Electroless Production of Fertilizer (Struvite) and Hydrogen from Synthetic Agricultural Wastewaters

Application of physicochemical techniques to the removal of ammonia nitrogen from water: a systematic review

Ammonia nitrogen is a common pollutant in water and soil, known for its biological toxicity and complex removal process. Traditional biological methods for removing ammonia nitrogen are often inefficient, especially under varying temperature conditions. This study reviews physicochemical techniques for the treatment and recovery of ammonia nitrogen from water. Key methods analyzed include ion exchange, adsorption, membrane separation, struvite precipitation, and advanced oxidation processes (AOPs). Findings indicate that these methods not only remove ammonia nitrogen but also allow for nitrogen recovery. Ion exchange, adsorption, and membrane separation are effective in separating ammonia nitrogen, while AOPs generate reactive species for efficient degradation. Struvite precipitation offers dual benefits of removal and resource recovery. Despite their advantages, these methods face challenges such as secondary pollution and high energy consumption. This paper highlights the development principles, current challenges, and future prospects of physicochemical techniques, emphasizing the need for integrated approaches to enhance ammonia nitrogen removal efficiency.

Enhanced strategies for phosphate recovery from urine by magnesium galvanic process

Magnesium galvanic process (MGP) can be applied to recover phosphate from source-separated urine. However, information on how the urine matrix affects MGP performance is limited. Therefore, this study investigated the mechanism of phosphate recovery by MGP in synthetic and real urine matrixes. Our results showed that the major components in urine (i.e., NH4+, Cl-, and HCO3-) all exhibited acceleration effects on corrosion of Mg plate. However, the underlying action mechanism of each component was distinct. Ammonium facilitated the conversion from MgO to Mg(OH)2, chloride complexed with Mg2+ ions, and bicarbonate led to complexation as well as formation of MgCO3. Furthermore, our results revealed an interesting aspect where although bicarbonate alone accelerated the corrosion of Mg plate, its coexistence with other ions inhibited overall performance due to the blocking effect of formed MgCO3 on chloride penetration and reduction in free magnesium ion concentration. After elucidating the interaction of NH4+, Cl-, and HCO3- on the passive layer of the Mg plate, we proposed to pretreat urine with HCl, which resulted in a significant enhancement in current production and phosphate recovery. This improved MGP was further tested in a continuous flow reactor, which recovered over 95% of phosphate in real urine for more than 1 h. The phosphate precipitates were confirmed as high purity struvite. Generally, the improved MGP, which simultaneously produced Mg2+, dihydrogen, and electricity with no energy input, is a promising sustainable and green alternative for phosphate recovery from source-separated urine.

Electrochemical Wastewater Refining: A Vision for Circular Chemical Manufacturing

Wastewater is an underleveraged resource; it contains pollutants that can be transformed into valuable high-purity products. Innovations in chemistry and chemical engineering will play critical roles in valorizing wastewater to remediate environmental pollution, provide equitable access to chemical resources and services, and secure critical materials from diminishing feedstock availability. This perspective envisions electrochemical wastewater refining─the use of electrochemical processes to tune and recover specific products from wastewaters─as the necessary framework to accelerate wastewater-based electrochemistry to widespread practice. We define and prescribe a use-informed approach that simultaneously serves specific wastewater-pollutant-product triads and uncovers a mechanistic understanding generalizable to broad use cases. We use this approach to evaluate research needs in specific case studies of electrocatalysis, stoichiometric electrochemical conversions, and electrochemical separations. Finally, we provide rationale and guidance for intentionally expanding the electrochemical wastewater refining product portfolio. Wastewater refining will require a coordinated effort from multiple expertise areas to meet the urgent need of extracting maximal value from complex, variable, diverse, and abundant wastewater resources.

Basket anode filled with CaCO3 particles: A membrane-free electrochemical system for boosting phosphate recovery and product purity

Phosphorus (P) is often regarded as the primary stimulant for eutrophication, while its importance as a crucial life element is also well acknowledged. Given its future scarcity, P recycling from waste streams is suggested and practiced. Electrochemically mediated precipitation (EMP) is a robust and chemical-free process for P removal and recovery, yet it requires further developments. The first generation of the CaCO₃-packed electrochemical precipitation column successfully solved the problem of H⁺-OH^- recombination, achieving enhanced P removal efficiency with less energy consumption but suffering from low Ca-phosphate purity in recovered products. Herein, a new concept of a basket-anode electrochemical system is proposed and validated to prevent direct H⁺-OH^- recombination and enhance product purity. The CaCO₃ pellets packed basket anode alleviates the OH^- depletion by CaCO₃-H⁺ interaction and provides extra Ca²⁺ for enhanced P removal. The novel structure of the basket anode, by its derived acidic anode region and alkaline cathode region, completely avoids the precipitation of Ca-phosphate on the packed CaCO₃ and greatly facilitates the collection of high-quality Ca-phosphate product. Our results suggest that almost 100% of the removed P was in high-purity, highly crystalline Ca-phosphate on the cathode. The recovered products contained significantly more P (13.5 wt%) than in the previous study (0.1 wt%) at similar energy consumptions (29.8 kWh/kg P). The applied current density, pellets size, and influent P concentration were critical for P removal performance, product purity, and power consumption. We further demonstrated the long-term stability of this novel system and its technical and economic feasibility in treating real stored urine. Our study provides new cell architectural designs to enhance the performance of EMP systems and may inspire innovations and developments in other electrochemical water treatment processes.

Optimization and kinetic modeling of phosphate recovery as struvite by electrocoagulation from source-separated urine

Phosphorus recovery is indispensable due to the rapid depletion of its natural reserves and excessive utility in agriculture. Though human urine has high nutrient content including phosphate, nitrogen and potassium; direct use as a fertilizer is restricted due to hygienic, environmental, social and ethical issues. To overcome these limitations, the nutrients are precipitated by the external addition of magnesium (Mg) to form a slow-releasing fertilizer called struvite. The present study aims to maximize phosphate recovery through optimizing struvite production by an emerging electrocoagulation technique. A maximum of 95% phosphate recovery was achieved using inter-electrode distance of 0.5 cm, 2 A current from undiluted urine using Mg-Mg electrodes in a reaction time of 30 min. Further, kinetic modeling of phosphate recovery through electrocoagulation was conducted to comprehend the intended mechanism through the order of kinetics. The results revealed that the data best correlated with first-order kinetics with a correlation coefficient of 0.95. Electrocoagulation improved the supernatant quality by reducing the ion concentrations other than phosphate (30-50%), salinity (40-45%), and microbial population (99%). Qualitative assessment of the precipitate through sophisticated analysis further confirmed the presence of struvite crystals.

Electrocatalytic Upcycling of Nitrate Wastewater into an Ammonia Fertilizer via an Electrified Membrane

Electrochemically upcycling wastewater nitrogen such as nitrate (NO₃^-) and nitrite (NO₂^-) into an ammonia fertilizer is a promising yet challenging research topic in resource recovery and wastewater treatment. This study presents an electrified membrane made of a CuO@Cu foam and a polytetrafluoroethylene (PTFE) membrane for reducing NO₃^- to ammonia (NH₃) and upcycling NH₃ into (NH₄)₂SO₄, a liquid fertilizer for ready-use. A paired electrolysis process without external acid/base consumption was achieved under a partial current density of 63.8 ± 4.4 mA·cm^-2 on the cathodic membrane, which removed 99.9% NO₃^- in the feed (150 mM NO₃^-) after a 5 h operation with an NH₃ recovery rate of 99.5%. A recovery rate and energy consumption of 3100 ± 91 g-(NH₄)₂SO₄·m^-2·d^-1 and 21.8 ± 3.8 kWh·kg^-1-(NH₄)₂SO₄, respectively, almost outcompete the industrial ammonia production cost in the Haber-Bosch process. Density functional theory (DFT) calculations unraveled that the in situ electrochemical conversion of Cu²⁺ into Cu¹⁺ provides highly dynamic active species for NO₃^- reduction to NH₃. This electrified membrane process was demonstrated to achieve synergistic nitrate decontamination and nutrient recovery with durable catalytic activity and stability.

Assessment of Struvite as an Alternative Sources of Fertilizer-Phosphorus for Flood-Irrigated Rice

Phosphorus (P) recovery from wastewaters as struvite (MgNH4PO4·6H2O) may be a viable alternative fertilizer-P source for agriculture. The objective of this study was to evaluate the economic and environmental implications of struvite as a fertilizer-P source for flood-irrigated rice (Oryza sativa) relative to other commonly used commercially available fertilizer-P sources. A field study was conducted in 2019 and 2020 to evaluate the effects of wastewater-recovered struvite (chemically precipitated struvite (CPST) and electrochemically precipitated struvite (ECST)) on rice yield response in a P-deficient, silt–loam soil in eastern Arkansas relative to triple superphosphate, monoammonium and diammonium phosphate, and rock phosphate. A life cycle assessment methodology was used to estimate the global warming potentials associated with rice produced with the various fertilizer-P sources. Life cycle inventory data were based on the field trials conducted with and without struvite application for both years. A partial budget analysis showed that, across both years, net revenues for ECST and CPST were 1.4 to 26.8% lower than those associated with the other fertilizer-P sources. The estimated greenhouse gas emissions varied between 0.58 and 0.70 kg CO2 eq kg rice−1 from CPST and between 0.56 and 0.81 kg CO2 eq kg rice−1 from ECST in 2019 and 2020, respectively, which were numerically similar to those for the other fertilizer-P sources in 2019 and 2020. The similar rice responses compared to commercially available fertilizer-P sources suggest that wastewater-recovered struvite materials might be an alternative fertilizer-P-source option for flood-irrigated rice production if struvite can become price-competitive to other fertilizer-P sources.

Nitrogen and phosphorous recycling from human urine by household electrochemical fixed bed in sparsely populated regions

Decentralized treatment of human urine in sparsely populated regions could avoid the problem of sewage collection in traditionally centralized treatment schemes and simultaneously utilize the recovered N/P fertilizer in-situ to nurture gardens. Herein, an integrated electrochemical fixed bed packed with divided magnesite and carbon zones was constructed for the pretreatment of human urine, followed by the recovery of 95.0% NH₄⁺ and 85.8% PO₄^3- via struvite precipitation and NH₃ volatilization as well as the on-site employment of the produced struvite as fertilizer. In the process, the acid/base zones created by electrochemical water splitting dissolved the magnesite filler as the Mg²⁺ source of struvite, further creating an ideal pH environment for struvite precipitation and NH₃ volatilization in the effluent. Without the need to control solution pH by chemical addition, the system can resist impacts from changes in water quality by adjustment of the current density and flow rate, indicating its great potential for automatic operation. Life cycle assessment indicated that the on-site employment of produced struvite avoids the long-distance fertilizer transportation required for fertilization, thus reducing carbon emission by a hundred million tons per year if the household facility is driven by clean electricity.

Self-Co-Electrolysis for Co-Production of Phosphate and Hydrogen in Neutral Phosphate Buffer Electrolyte

The spontaneous reaction between Zn and H₂ O is of critical importance and could plausibly be used to produce H₂ gas, especially under neutral conditions. However, this reaction has long been overlooked owing to its sluggish kinetics and Zn consumption. Herein, a unique self-co-electrolysis system (SCES) is reported, which uses a Zn anode, a CoP-based catalytic cathode, and a neutral phosphate buffer solution (PBS) as the electrolyte. In this SCES, Zn is not only a sacrificial anode but also an important precursor of high-value-added NaZnPO₄ . Additionally, the composition and phase structure of NaZnPO₄ can be well regulated. In this study, a high-performance N,Cu-CoP/carbon cloth (CC) catalyst is synthesized to catalyze the cathodic hydrogen evolution reaction (HER) at an especially low overpotential of 64.7 mV at 10 mA cm^{- 2} . H₂ gas (13.7 mL cm^{- 2} h^{- 1} ) and NaZnPO₄ (3.73 mg cm^{- 2} h^{- 1} ) are obtained at the cathode and anode, respectively, in the N,Cu-CoP/CC||Zn SCES spontaneously. Moreover, the SCES has a favorable open-circuit voltage (OCV) of 0.79 V and a maximum power density of 1.83 mW cm^{- 2} . Density functional theory (DFT) calculations are performed to elucidate the electronic structure and HER catalytic mechanism of the N and Cu co-doped CoP catalysts.

Spontaneous nutrient recovery and disinfection of aquaculture wastewater via Mg-coconut shell carbon composites

Aquaculture wastewater contained large amounts of pathogenic microorganisms, nitrogen (N) and phosphorus (P). In this study, the nutrient recoveries and wastewater disinfection were simultaneously achieved using Mg-coconut shell carbon (Mg-CSC). The composites were prepared by a ball milling method. The hydrogen peroxide (H₂O₂) was in-situ generated by the dissolved oxygen reduction driven by Mg corrosion on the CSC surface, which inactivated the microorganisms. Besides that, Mg corrosion provided sufficient Mg ions and appropriate pH conditions for struvite formation. The results show that 5.4-log E.coli removal was achieved under different conditions. Improving the Mg/CSC ratio and composite dosage could shorten the time required for disinfection. In addition to H₂O₂, singlet oxygen played a critical role. Reactive oxygen species destroyed the cellular structure and killed the bacteria. The recoveries of NH₄⁺-Nand P under certain conditions were about 60% and 91%, respectively. An increased composite dosage could improve the recovery ratio of P. Excessive dosages were not beneficial for removing NH₄⁺-N. The characterization result revealed that struvite crystals were the main precipitates on the CSC surface. The Mg-CSC composites also revealed satisfied nutrient recovery and disinfection performances in the real aquaculture wastewater treatment process.

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.

An Electrochemical Study of Ammonium Dihydrogen Phosphate on Mg and Mg Alloy Electrodes

In this work, the electrochemistry of ammonium dihydrogen phosphate in aqueous solution on Mg and Mg AZ31 alloy (Al 3 wt%, Zn 1 wt%, balanced Mg) electrodes was studied using electrochemical characterization similar to electro-agglomeration and physical characterization to shed some light on the electrochemical mechanism of struvite formation as phosphate precipitation in waste. It was found that the Mg AZ31 alloy exhibited higher corrosion current densities (jcorr), and thus higher Mg dissolution rates and corrosion rates (vcorr) when compared with pure Mg. This finding was confirmed by ion chromatography (IC) analysis. Results also showed a phosphorus removal efficiency (PRem) of 16.8% together with ~53 mL H2 production for pure Mg and 17.2% with ~61 mL H2 production for Mg AZ31 alloy. The precipitates formed on the two Mg electrode materials were physically characterized by SEM, XRD, XPS, and energy-dispersive X-ray spectroscopy, which indicated the formation of struvite (magnesium ammonium phosphate hexahydrate-MgNH4PO4*6H2O). It was found that (i) the thickness of the films was influenced by the applied scan rates, which also had a significant impact on the morphology, and (ii) hydrogen bubble formation influenced the precipitates, whereby the film thicknesses were negatively impacted.

Graphical abstract