Influence of Cell Configuration and Long-Term Operation on Electrochemical Phosphorus Recovery from Domestic Wastewater

Simultaneous phosphorus precipitation and sludge thickening by electrolysis with an anode covered by bivalve shells

A wastewater treatment plant with a large inflow of phosphorus (P) is a potential P source that can act as an alternative to phosphate rocks and a renewable source of P. During electrolysis with inert electrodes, hydroxide ions generated from the cathode cause calcium phosphate (CaP) precipitation, and oxygen and hydrogen generated from the electrodes cause thickening of the sludge by electroflotation in sludge treatment streams. However, these two effects have not been achieved simultaneously because the precipitation of CaP requires much more time than that required for thickening by electroflotation. In this study, an electrolysis system that used an anode covered with bivalve shells was used. Batch experiments were conducted and the results demonstrated that covering the anode with shells resulted in their dissolution and that the calcium ions provided by this process considerably enhanced P removal in the form of CaP, thereby shortening the time required for CaP precipitation. In continuous experiments with excess sludge, electrolysis with shells accomplished sludge thickening by electroflotation (the thickened sludge had 5.5 times the total solids in the original excess sludge) and low relative phosphate-P concentrations (0.0545-0.0812) in the effluent compared to the influent. This effect is attributed to CaP precipitation. Additional mixing of the CaP precipitates in the effluent enhanced their settleability. The results demonstrate that electrolysis using an anode covered with bivalve shells simultaneously achieved CaP precipitation and sludge thickening.

A Novel Hybrid Membrane Process Coupled with Freeze Concentration for Phosphorus Recovery from Cheese Whey

The ever-increasing demand for phosphorus fertilisers for securing global food production, coupled with finite phosphate rock reserves, is one of the emerging problems in the world. Indeed, phosphate rock is listed as an EU critical raw material, triggering attention to find an alternative source to substitute the use of this limited resource. Cheese whey, characterized by a high content of organic matter and phosphorus, represents a promising feedstock for phosphorus recovery and recycling. An innovative application of a membrane system coupled with freeze concentration was assessed to recover phosphorus from cheese whey. The performances of a microfiltration membrane (0.2 µm) and an ultrafiltration (200 kDa) membrane were evaluated and optimized under different transmembrane pressures and crossflow velocities. Once the optimal operating conditions were determined, a pre-treatment including lactic acid acidification and centrifugation was applied to increase the permeate recovery. Finally, the efficiency of progressive freeze concentration for the treatment of the permeate obtained from the optimum conditions (UF 200 kDa with TMP of 3 bar, CFV of 1 m/s and lactic acid acidification) was evaluated at specific operating conditions (-5 °C and 600 rpm of stirring speed). Finally, 70% of phosphorus could be recovered from cheese whey using the coupled technology of the membrane system and freeze concentration. A phosphorus-rich product was obtained with high agronomic value, which constitutes a further step towards establishing a broader circular economy framework.

An integrated strategy for nutrient harvesting from hydrolyzed human urine as high-purity products: Tracking of precipitation transformation and precise regulation

The nutrient recovery from source-separated urine is of great significance for a sustainable and closed nutrient loop. However, common urine-processing techniques have several constraints, including inefficient recovery, low product purity and incapability of simultaneously harvesting multiple nutrients. In this study, an integrated strategy of P precipitation and N stripping was first proposed to harvest nutrients from hydrolyzed human urine as high-purity products via precisely regulating Ca/P dosing ratio. Ca(OH)2 was utilized to trigger Ca-P precipitation and elevate pH level. Different from the previously reported conventional struvite method, P recovery was oriented to calcium phosphate. P harvesting behavior was investigated as a function of key factors including initial P concentration and the dosing ratio. A thermodynamic model was constructed to unveil the precipitation transformation mechanism and visualize P recovery for an enhanced controllability. For N harvesting, Ca(OH)2 was dosed to increase the pH of the urine to converts ammonium to ammonia. The resulting ammonia was stripped and then adsorbed by H2SO4 as high-purity ammonium sulfate. Moreover, the sulfate derived from acidification treatment was recovered as calcium sulfate in the interests of material recycling and mitigating secondary contaminations. Results exhibited P recovery efficiency could reach 100 % and purity for calcium phosphate could be above 90 % within a Ca/P ratio range of 1.67-2.0. Further boosting pH to 12, over 85 % of S and 95 % of N was retrieved. The comprehensive scheme provides an efficient approach towards the precise P and N harvesting from hydrolyzed urine and advances the knowledge of precipitation transformation mechanism.

Phosphorus harvesting from fresh human urine: A strategy of precisely recovering high-purity calcium phosphate and insights into the precipitation conversion mechanism

Phosphorus (P) harvesting from source-separated urine to optimize the overall nutrient loop is one of the most appealing benefits and is a global research interest in wastewater management and treatment. However, current P precipitation is mainly oriented to struvite, which is limited by the issues such as relatively low product purity and high cost of Mg source. Distinguished from previous conventional struvite precipitation, the strategy of precisely harvesting P from fresh human urine as high-purity calcium phosphate was first proposed in this study. This enhanced strategy can optimize P harvesting performance and product purity by simply regulating the consumption of calcium-based materials via model simulation and experimental validation. The thermodynamic model was constructed to probe the precipitation conversion mechanism, and visually predict the component and yield for products under various operating conditions. Batch experiments were conducted to investigate P recovery performance as a function of initial Mg²⁺ concentration, initial pH level, as well as degree of urine hydrolysis. Moreover, the alternative dosing scheme with different calcium salts and alkali was presented, diversifying the options for efficient P recovery. The results showed that, from the perspective of acidic storage for fresh urine, P recovery can be boosted along with eliminating urine hydrolysis. In urine with an initial pH=2.0, P can be completely recovered and purity for calcium phosphate can be optimized to 100% within a Ca/P ratio range of 1.67-2.3. Overall, this work is of great significance for precisely and efficiently harvesting P from urine and provides an integrated strategy for P resource recovery from urine.

Calcium carbonate: controlled synthesis, surface functionalization, and nanostructured materials

Calcium carbonate (CaCO₃) is an important inorganic mineral in biological and geological systems. Traditionally, it is widely used in plastics, papermaking, ink, building materials, textiles, cosmetics, and food. Over the last decade, there has been rapid development in the controlled synthesis and surface modification of CaCO₃, the stabilization of amorphous CaCO₃ (ACC), and CaCO₃-based nanostructured materials. In this review, the controlled synthesis of CaCO₃ is first examined, including Ca²⁺-CO₃^2- systems, solid-liquid-gas carbonation, water-in-oil reverse emulsions, and biomineralization. Advancing insights into the nucleation and crystallization of CaCO₃ have led to the development of efficient routes towards the controlled synthesis of CaCO₃ with specific sizes, morphologies, and polymorphs. Recently-developed surface modification methods of CaCO₃ include organic and inorganic modifications, as well as intensified surface reactions. The resultant CaCO₃ can then be further engineered via template-induced biomineralization and layer-by-layer assembly into porous, hollow, or core-shell organic-inorganic nanocomposites. The introduction of CaCO₃ into nanostructured materials has led to a significant improvement in the mechanical, optical, magnetic, and catalytic properties of such materials, with the resultant CaCO₃-based nanostructured materials showing great potential for use in biomaterials and biomedicine, environmental remediation, and energy production and storage. The influences that the preparation conditions and additives have on ACC preparation and stabilization are also discussed. Studies indicate that ACC can be used to construct environmentally-friendly hybrid films, supramolecular hydrogels, and drug vehicles. Finally, the existing challenges and future directions of the controlled synthesis and functionalization of CaCO₃ and its expanding applications are highlighted.

Electrochemical nutrient removal from natural wastewater sources and its impact on water quality

In this study, a suite of natural wastewater sources is tested to understand the effects of wastewater composition and source on electrochemically driven nitrogen and phosphorus nutrient removal. Kinetics, electrode behavior, and removal efficiency were evaluated during electrochemical precipitation, whereby a sacrificial magnesium (Mg) anode was used to drive precipitation of ammonium and phosphate. The electrochemical reactor demonstrated fast kinetics in the natural wastewater matrices, removing up to 54% of the phosphate present in natural wastewater within 1 min, with an energy input of only 0.04 kWh.m^-3. After 1 min, phosphate removal followed a zero-order rate law in the 1 min - 30 min range. The zero-order rate constant (k) appears to depend upon differences in wastewater composition, where a faster rate constant is associated with higher Cl^- and NH₄⁺ concentrations, lower Ca²⁺ concentrations, and higher organic carbon content. The sacrificial Mg anode showed the lowest corrosion resistance in the natural industrial wastewater source, with an increased corrosion rate (v_corr) of 15.8 mm.y^-1 compared to 1.9-3.5 mm.y^-1 in municipal wastewater sources, while the Tafel slopes (β) showed a direct correlation with the natural wastewater composition and origin. An overall improvement of water quality was observed where important water quality parameters such as total organic carbon (TOC), total suspended solids (TSS), and turbidity showed a significant decrease. An economic analysis revealed costs based upon experimental Mg consumption are estimated to range from 0.19 $.m^-3 to 0.30 $.m^-3, but costs based upon theoretical Mg consumption range from 0.09 $.m^-3 to 0.18 $.m^-3. Overall, this study highlights that water chemistry parameters control nutrient recovery, while electrochemical treatment does not directly produce potable water, and that economic analysis should be based upon experimentally-determined Mg consumption data. Synopsis Statement: Magnesium-driven electrochemical precipitation of natural wastewater sources enables fast kinetics for phosphate removal at low energy input.

Electrochemically mediated precipitation of phosphate minerals for phosphorus removal and recovery: Progress and perspective

Phosphorus (P) is an essential element for the growth and reproduction of organisms. Unfortunately, the natural P cycle has been broken by the overexploitation of P ores and the associated discharge of P into water bodies, which may trigger the eutrophication of water bodies in the short term and possible P shortage soon. Consequently, technologies emerged to recover P from wastewater to mitigate pollution and exploit secondary P resources. Electrochemically induced phosphate precipitation has the merit of achieving P recovery without dosing additional chemicals via creating a localized high pH environment near the cathode. We critically reviewed the development of electrochemically induced precipitation systems toward P removal and recovery over the past ten years. We summarized and discussed the effects of pH, current density, electrode configuration, and water matrix on the performance of electrochemical systems. Next to ortho P, we identified the potential and illustrated the mechanism of electrochemical P removal and recovery from non-ortho P compounds by combined anodic or anode-mediated oxidation and cathodic reduction (precipitation). Furthermore, we assessed the economic feasibility of electrochemical methods and concluded that they are more suitable for treating acidic P-rich waste streams. Despite promising potentials and significant progress in recent years, the application of electrochemical systems toward P recovery at a larger scale requires further research and development. Future work should focus on evaluating the system's performance under long-term operation, developing an automatic process for harvesting P deposits, and performing a detailed economic and life-cycle assessment.

Electrochemical recovery of phosphorus from wastewater using tubular stainless-steel cathode for a scalable long-term operation

Phosphorus (P) is an irreplaceable element, playing a vital role in living organisms, yet has limited earth reserves. The possibility of P recovery from wastewaters by electrochemically-induced calcium phosphate precipitation (ECaPP) was demonstrated previously. The current study presents a novel scalable prototype consisting of a column-shaped electrochemical reactor, a tubular stainless-steel cathode, and a Pt coated Ti anode. The adhesion of solids to the cathode, important for product recovery, was shown not to be negatively impacted by electrodes' vertical placement. The influence of current (density), hydraulic retention time (HRT), and initial phosphate concentration in this prototype were examined under continuous flow operation. The system accomplished the highest P removal rate (1267 mg/day) at 1.5 d HRT and 800 mA in treating undiluted cheese wastewater with 48.5 kWh/kg P. Moreover, the prototype showed high stability and efficiency (> 50%) over 173 days of continuous operation without performing maintenance. After turning off the current (0 mA), the system realized a surprising P removal jump up to 97.3%, revealing the delayed diffusion of hydroxide ions by the deposition layer. The calculation of CAPEX and OPEX of ECaPP in treating 100 m³ cheese wastewater per week indicates that the ECaPP plant can realize net-positive from the 12^th year. The recovered solids have relatively high P content (> 9wt%) and insignificant contamination of heavy metals. Overall, the proven suitability of the scalable prototype can pave the way towards the actual adoption of the ECaPP process.

Electrochemical Recovery of Phosphorus from Acidic Cheese Wastewater: Feasibility, Quality of Products, and Comparison with Chemical Precipitation

The recovery of phosphorus (P) from high-strength acidic waste streams with high salinity and organic loads is challenging. Here, we addressed this challenge with a recently developed electrochemical approach and compared it with the chemical precipitation method via NaOH dosing. The electrochemical process recovers nearly 90% of P (∼820 mg/L) from cheese wastewater in 48 h at 300 mA with an energy consumption of 64.7 kWh/kg of P. With chemical precipitation, >86% of P was removed by NaOH dosing with a normalized cost of 1.34-1.80 euros/kg of P. The increase in wastewater pH caused by NaOH dosing triggered the formation of calcium phosphate sludge instead of condensed solids. However, by electrochemical precipitation, the formed calcium phosphate is attached to the electrode, allowing the subsequent collection of solids from the electrode after treatment. The collected solids are characterized as amorphous calcium phosphate (ACP) at 200 mA or a precipitation pH of ≥9. Otherwise, they are a mixture of ACP and hydroxyapatite. The products have sufficient P content (≤14%), of which up to 85% was released within 30 min in 2% citric acid and a tiny amount of heavy metals compared to phosphate rocks. This study paves the way for applying electrochemical removal and recovery of phosphorus from acidic P-rich wastewater and offers a sustainable substitute for mined phosphorus.

Electrochemical recovery of H2 and nutrients (N, P) from synthetic source separate urine water

This study examined an electrochemical method of H₂ production and nutrient recovery from synthetic source separated urine (SSU). The efficacy of H₂ production was examined through hydrogen recovery experiments (HRE) using Ni foam electrodes. Similarly, nutrient (N and P) recovery was also examined in post-nutrient recovery experiments (NRE) with sacrificial Mg electrodes. To achieve higher nutrient recovery in the post-nutrient recovery process, the most important operating parameters (initial solution pH (pH_i) and current density) were optimized. Optimization of NRE revealed that > 90% NH₃-N and PO₄^3--P could be recovered at 8 mA cm^-2 with a pH_i of 6-8. Notable NH₃-N and PO₄^3--P reduction were observed at an equimolar Mg²⁺ dissolution ratio (1:1) of Mg²⁺:NH₄⁺ and a 1.1:1 ratio of Mg²⁺:PO₄^3- respectively. However, poor total Kjeldahl nitrogen (TKN) reduction was observed. Thus, we anticipate that direct electrochemical conversion of urea to N₂ at the anode followed by H₂ generation at the cathode is a more sustainable way to reduce TKN. Batch HRE showed that the initial TKN, 1094 mg L^-1 (934 mg L^-1 from urea-N and 160 mg L^-1 from NH₄Cl), was significantly reduced to 360 mg L^-1 by Ni-Ni electrolysis, whereas around 53.8 g H₂ gas was received from this Ni-Ni electrolysis system with a flow rate of 5-5.8 g mol^-1 day^-1. Overall, this work produced a 68% reduction in TKN due to electrochemical conversion of urea into H₂.

Overview of recent developments of resource recovery from wastewater via electrochemistry-based technologies

As the rapid increase of the worldwide population, recovering valuable resources from wastewater have attracted more and more attention by governments and academia. Electrochemical technologies have been extensively investigated over the past three decades to purify wastewater. However, the application of these technologies for resource recovery from wastewater has just attracted limited attention. In this review, the recent (2010-2020) electrochemical technologies for resource recovery from wastewater are summarized and discussed for the first time. Fundamentals of typical electrochemical technologies are firstly summarized and analyzed, followed by the specific examples of electrochemical resource recovery technologies for different purposes. Based on the fundamentals of electrochemical reactions and without the addition of chemical agents, metallic ions, nutrients, sulfur, hydrogen and chemical compounds can be effectively recovered by means of electrochemical reduction, electrochemical induced precipitation, electrochemical stripping, electrochemical oxidation and membrane-based electrochemical processes, etc. Pros and cons of each electrochemical technology in practical applications are discussed and analyzed. Single-step electrochemical process seems ineffectively to recover valuable resources from the wastewater with complicated constituents. Multiple-step processes or integrated with biological and membrane-based technologies are essential to improve the performance and purity of products. Consequently, this review attempts to offer in-depth insights into the developments of next-generation of electrochemical technologies to minimize energy consumption, boost recovery efficiency and realize the commercial application.

Simultaneous Sulfite Electrolysis and Hydrogen Production Using Ni Foam-Based Three-Dimensional Electrodes

The electrochemical oxidation of sulfite ions offers encouraging advantages for large-scale hydrogen production, while sulfur dioxide emissions can be effectively used to obtain value-added byproducts. Herein, the performance and stability during sulfite electrolysis under alkaline conditions are evaluated. Nickel foam (NF) substrates were functionalized as the anode and cathode through electrochemical deposition of palladium and chemical oxidation to carry out the sulfite electro-oxidation and hydrogen evolution reactions, respectively. A combined analytical approach in which a robust electrochemical flow cell was coupled to different in situ and ex situ measurements was successfully implemented to monitor the activity and stability during electrolysis. Overall, satisfactory sulfite conversion and hydrogen production efficiencies (>90%) at 10 mA·cm^-2 were mainly attributed to the use of NF in three-dimensional electrodes with a large surface area and enhanced mass transfer. Furthermore, stabilization processes associated with electrochemical dissolution and sulfur crossover through the membrane induced specific changes in the chemical and physical properties of the electrodes after electrolysis. This study demonstrates that NF-based electrocatalysts can be incorporated in an efficient electrochemical flow cell system for sulfite electrolysis and hydrogen production, with potential applications at a large scale.

Electrochemical removal of phosphate in the presence of calcium at low current density: Precipitation or adsorption？

Phosphorus removal and recovery from waste streams are crucial to prevent eutrophication and sustain fertilizer production. As has been shown in our previous papers, electrochemical treatment has the potential to achieve this goal. However, the adoption of electrochemical approach is limited by its high energy consumption. Here, we investigate the possibility of electrochemical phosphorus removal at extremely low current density using graphite felt as the cathode. We found a current density as low as 0.04 A/m² can enhance the removal of phosphate in our electrochemical system. The removal of phosphate at extremely low current density resulted from electrochemical induced calcium phosphate precipitation and not by electrochemical adsorption. Electrochemical treatment of real domestic wastewater at 0.2 A/m² almost eliminates the precipitation of Mg(OH)₂ and limits the formation of CaCO₃. The recovered precipitates are dominated by calcium phosphate (59%), followed by 35% CaCO₃ and 6% Mg(OH)₂. The specific energy consumption of this newly electrochemical system is between 4.4 and 26.4 kW h/kg P, which is 2 orders of magnitude lower than our previous system (110-2238 kW h/kg P). Key factors for this improvement prove to be enlarged precipitation area and hydroxide flux retardation by graphite felt. Practically, our study offers a potential way to reduce the energy consumption in electrochemical removal of phosphate by using a graphite felt cathode and at a current density below 0.2 A/m². Fundamentally, our study contributes to the understanding of adsorption and precipitation in electrochemical removal of phosphate at an extremely low current density and with carbon-based electrodes.

Calcium Carbonate Packed Electrochemical Precipitation Column: New Concept of Phosphate Removal and Recovery

Phosphorus (P) is a vital micronutrient element for all life forms. Typically, P can be extracted from phosphate rock. Unfortunately, the phosphate rock is a nonrenewable resource with a limited reserve on the earth. High levels of P discharged to water bodies lead to eutrophication. Therefore, P needs to be removed and is preferably recovered as an additional P source. A possible way to achieve this goal is by electrochemically induced phosphate precipitation with coexisting calcium ions. Here, we report a new concept of phosphate removal and recovery, namely a CaCO₃ packed electrochemical precipitation column, which achieved improved removal efficiency, shortened hydraulic retention time, and substantially enhanced stability, compared with our previous electrochemical system. The concept is based on the introduction of CaCO₃ particles, which facilitates calcium phosphate precipitation by buffering the formed H⁺ at the anode, releases Ca²⁺, acts as seeds, and establishes a high pH environment in the bulk solution in addition to that in the vicinity of the cathode. It was found that the applied current, the CaCO₃ particle size, and the feed rate affect the removal of phosphate. Under optimized conditions (particle size, <0.5 mm; feed rate, 0.4 L/d; current, 5 mA), in a continuous flow system, the CaCO₃ packed electrochemical precipitation column achieved 90 ± 5% removal of phosphate in 40 days and >50% removal over 125 days with little maintenance. The specific energy consumptions of this system lie between 29 and 61 kWh/kg P. The experimental results demonstrate the promising potential of the CaCO₃ packed electrochemical precipitation column for P removal and recovery from P-containing streams.