretreatment methods including ultrasonic cleaning and attrition-scrubbing were studied to reduce the influence of serious surface pollution of early tailings on ilmenite floatability, and attrition-scrubbing proved to be the best one. Associated mechanisms of flocculants influence on ilmenite floatability and the attrition-scrubbing effects were explored using micro-flotation and XPS tests. After a series of fundamental studies, the industrial production of iron and ilmenite concentrate went into operation and the industrial debugging results were roughly satisfactory. At last, a brief economic analysis was given for the present work.

Feedstock-Dependent Phosphate Recovery in a Pilot-Scale Hydrothermal Liquefaction Bio-Crude Production

Microalgae (Spirulina) and primary sewage sludge are considerable feedstocks for future fuel-producing biorefinery. These feedstocks have either a high fuel production potential (algae) or a particularly high appearance as waste (sludge). Both feedstocks bring high loads of nutrients (P, N) that must be addressed in sound biorefinery concepts that primarily target specific hydrocarbons, such as liquid fuels. Hydrothermal liquefaction (HTL), which produces bio-crude oil that is ready for catalytic upgrading (e.g., for jet fuel), is a useful starting point for such an approach. As technology advances from small-scale batches to pilot-scale continuous operations, the aspect of nutrient recovery must be reconsidered. This research presents a full analysis of relevant nutrient flows between the product phases of HTL for the two aforementioned feedstocks on the basis of pilot-scale data. From a partial experimentally derived mass balance, initial strategies for recovering the most relevant nutrients (P, N) were developed and proofed in laboratory-scale. The experimental and theoretical data from the pilot and laboratory scales are combined to present the proof of concept and provide the first mass balances of an HTL-based biorefinery modular operation for producing fertilizer (struvite) as a value-added product.

A comparison between sulfuric acid and oxalic acid leaching with subsequent purification and precipitation for phosphorus recovery from sewage sludge incineration ash

Wet chemical approach is widely applied for P extraction from incinerated sewage sludge ash (ISSA) due to the relatively simple process and low lost. In this study, H₂SO₄ and H₂C₂O₄ were compared to recover P from ISSA through three steps of acid leaching, cation exchange resin (CER) purification and precipitation. Transformations of P speciation and mineral phases in ISSA from 600 to 900 °C were studied. The results showed that the ISSA samples were mainly composed of inorganic P (IP), and part of non-apatite IP (NAIP, mainly AlPO₄) would transform to apatite P (AP, Ca₃(PO₄)₂) with the increase in temperature. The ratio of NAIP to IP dropped from 71.9% at 600 °C to 53.7% at 900 °C. Effect of acid concentration on the leaching efficiency of P from the ISSA samples incinerated at different temperatures by H₂SO₄ and H₂C₂O₄ was investigated, and the leaching behaviors of key elements of P, Ca, Al and Fe were compared. H₂C₂O₄ exhibited a better performance than H₂SO₄ for the leaching efficiency of P. Severe sintering of ash particles occurred at temperature >800 °C inhibited the P leaching by H₂SO₄. During CER purification, the impurity elements in the H₂SO₄ leachate were easily removed by CER, whereas the Al and Fe elements in the H₂C₂O₄ leachate were hardly removed due to the formation of anionic complexes between Al³⁺/Fe³⁺ and oxalic ions. Finally, high-purity struvite product was synthesized from the purified H₂SO₄ leachate, which could be directly utilized as a fertilizer with negligible environmental risk. Amorphous aluminum and iron hydroxyphosphates were obtained from the H₂C₂O₄ leachate. This study provides insights for P recovery from ISSA samples by different acid leaching systems.

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

Phosphorus (P) is an essential nutrient for all organisms, and the recovery of P from sewage sludge (SS) has been the focus of recent research. The effect of temperature and chlorine-based additives (MgCl₂ and CaCl₂) on P recovery and heavy metal (Cu, Zn, and Cr) removal during SS incineration were investigated. The results showed that temperature and chlorine-based additives increased the P fixation and improved the P-bioavailability. The fixation rate of P reached a maximum of 98.5% in SS using 3% Mg (MgCl₂) at 900 °C and 97.8% in SS using 5%Ca (CaCl₂) at 800 °C. Additionally, the mechanism of P associated with aluminum oxides/hydroxides (Al-P) transferring to that of magnesium oxides/hydroxides (Mg-P) and calcium oxides/hydroxides (Ca-P) was also investigated. The results indicated that Mg₃(PO₄)₂ was formed via the reaction between AlPO₄ and MgCl₂ during incineration, which increased the P solubility in 2% citric acid. When AlPO₄ was incinerated with CaCl₂, Ca₂PO₄Cl which has a higher P-bioavailability than AlPO₄ was formed. In addition, the mass fraction and leaching concentration of Cu and Zn in treated SS greatly decreased during SS incineration, while no reduction in Cr. These findings suggest that chlorine-based additives can be used to treat SS at high temperatures to obtain an ideal material for P-fertilizer production.

Recovery of phosphate as struvite from low-temperature combustion sewage sludge ash (LTCA) by cation exchange

As a phosphorus-rich material, low-temperature combustion sewage sludge ash (LTCA) contains over 9 wt% content of phosphorus (P) and a large proportion of impurities, especially the content of Fe arrives at 14.59 wt%. To fully utilize LTCA as a fertilizer, this study investigated a procedure for P recovery from LTCA via struvite crystallization with fewer impurities. The adsorption characteristics of P and Fe by cation exchange resin (CER) were explored by simulating using the macroscopic parametric equation Thomas model. Optimum purification conditions for P-rich leachate by cation exchange column method were determined. Results showed that approximately 97.21 wt% of P was extracted from LTCA at HCl concentration of 0.8 M and liquid/solid ratio of 20.0 ml/g. More than 90 wt% of impurities could be detached by making P-rich leachate flow through cation exchange bed filled by CER at 300 ml/h. The macroscopic parametric equation Thomas model could clearly describe the adsorption characteristics of Fe in P-rich leachate by CER. Theoretical basis for purification of high concentration Fe in P-rich leachate by CER was provided. Approximately 84.04 wt% of total P in LTCA was recovered as struvite crystal which had low concentrations of heavy metals (5.96 mg/kg for Cr, 45.21 mg/kg for Cu, 29.67 mg/kg for Ni, 2.24 mg/kg for Pb, and 290.6 mg/kg for Zn) and could be eco-friendly for agricultural application. X-ray diffraction and SEM-EDS analysis validated the formation of struvite.

Kinetics and capacity of phosphorus extraction from solid residues obtained from wet air oxidation of sewage sludge

Solid residues from thermal treatments of sewage sludge (SS) represent a valuable source of phosphorus (P) for the fertilizer production. This study aims at evaluating the P recovery potential from solid residues obtained from wet air oxidation of SS under subcritical water conditions (WAO residues). A series of P extraction experiments was performed by acidic and alkaline leaching at different liquid to solid ratios. Hot chemical extractions and P fractionations were also carried out to characterize the chemical composition of the WAO residues. The main objectives of this work were to determine the best operating conditions for P extraction, and to describe and understand the kinetics and the main mechanisms leading to P release. The results obtained in this study indicate that 1 M citric acid and 1 M HCl at the liquid to solid ratio of 10 L/kg can extract 61% and 65% of the total P content after 2 h of contact time at room temperature, thus giving P extraction capacities of 81 and 86 g P/kg WAO residues, respectively. The analysis of kinetic data indicates that P extraction with 1 M HCl is faster, but 1 M citric acid can give higher P extraction efficiencies at the equilibrium. The molar ratios of Ca to P of the leachates suggest that P extraction from WAO residues was primarily due to the dissolution of a mixture of various Ca-P complexes.

Optimizing the H3PO4 leaching conditions of post-precipitated sewage sludge using response surface methodology

The leaching procedure of post-precipitated aluminium phosphate sludge with dilute phosphoric acid was developed. The leaching offers a route to recover both critical phosphorous from sewage sludge and the metal used in precipitation. Using phosphoric acid as leaching solution makes it possible to continue the recovery process without the need to remove chloride or sulfate anions. The optimization of the leaching was based on experimental three-level-four-variable central composite face-centered design. The four variables included were acid concentration, volume of acid, temperature and time of leaching. The leaching was conducted for dewatered and water-containing sludge (total solid content 3-4%) and for both second-order regression models were obtained. For water-containing sludge optimal conditions for leaching are solid to liquid ratio (S/L) 400 gL^-1, a temperature of 60 °C and a leaching time of 6 h. For the dewatered sludge, optimal leaching is attained when S/L ratio 119 gL^-1 with 2 M acid is used at a temperature of 20 °C. The obtained results enable the developing of full-scale process where phosphate in the sludge is refined to phosphorous acid and metal used in sludge production recycled back to precipitation.

Improved utilization of phosphorous from sewage sludge (as Fertilizer) after treatment by Low-Temperature combustion

The utilization of phosphorus from sewage sludge is an important method used to solve the shortage of phosphorus resources in the world. However, high levels of toxic compounds and low phosphorus bioavailability in sewage sludge are the main factors limiting its direct agricultural use. This paper proposes a low-temperature combustion method that can enrich the phosphorus in sludge ash. Low temperature-treated sewage sludge ash (LTSA) at different oxygen concentrations (20%, 60%, 100%) were obtained through a specific experimental device. Then, the species and leaching characteristics of phosphorus in LTSAs were analyzed and compared with pyrolysis sewage sludge char (PSSC) and incinerated sewage sludge ash (ISSA). Results show that low-temperature combustion of sludge increased the total phosphorus content in the bottom ash by 45.6%, and the bioavailable phosphorus content increased 2.9 times. Further, by increasing the concentration of oxygen while carrying out low-temperature combustion of sludge, part of the non-apatite inorganic P was converted to apatite P (AP), resulting in a 46.3% increase in AP in the sludge. Low-temperature combustion can also convert heavy metals (Cd, Cr, Cu, Pb, and Zn) in the sludge from an easily leachable form (acid extractable fraction and reducible fraction) to a stable form (reducible fraction) and decrease the leaching of heavy metals. Leaching of Cr and Cu decreased by 97.56% and 98.52%, respectively.

Fertilizer and Soil Solubility of Secondary P Sources-The Estimation of Their Applicability to Agricultural Soils

The demand for phosphorus (P) sources is increasing with the growing world population, while objections to direct agricultural use of waste P sources, such as sewage sludge, are being raised. Therefore, the need arises to employ safe and efficient secondary P fertilizer sources, originating from P-rich wastes. These recycling sources are commonly tested in accordance with the current fertilizer rules, designed originally for conventional apatite-based P fertilizers. The behavior of sewage sludge ash, an inorganic recycling secondary P source, was investigated under soil-like conditions. Standardized soil P tests, including the soil buffering capacity test and the Olsen, the Mehlich3, and water extraction methods, were employed together with standardized fertilizer P-solubility tests by neutral ammonium citrate and 2% citric acid extraction. In addition, total content and the overall soil mobility of selected metallic elements present in sewage sludge ash were investigated. The suitability of standardized soil tests for the evaluation of recycling P sources was shown. An apparent influence of Ca:Al content ratio on sewage sludge ash behavior under different soil-like conditions shows the inadequacy of the current fertilizer test and the necessity to understand soil-like behavior of secondary P sources, when considering these as possible agricultural P bearers (fertilizers).

Change in re-use value of incinerated sewage sludge ash due to chemical extraction of phosphorus

The potential of six different extractants to recover phosphorus (P) from incinerated sewage sludge ash (ISSA) was evaluated. Secondary effects such as the co-dissolution of Zn and Cu were also considered. The residual ISSA from each study was assessed in particular detail, focusing on the leachability of remaining Zn and Cu, major element composition, crystalline phases and overall degree of crystallinity and particle size distribution. The residual ISSA was also evaluated as a pozzolanic material using a Strength Activity Index (SAI) test with mortars containing Portland cement with a 20% substitution by ISSA. All results were compared to tests with untreated ISSA. Overall, the use of 3 of the 6 extractants could be ruled out due to poor P recovery potential and/or a serious compromise of the potential reuse of residual ISSA in Portland cement-based materials. The results highlight the added value of considering the potential reuse of residual ISSA when trying to optimize P recovery from ISSA by wet methods.

Sewage sludge as a fuel and raw material for phosphorus recovery: Combined process of gasification and P extraction

Increasing problems associated with sewage sludge disposal are observed nowadays. As the thermal conversion of sewage sludge (combustion, co-combustion, gasification and pyrolysis) appears to be the most promising alternative for its management, the solid residues left after gasification were examined. The present study evaluates the potential of this waste as an alternative phosphorus source in the context of phosphorus recovery. The obtained solid gasification residues were characterised (chemical and phase composition, thermal properties, surface properties and technological parameters used for phosphorus raw materials) and compared to commercial phosphate raw materials. It was revealed that gasification residue is a valuable source of phosphorus and microelements, comparable to sewage sludge ash (SSA) considered nowadays as secondary phosphorus raw materials. Chemical properties as well as technological parameters characteristic for natural phosphate ores are different. Solid gasification residue was leached with mineral acids (phosphoric and nitric) according to the patented method of phosphorus recovery - PolFerAsh, developed by Cracow University of Technology. It was revealed that phosphorus can be selectively leached from solid gasification residue with high efficiency (73-82%); moreover, most of the iron and heavy metals stay in the solid phase due to the low concentration of acids and proper solid to liquid phase ratio. The obtained leachates are valuable products that can be considered for the production of fertilisers. Combining the gasification process with nutrient recovery provides the opportunity for more environmentally efficient technologies driven by sustainable development rules.

Phosphorous recovery from sewage sludge using calcium silicate hydrates

Phosphorous is an essential limiting nutrient for which there is no substitute. Its efficient recovery from sewage treatment plants is important to mitigate both dependence on limited reserves of exploitable phosphate rock and eutrophication of surface waters. Here, we evaluate the use of calcium silicate hydrates (CSH) to recover phosphorous eluted from sewage sludge. Phosphorous elution experiments were conducted with acid and base leaching solutions. The phosphorous recovery efficiency with CSH was compared to that with other calcium compounds, and the final product was analyzed to assess its potential value as fertilizer. Dried sewage sludge from the West Lake Ecological Water Resource Center, South Korea, having 123 g-P kg^-1, was used for these tests. About 55% of the phosphorus in the sludge was released with an elution solution of 0.1 M H₂SO₄. A dose of 15 g L^-1 of CSH recovered 89.6% of the eluted phosphorous without the need for additional pre-treatment, and the resulting calcium phosphate product (in brushite form, based on XRD analysis) exhibited superior settleability than that resulting from Ca(OH)₂- and CaCl₂-induced precipitation. XRD peaks of the calcium sulfate hydrate (in gypsum form) and residual CSH were also observed. The final product contained a relatively high content of the total P₂O₅ eluted in a 2% citric acid solution (43.1%), which suggests that it might be readily used to fertilize crops.

Phosphorus recovery and leaching of trace elements from incinerated sewage sludge ash (ISSA)

Chemical extraction of phosphorus (P) from incinerated sewage sludge ash (ISSA) is adversely influenced by co-dissolution of metals and metalloids. This study investigated P recovery and leaching of Zn, Cu, Pb, As and Ni from ISSA using inorganic acids (sulphuric acid and nitric acid), organic acids (oxalic acid and citric acid), and chelating agents (ethylenediaminetetraacetic acid (EDTA) and ethylene diamine tetramethylene phosphonate (EDTMP)). The aim of this study was to optimize a leaching process to recover P-leachate with high purity for P fertilizer production. The results show that both organic and inorganic acids extract P-containing phases but organic acids leach more trace elements, particularly Cu, Zn, Pb and As. Sulphuric acid was the most efficient for P recovery and achieved 94% of total extraction under the optimal conditions, which were 2-h reaction with 0.2 mol/L H₂SO₄ at a liquid-to-solid ratio of 20:1. EDTA extracted only 20% of the available P, but the leachates were contaminated with high levels of trace elements under optimum conditions (3-h reaction with EDTA at 0.02 mol/L, pH 2, and liquid-to-solid ratio of 20:1). Therefore, EDTA was considered an appropriate pre-treatment agent for reducing the total metal/metalloid content in ISSA, which produced negligible changes in the structure of ISSA and reduced contamination during subsequent P extraction using sulphuric acid.

Fate of metals before and after chemical extraction of incinerated sewage sludge ash

Chemical extraction of incinerated sewage sludge ash (ISSA) can effectively recycle P, but it may change the speciation and mobility of the remaining metals. This study investigated the changes of the leaching potential and distribution of metals in the chemically extracted ISSA. Batch extraction experiments with different extractants, including inorganic acids, organic acids, and chelating agents, were conducted on the ISSA collected from a local sewage sludge incinerator. The extraction of Zn, Cu, Pb, Ni, Cd, Ba, Cr and As from the ISSA and the corresponding changes of the mobility and speciation were examined. The results showed that the metals in ISSA were naturally stable because large portions of metals were associated with the residual fraction. The inorganic (HNO₃ and H₂SO₄) and organic acids (citric acid and oxalic acid) significantly co-dissolved the metals through acid dissolution, but the reduction in the total concentrations did not tally the leaching potential of the residual metals. The increase in the exchangeable fraction due to destabilization by the extractants significantly enhanced the mobility and leachability of the metals in the residual ISSA. Chelating agents (EDTA and EDTMP) only extracted a small quantity of metals and had a marginal effect on the fate of the residual metals, but they significantly reduced the Fe/Mn oxide-bound fraction. In comparison, the bioaccessibility of residual metals were reduced to varying extent. Therefore, the disposal or reuse of chemically extracted ISSA should be carefully evaluated in view of possible increase in mobility of residual metals in the environment.

Characteristics and metal leachability of incinerated sewage sludge ash and air pollution control residues from Hong Kong evaluated by different methods

The improper disposal of incinerated sewage sludge ash (ISSA) and air pollution control residues (APCR) from sewage sludge incinerators has become an environmental concern. The physicochemical, morphological and mineralogical characteristics of ISSA and APCR from Hong Kong, and the leachability and risk of heavy metals, are presented in this paper. The results showed that a low hydraulic and pozzolanic potential was associated with the ISSA and APCR due to the presence of low contents of SiO₂, Al₂O₃ and CaO and high contents of P, S and Cl (especially for APCR). Although high concentrations of Zn and Cu (especially for ISSA) followed by Ni, Pb and As, Se were detected, a low leaching rate of these metals (especially at neutral and alkaline pH) rendered them classifiable as non-hazardous according to the U.S. EPA and Chinese national regulatory limits. The leached metals concentrations from ISSA and APCR were mainly pH dependent, and metals solubilization occurred mainly at low pH. Different leaching tests should be adopted based on the simulated different environmental conditions and exposure scenarios for assessing the leachability as contrasting results could be obtained due to the differences in complexing abilities and final pH of the leaching solutions.

Innovative solidification/stabilization of lead contaminated soil using incineration sewage sludge ash

The proper treatment of lead (Pb) contaminated soils and incinerated sewage sludge ash (ISSA) has become an environmental concern. In this study, ordinary Portland cement (OPC) and blended OPC containing incinerated sewage sludge ash (ISSA) were used to solidify/stabilize (S/S) soils contaminated with different concentrations of Pb. After curing for 7 and 28 d, the S/S soils were subjected to a series of strength, leaching and microscopic tests. The results showed that replacement of OPC by ISSA significantly reduced the unconfined compressive strength (UCS) of S/S soils and leached Pb. In addition, the leaching of Pb from the monolithic samples was diffusion controlled, and increasing the ISSA addition in the samples led to a lower diffusion coefficient and thus an increase in the feasibility for "controlled utilization" of S/S soils. Furthermore, the proposed S/S method significantly decreased the amount of Pb associated with carbonates and increased the amount of organic and residual Pb in S/S soils, reflecting that the risk of Pb contaminated soils can be effectively mitigated by the incorporating of ISSA. Overall, the leachability of Pb was controlled by the combined effect of adsorption, encapsulation or precipitation in the S/S soils.

Fertilisers production from ashes after sewage sludge combustion - A strategy towards sustainable development

Sustainable development and circular economy rules force the global fertilizer industry to develop new phosphorous recovery methods from alternative sources. In this paper a phosphorus recovery technology from Polish industrial Sewage Sludge Ashes was investigated (PolFerAsh - Polish Fertilizers form Ash). A wet method with the use of mineral acid and neutralization was proposed. Detailed characteristic of SSA from largest mono-combustion plans were given and compared to raw materials used on the market. The technological factors associated with such materials were discussed. The composition of the extracts was compared to typical industrial phosphoric acid and standard values characterizing suspension fertilizers. The most favorable conditions for selective precipitation of phosphorus compounds were revealed. The fertilizers obtained also meet EU regulations in the case of the newly discussed Cd content. The process was scaled up and a flow mass diagram was defined.

Comparison of phosphorus recovery from incineration and gasification sewage sludge ash

Incineration of sewage sludge is a common practice in many western countries. Gasification is an attractive option because of its high energy efficiency and flexibility in the usage of the produced gas. However, they both unavoidably produce sewage sludge ashes, a material that is rich in phosphorus, but which is commonly landfilled or used in construction materials. With current uncertainty in phosphate rock supply, phosphorus recovery from sewage sludge ashes has become interesting. In the present work, ashes from incineration and gasification of the same sewage sludge were compared in terms of phosphorus extractability using electrodialytic (ED) methods. The results show that comparable recovery rates of phosphorus were achieved with a single ED step for incineration ashes and a sequential combination of two ED steps for gasification ashes, which was due to a higher influence of iron and/or aluminium in phosphorus solubility for the latter. A product with lower level of metallic impurities and comparable to wet process phosphoric acid was eventually obtained from gasification ashes. Thus, gasification becomes an interesting alternative to incineration also in terms of phosphorus separation.

Comparison of phosphorus recovery from incinerated sewage sludge ash (ISSA) and pyrolysed sewage sludge char (PSSC)

This research compares and contrasts the physical and chemical characteristics of incinerator sewage sludge ash (ISSA) and pyrolysis sewage sludge char (PSSC) for the purposes of recovering phosphorus as a P-rich fertiliser. Interest in P recovery from PSSC is likely to increase as pyrolysis is becoming viewed as a more economical method of sewage sludge thermal treatment compared to incineration. The P contents of ISSA and PSSC are 7.2-7.5% and 5.6%, respectively. Relative to the sludge, P concentrations are increased about 8-fold in ISSA, compared to roughly 3-fold in PSSC. Both PSSC and ISSA contain whitlockite, an unusual form of calcium phosphate, with PSSC containing more whitlockite than ISSA. Acid leaching experiments indicate that a liquid/solid ratio of 10 with 30min contact time is optimal to release PO₄-P into leachate for both ISSA and PSSC. The proportion of P extracted from PSSC is higher due to its higher whitlockite content. Heavy metals are less soluble from PSSC because they are more strongly incorporated in the particles. The results suggest there is potential for the development of a process to recover P from PSSC.

Sequential electrodialytic recovery of phosphorus from low-temperature gasification ashes of chemically precipitated sewage sludge

Phosphorus recycling from secondary materials like sewage sludge ashes offers an alternative to mining of phosphates from primary resources and a mean to counteract the current phosphorous rock depletion concern. A separation of P from the bulk ash is normally required, due to its low plant availability and the presence of heavy metals. Previously, more than 80% of P was recovered from incineration sewage sludge ashes using a two-compartment electrodialytic cell. In contrast, the recovery was below 30% for ashes from low-temperature gasification using the same setup. The low recovery was due to a high presence of Al- and Fe(III)-P bindings. In the present study, an electrodialytic process combining sequentially a pair of two-compartment cells allowed a recovery of up to 70% of phosphorus from these ashes. The use of a second cell, where the ash was suspended in an alkaline solution, allowed the P solubilisation from aluminium and ferric phosphates. In addition, P was separated from most metals as they became insoluble under the prevailing chemical environment. The obtained ratio of Al, Fe, Mg and most heavy metals to P was comparable to wet process phosphoric acid. Therefore, this sequential process was found to be suitable to recycle P and potentially use it in the production of common fertilizers like diammonium phosphate.

Insight into chemical phosphate recovery from municipal wastewater

Phosphate plays an irreplaceable role in the production of fertilizers. However, its finite availability may not be enough to satisfy increasing demands for the fertilizer production worldwide. In this scenario, phosphate recovery can effectively alleviate this problem. Municipal wastewater has received high priority to recover phosphate because its quantity is considerable. Therefore, phosphate recovery from municipal wastewater can bring many benefits such as relieving the burden of increasing production of fertilizers and reduction in occurrence of eutrophication caused by the excessive concentration of phosphate in the released effluent. The chemical processes are the most widely applied in phosphate recovery in municipal wastewater treatment because they are highly stable and efficient, and simple to operate. This paper compares chemical technologies for phosphate recovery from municipal wastewater. As phosphate in the influent is transferred to the liquid and sludge phases, a technical overview of chemical phosphate recovery in both phases is presented with reference to mechanism, efficiency and the main governing parameters. Moreover, an analysis on their applications at plant-scale is also presented. The properties of recovered phosphate and its impact on crops and plants are also assessed with a discussion on the economic feasibility of the technologies.

Valorisation of ferric sewage sludge ashes: Potential as a phosphorus source

Sewage sludge ashes (SSA), although a waste, contain elements with socio-economic and environmental potential that can be recovered. This is the case of phosphorus (P). SSA from two Danish incinerators were collected during two years and characterized. The sampling was done immediately after incineration (fresh SSA) or from an outdoor deposit (deposited SSA). Although morphology and mineral composition were similar, physico-chemical and metal concentration differences were found between incinerator plants and sampling periods. No differences were observed between deposited and fresh SSA, except for the parameters directly influenced by disposal conditions (e.g. moisture content). All the SSAs had high concentrations of P (up to 16wt%), but they all exceeded Danish EPA Cd and Ni thresholds for direct application at agricultural soil. Fresh and deposited SSA were acid washed aiming P extraction, achieving 50gP/kg (approx. 37% of total P), but metals were also co-extracted to the liquid phase. To avoid and/or minimize the metals pollution of the extracted P, selective P recovery from the SSA was tested, using the electrodialytic (ED) process. ED laboratory cells, with 3 compartments (3c) and 2 compartments (2c), and two acid concentrations (H2SO4, 0.08M and 0.19M) were used for 7days. The most concentrated acid solution increased P solubilization. The 2c-cell combined with the higher acid concentration resulted in higher P recoveries, 125g of P/kg of SSA in the anolyte. The obtained results showed that the ED process is a valuable tool for the SSA valorisation as it promotes simultaneous P recovery and metals extraction from the SSA.

Phosphorous recovery from sewage sludge ash suspended in water in a two-compartment electrodialytic cell

Phosphorus (P) is indispensable for all forms of life on Earth and as P is a finite resource, it is highly important to increase recovery of P from secondary resources. This investigation is focused on P recovery from sewage sludge ash (SSA) by a two-compartment electrodialytic separation (EDS) technique. Two SSAs are included in the investigation and they contained slightly less P than phosphate rock used in commercial fertilizer production and more heavy metals. The two-compartment electrodialytic technique enabled simultaneous recovery of P and separation of heavy metals. During EDS the SSA was suspended in water in the anolyte, which was separated from the catholyte by a cation exchange membrane. Electrolysis at the anode acidified the SSA suspension, and hereby P, Cu, Pb, Cd and Zn were extracted. The heavy metal ions electromigrated into the catholyte and were thus separated from the filtrate with P. More than 95% P was extracted from both SSAs. The charge transfer to obtain this varied when treating the two SSAs, and for one ash it was about 30% higher than for the other as a result of a higher buffering capacity against acidification. The repeatability of EDS results between experiments with the same SSA and the same experimental conditions was good, which shows that the process is easy to control at the studied laboratory conditions. About 80% P and 10% of the heavy metals remained in the filtrate from the anolyte after treatment of both SSAs. The heavy metal content relative to P in the filtrate by far meet the limiting values for use of industrial wastes as fertilizers, thus the filtrate is ready for direct processing into P-fertilizer.

The effect of lime-dried sewage sludge on the heat-resistance of eco-cement

The treatment and disposal of sewage sludge is a growing problem for sewage treatment plants. One method of disposal is to use sewage sludge as partial replacement for raw material in cement manufacture. Although this process has been well researched, little attention has been given to the thermal properties of cement that has had sewage sludge incorporated in the manufacturing process. This study investigated the fire endurance of eco-cement to which lime-dried sludge (LDS) had been added. LDS was added in proportions of 0%, 3%, 6%, 9%, and 12% (by weight) to the raw material. The eco-cement was exposed to 200, 400, or 600 °C for 3 h. The residual strength and the microstructural properties of eco-cement were then studied. Results showed that the eco-cement samples suffered less damage than conventional cement at 600 °C. The microstructural studies showed that LDS incorporation could reduce Ca(OH)(2) content. It was concluded that LDS has the potential to improve the heat resistance of eco-cement products.

Chemical speciation, mobility and phyto-accessibility of heavy metals in fly ash and slag from combustion of pelletized municipal sewage sludge

Combustion of pelletized municipal sewage sludge (MSS) can generate pestilent byproducts: fly ash and slag. Comparisons of heavy metal sequential extraction results among MSS, fly ash and slag showed that after combustion, the bioavailable heavy metal fractions (acid soluble/exchangeable, reducible and oxidizable fractions) were mostly transformed into the very stable heavy metal fractions (residual fractions). On the other hand, the results of toxicity characteristic leaching procedure (TCLP), diethylenetriamine pentaacetic acid and HCl extraction (phyto-accessibility assessment) demonstrated that the mobility and toxicity of heavy metals were greatly reduced. The direct and long-term bioavailability and eco-toxicity of heavy metals in fly ash and slag were relieved, which implied that combustion of pelletized MSS could be a promising and completely safe disposal technology for MSS treatment.

Transformation of apatite phosphorus and non-apatite inorganic phosphorus during incineration of sewage sludge

The recovery of phosphorus from incinerated sewage sludge ash (SSA) is assumed to be economical. Transformation from non-apatite inorganic phosphorus (NAIP) to apatite phosphorus (AP), which has a higher bioavailability and more extensive industrial applications, was studied at 750-950°C by sewage sludge incineration and model compound incineration with a calcium oxide (CaO) additive. Thermogravimetric differential scanning calorimetry analysis and X-ray diffraction measurements were used to analyze the reactions between NAIP with CaO and crystallized phases in SSA. High temperatures stimulated the volatilization of NAIP instead of AP. Sewage sludge incineration with CaO transformed NAIP into AP, and the percentage of AP from the total phosphorus reached 99% at 950°C. Aluminum phosphate reacted with CaO, forming Ca2P2O7 and Ca3(PO4)2 at 750-950°C. Reactions between iron phosphate and CaO occurred at lower temperatures, forming Ca(PO3)2 before reaching 850°C.

Recovery potential of German sewage sludge ash

Incineration of sewage sludge is expected to increase in the future due to growing concerns about the direct use of sludge in agriculture. Sewage sludge is the pollutant sink of wastewater treatment and thus loaded with contaminants that might pose environmental hazards. Incineration degrades organic pollutants efficiently, but since the ash is currently mostly disposed of, all valuable component like phosphorus (P) and technologically relevant metals present in the sewage sludge ash (SSA) are removed from the economic cycle entirely. We conducted a complete survey of SSA from German mono-incineration facilities and determined the theoretical recovery potential of 57 elements. German SSA contains up to 19,000 t/a P which equals approximately 13% of phosphorus applied in the German agriculture in form of phosphate rock based mineral fertilizers. Thus, SSA is an important secondary resource of P. However, its P-solubility in ammonium citrate solution, an indicator for the bioavailability, is only about 26%. Treatment of SSA is recommended to enhance P bioavailability and remove heavy metals before it is applied as fertilizer. The recovery potential for technologically relevant metals is generally low, but some of these elements might be recovered efficiently in the course of P recovery exploiting synergies.