Sewage sludge pyrolysis coupled with self-supplied steam reforming for high quality syngas production and the influence of initial moisture content

Investigation on the interaction mechanism during co-combustion of sewage sludge and coal slime: The effect of coal slime type and pretreatment method

Co-combustion of sewage sludge (SS) and coal slime (CS) is the preferred method for mitigating their environmental impact and increasing their added value. However, the interaction mechanism between SS and CS during the co-combustion process has not yet developed a unified understanding. This work aims to obtain the effect of CS types on SS-CS co-combustion and reveal the interaction mechanism between SS and CS based on the influence of pretreatment methods on the interaction. The results showed that during co-combustion, SS reduced the ignition and burnout temperatures, and CS with high fixed carbon content (e.g., XCS) improved the comprehensive combustion characteristics. Principal component analysis showed that the effect of CS on co-combustion was more significant. The interaction between SS and CS mainly occurred within 100-700 °C, in which inhibition and synergism coexisted. The large differences in the interactions before and after de-volatilization and pickling treatments revealed that the volatiles and ash in SS were the main interaction factors. The analysis of the interaction mechanisms showed that the free radicals and heat released from the SS volatiles combustion accelerated the weight loss of CS, but the formation of tars from its incomplete combustion may inhibit the decomposition of CS. The interaction in the fixed carbon combustion stage was mainly caused by SS ash, which can catalyze the combustion of CS fixed carbon, but for the high ash CS (e.g., QCS), the combustion of fixed carbon was hindered by the addition of SS ash higher than 10 %. The final manifestation (synergy or inhibition) of SS and CS interactions was the result of the competitive balance of the above interactive behaviors. This work provides a more comprehensive understanding of the interaction between SS and CS during co-combustion.

Impact of temperature and residence time on sewage sludge pyrolysis for combined carbon sequestration and energy production

Environmental challenges related to sewage sludge call for urgent sustainable management of this resource. Sludge pyrolysis might be considered as a sustainable technology and is anticipated to support measures for mitigating climate change through carbon sequestration. The end products of the process have various applications, including the agricultural utilization of biochar, as well as the energy exploitation of bio-oil and syngas. In this research, sewage sludge was pyrolyzed at 500 °C, 600 °C, 750 °C, and 850 °C. At each temperature, pyrolysis was explored at 1hr, 2hrs, and 3hrs residence times. The ratio (H/Corg)at was tapped to imply organic carbon stability and carbon sequestration potential. Optimum operating conditions were achieved at 750 °C and 2hrs residence time. Produced biochar had (H/Corg)at ratio of 0.54, while nutrients' contents based on dry weight were 3.99%, 3.2%, and 0.6% for total nitrogen (TN), total phosphorus (TP), and total potassium (TK), respectively. Electrical conductivity of biochar was lesser than the feed sludge. Heavy metals in biochar aligned with the recommended values of the International Biochar Initiative. Heat content of condensable and non-condensable volatiles was sufficient to maintain the temperature of the furnace provided that PYREG process is considered. However, additional energy source is demanded for sludge drying.

Sludge pyrolysis integrated biomass gasification to promote syngas: Comparison of different biomass

The sludge pyrolysis and biomass gasification (SPBG) integrated process has been demonstrated to promote hydrogen-rich gas generation from the two solid waste materials by interaction, however, the effect of biomass species is unclear. Six agriculture and forestry biomass were chosen to participate SPBG in the current study to monitor the roles of biomass on product evolution. The results revealed that SPBG has promoted the syngas for all the biomass samples with the gas yields increased by 10.30 %-38.90 %, while the H2 yields increased by 17.31 %-81.40 %. By statistical analysis, it can be concluded that H2 was mainly derived from the gasification reaction of the biomass char and water in the sludge volatile, followed by the cracking of tar, while H elements released from biomass were mainly transformed into CH4 and C2Hy. The syngas composition verified a lot for SPBG experiments with different biomasses. Cellulose intensifies the production of CO through CO bonds cracking on char, while hemicellulose intensifies the production of CH4 through tar polymerization. Therefore, biomass with higher concentrations of cellulose and hemicellulose exhibited improved performance in gas production.

Gasification of biomass for syngas production: Research update and stoichiometry diagram presentation

Gasification is a thermal process that converts organic materials into syngas, bio-oil, and solid residues. This mini-review provides an update on current research on producing high-quality syngas from biomass via gasification. Specifically, the review highlights the effective valorization of feedstocks, the development of novel catalysts for reforming reactions, the configuration of novel integrated gasification processes with an assisted field, and the proposal of advanced modeling tools, including the use of machine learning strategies for process design and optimization. The review also includes examples of using a stoichiometry diagram to describe biomass gasification. The research efforts in this area are constantly evolving, and this review provides an up-to-date overview of the most recent advances and prospects for future research. The proposed advancements in gasification technology have the potential to significantly contribute to sustainable energy production and reduce greenhouse gas emissions.

MSW pyro-gasification using high-temperature CO2 as gasifying agent: Influence of contact mode between CO2, char and volatiles on final products

The volatiles and char derived from municipal solid waste (MSW) pyrolysis can be catalytically reformed and gasified using high-temperature CO2 (HT-CO2) as gasifying agent and char as a catalyst simultaneously to obtain high quality synthesis gas, but the reactor's design for this purpose is still a question. In this research, the contact configuration between the HT-CO2, the volatile compounds, and the char from MSW pyrolysis were studied to understand the relevant reaction behaviors and to establish guidelines for the reactor's design. Three contact modes were designed, including: M1, where volatiles and HT-CO2 contact first, then contact the char; M2, where volatiles, CO2, and char contact simultaneously at the bottom of the char layer; and M3, where CO2 contacts with the char first, then the volatiles contact in the middle of the char layer. The temperature evolution in the char layer, the yields and properties of the resultant combustible gases, used char, and tar were investigated. Experimental results revealed that the contact mode significantly affected the levels of char gasification and volatiles' reforming. For M1, intense thermal cracking of volatiles occurred and 65.41% of the input heat of HT-CO2 was consumed for thermal cracking, resulting in substantial carbon deposition and limited energy transfer from char to the synthesis gas. While, the char contacting HT-CO2 firstly in M3 improved its catalytic activity, causing 73.33 % of the input heat utilized for gasification and reforming; as a result, the maximum synthesis gas yield of 0.71 Nm3/kgMSW and gas energy ratio of 76.3 % were obtained respectively in M3 with the lowest tar yield of 5.45 %; additionally, the used char corresponded to the highest specific surface area of 10.12 m2/g. Ultimately, M3 is constructive and recommended, and the findings of this study offer helpful guidance for the design of pyro-gasification reactors.

Optimizing adsorption performance of sludge-derived biochar via inherent moisture-regulated physicochemical properties

Understanding the impact of abundant inherent moisture in sewage sludge on the physicochemical properties and adsorption applications of sludge-derived biochar (SDB) contributed significantly to promoting economical sludge reuse. The moisture (0-80%) contributed to the development of micropore and mesopore in SDB at 400 °C, resulting in a maximum increase in specific surface area (SSA) and total pore volume (TPV) of SDB by 38.47% (84.811-117.437 m2/g) and 92.60% (0.0905-0.1743 m3/g), respectively. At 600/800 °C, moisture only facilitated mesopore formation, while was exacerbated with increasing moisture content. Despite reduction in SSA during this stage, TPV increased by a maximum of 20.47% (0.1700-0.2048 m3/g). The presence of moisture during pyrolysis led to an increase in the formation of 3-5 thickened benzene rings and defective structures in SDB, along with more C=O, O-C=O/-OH, pyrrole N, pyridine N, and thiophene. As a result, moisture (40%/80%) increased the maximum adsorption capacity (76.2694-88.0448/90.1190 mg/g) of SDB (600 °C) for tetracycline, mainly due to enhanced pore filling effect and hydrogen bonding induced by improved physicochemical properties. This study offered a novel approach for optimizing the performance of SDB adsorption applications by manipulating the sludge moisture, which is critical for practical sludge management.

Comprehensive effects of grain-size modification of electrolytic manganese residue on deep dehydration performance and microstructure of sludge

As the by-product accompanied by sewage treatment, sludge has complex composition and high moisture content, therefore, its reutilization and disposal are still a challenge. In this paper, five kinds of quartz sand conditioners with different particle sizes (denoted as QS1, QS2, QS3, QS4 and QS5, respectively) were used to explore the effect of particle size distribution of conditioners on sludge dewatering performance. The moisture content, capillary suction time (CST), time to filter (TTF), specific resistance of filtration (SRF), particle size distribution curve, pore distribution law, scanning electron microscopy, isothermal adsorption-desorption curve and extracellular polymeric substances distribution were employed to characterize the modified sludge and explore the improvement mechanism. The results show that the particle size distribution of the conditioner significantly affects the efficiency of sludge dewatering. The wt% of sludge regulated with QS1 (QS1-S) could be reduced to 52%, and its CST value, TTF value and SRF value is 57.93 s, 278 s and 1.84 × 10⁸ s² g^-1, respectively. The conjecture about the effect of difference of particle size distribution on sludge dewatering performance was verified with the original Electrolytic Manganese Residue (EMR) and the grain-size modified Electrolytic Manganese Residue (EMR6). Compared with those of the EMR-conditioned sludge, the CST, TTF and SRF of EMR6-conditioned sludge was decreased by 8.7%, 22.3% and 11.2%, respectively. According to analysis of surface microstructure, the surface of the sludge cake modified with QS1 is rough and sparse with rich pore structure. Compared with those of the undisturbed sludge (A0), the pore volume and specific surface area of the sludge modified with QS1 was increased by 61.65% and 38.62%, respectively. After grain-size modification, the dehydration effect of EMR6 (D10 4.25 μm, D50 19.65 μm, D90 73.26 μm) was significantly enhanced, and the D10, D50 and D90 value was close to that of QS1. It can be concluded that the particle size of QS1 (D10 3.27 μm, D50 15.66 μm, and D90 62.23 μm) can improve the dewatering performance of sludge by shearing the sludge particles to change the original sludge particle size distribution and improving the blockage of sludge dewatering channels.

Synergistic optimization of syngas quality and heavy metal immobilization during continuous microwave pyrolysis of sludge: Competitive relationships, reaction mechanisms, and energy efficiency assessment

To realize the efficient resource utilization of sewage sludge, this work explored the competitive relationship and reaction mechanisms between syngas quality optimization and heavy metals (HMs) immobilization. The results showed that continuous microwave pyrolysis (CMP) technology with an instantaneous temperature increase could shorten the pyrolysis time, and the biogas yield and syngas concentration reached 51.68 wt% and 83.6 vol%, respectively. Although a higher pyrolysis (750 °C) temperature could optimize the syngas quality, the HMs immobilization efficiency was reduced due to the deep pyrolysis of the biochar. The moderate pyrolysis temperature (650 °C) facilitated the rapid formation of biochar with abundant surface functional groups and pore structure, thus enhancing HMs immobilization. Furthermore, the HMs could also form more stable crystalline compounds with inorganic components (SiO₂, Al₂O₃, inorganic sulfur). By optimizing the process parameters, the risk factor of HMs in the sludge decreased from 117.36 to 62.5 while obtaining high-quality syngas. The energy utilization efficiency of microwave pyrolysis also increased significantly from 11.20% to 82.01%. This work provided new insight into the efficient resource utilization and environmentally friendly treatment of sludge, and demonstrated that CMP technology has significant potential for future industrial applications as an alternative to traditional pyrolysis.

Improvement in the physicochemical characteristics of biochar derived from solid digestate of food waste with different moisture contents

The management of digestate from food waste (DFW) has become a worldwide challenge. Pyrolysis is a promising technology to generate biochar from the DFW. However, unlike other biomass, DFW usually has high salt and moisture content, which affects the properties of biochar generated from pyrolysis. The characteristics of biochar derived from DFW with different MCs (5%, 20%, 40%, and 60%) were investigated in the present study. It was found that more micropore and mesopore structures were generated in the biochar with the increase of MC from 5% to 60%, resulting in the Brunauer-Emmett-Teller surface area of the biochar increased from 89.23 m² g^-1 to 117.75 m² g^-1. The MC could also promote the variation of oxygen-containing functional groups and the generation of amorphous carbon structures, which are beneficial for the adsorption property of the biochar. Pyrolysis could stabilize the metals in the biochar, while MC has little effect on the metal speciations. These results provide fundamental information on the impact of MC on the properties of biochar derived from DFW and are important for the optimization of the pre-drying process.

Steam Pyrolysis of Oil Sludge for Energy-Valuable Products

Experimental studies of the steam pyrolysis of oil sludge were performed using a flow-type pilot plant with 300 kg/h capacity (raw material) to obtain energy-valuable products, such as liquid hydrocarbons (30.4 wt%), semi-coke (39.6 wt%), non-condensable gas-phase compounds (26.5 wt%), and bitumen (3.5 wt%). The pyrolysis process was conducted at a temperature of 650 ° C and with a steam flow rate of 150 kg/h. Liquid hydrocarbons were considered a target product. Comprehensive studies of their physicochemical characteristics, atomization process, droplet ignition, and combustion were carried out. The studied sample had physicochemical characteristics similar to traditional fuel oil (calorific value—42.6 MJ/kg, sulfur content—0.8 wt%). The jet spraying angle was 25° in view of the improved rheological properties of the test sample, with a homogeneous jet structure and a predominant droplet diameter of no more than 0.4 mm. The flame combustion process was accompanied by the formation of microexplosions, the frequency and intensity of which depended on the temperature of the air (Tg = 450–700 °C). This study, in view of its applied nature, is of interest in the design of new installations and technological systems for hydrocarbon pyrolysis.

Gasification of municipal solid waste (MSW) as a cleaner final disposal route: A mini-review

The production of hydrogen-rich syngas from municipal solid waste (MSW) by pyrolysis/gasification is one of the most promising waste-to-energy pathways for realizing a circular bioeconomy. This mini-review provides an overview of current research and development efforts in the field, focusing on the development of syngas upgrades and novel gasification processes, with the ultimate goal of making MSW gasification a sustainable and affordable route for the final disposal of MSW. A graphical assessment protocol is proposed to support comprehension of the main reactions that are involved in the MSW gasification. MSW gasification studies are reviewed with the prospects considered to provide a reference for future work.

Microwave assisted carbonization and activation of biochar for energy-environment nexus: A review

Conventional thermochemical conversion techniques for biofuel production from lignocellulosic biomass is often non-selective and energy inefficient. Microwave assisted pyrolysis (MAP) is cost and energy-efficient technology aimed for value-added bioproducts recovery from biomass with less environmental impacts. The present review emphasizes the performance of MAP in terms of product yield, characteristics and energy consumption and further it compares it with conventional pyrolysis. The significant role of biochar as catalyst in microwave pyrolysis for enhancing the product selectivity and quality, and the influence of microwave activation on product composition identified through sophisticated techniques has been highlighted. Besides, the application of MAP based biochar as soil conditioner and heavy metal immobilization has been illustrated. MAP accomplished at low temperature creates uniform thermal gradient than conventional mode, thereby producing engineered char with hotspots that could be used as catalysts for gasification, energy storage, etc. The stability, nutrient content, surface properties and adsorption capacity of biochar was enhanced by microwave activation, thus facilitating its use as soil conditioner. Many reviews until now on MAP mostly dealt with operational conditions and product yield with limited focus on comparative energy consumption with conventional mode, analytical techniques for product characterization and end application especially concerning agriculture. Thus, the present review adds on to the current state of art on microwave assisted pyrolysis covering all-round aspects of production followed by characterization and applications as soil amendment for increasing crop productivity in addition to the production of value-added chemicals, thus promoting process sustainability in energy and environment nexus.

Improving the Solid Fuel Properties of Non-Lignocellulose and Lignocellulose Materials through Torrefaction

Biomass torrefaction is a thermal pre-treatment technique that improves solid fuel properties in relation to its efficient utilization for energy generation. In this study, the torrefaction performance of sewage sludge, a non-lignocellulose biomass and sugarcane bagasse, a lignocellulose biomass were investigated in an electric muffle furnace. The influence of torrefaction temperature on the physiochemical properties of the produced biomaterial were examined. Characterization of the raw and torrefied biomass material were studied using thermogravimetric analysis, Fourier transform infrared spectroscopy (FTIR) analysis and scanning electron microscopy. From the result obtained, it was evident that an increase in torrefaction temperature up to 350 °C caused a 33.89% and 45.94% decrease in volatile matter content of sewage sludge and sugarcane bagasse, respectively. At a higher temperature of 350 °C, the peak corresponding to OH stretching of hydroxyl group decreased in intensity for both biomasses, showing a decomposition of the hydroxyl group as a result of torrefaction. This enriched the lignin content of the torrefied samples, thus making these solid fuels good feedstock for energy production.

Investigation and improvement of the desulfurization performance of molten carbonates under the influence of typical pyrolysis gases

Co-pyrolysis with oxygen-lean waste tires could improve the quality of pyrolytic oil from the bio-wastes while H₂S/COS generated during co-pyrolysis process has a negative impact on the utilization of oil/syngas as well as the flue gas pollution control. Compared to traditional wet desulfurization process, high-temperature desulfurization via molten carbonates could reduce heat loss and favor the recycling of captured sulfur. Notably, small-molecule pyrolytic gases might change the species of sulfur-containing gases and promote the re-emission of absorbed sulfur from the molten salts. To fully understand the effects of pyrolysis gases (H₂/CO/H₂O/CO₂) on molten salts desulfurization efficiency as well as mutual conversion mechanism of H₂S and COS, equilibrium compositions calculations and adsorption experiments were carried out in the present study. The results showed that H₂/CO had few effects on molten salts desulfurization performance and mutual conversion of H₂S/COS. In contrast, CO₂ and H₂O had obvious adverse effects on desulfurization efficiency through the transferring of free S^2- into emitted sulfur-containing gases. More specifically, only a small amount of CO₂ reacted with S^2- to produce COS while more S^2- was converted to H₂S and released from the reactor outlet when H₂O was introduced. Fortunately, the impact of H₂O or CO₂ on molten salts desulfurization could be weakened with the addition of CaCO₃ by transferring the molten free S^2- into precipitated CaS. Besides, multi-stage desulfurization units connected in series and parallel were proposed and estimated, which was confirmed to show good performance to maintain the high desulfurization efficiency from the complicated pyrolytic gases.

Migration characteristics of heavy metals during sludge pyrolysis

A comprehensive study was conducted to investigate the pyrolysis characteristics of municipal sludge, and the activation energy of sludge pyrolysis was determined using the Model-free method. The detailed migration characteristics of heavy metals in the pyrolysis products were also investigated at different pyrolysis temperatures (250-850 °C). The results demonstrate that sludge pyrolysis is a multi-step process; the activation energy of pyrolysis increased with the pyrolysis conversion rate, and the average activation energy was calculated as 79.59 kJ mol^-1. As the pyrolysis temperature increased, the char yield decreased, the tar yield increased then decreased, and the gas yield increased. At 850 °C, the thermal volatilities of heavy metals followed the sequence Cu < Cr < Ni < Mn < Pb < As < Zn < Cd = Hg. In addition, Cu, Cr, and Ni were seldom involved in migration during pyrolysis while As, Cd, and Hg readily migrated even at low pyrolysis temperatures. The results provide a theoretical basis for sludge pyrolysis technologies and heavy metals migration control.