Volatility of heavy metals during incineration of tannery sludge in the presence of chlorides and phosphoric acid

Influence of chlorine on co-processing of hazardous wastes in brick kilns

Brick kiln co-treatment is a novel industrial hazardous wastes (IHWs) utilization process. However, the effects of chlorine (Cl) in wastes on heavy metals (HMs) during this process are overlooked. This study investigated the stabilization/solidification (S/S) and volatilization, as well as long and short-term leaching, of HMs in Cl-containing bricks. The results indicated enhanced formations of stable mineral phases (NiFe2O4, Ni2SiO4, Cd3Al2Si3O12, CdSiO3, FeCr2O4, Cr2O3, CuFe2O4, and CuAl2O4) in bricks at a low sintering temperature (800 °C) due to the affinity between Cl and HMs. By comparing HM concentrations before and after sintering in bricks, the study observed that Cl's presence significantly elevated the volatilization rates for Cd and Cu by 30.8% and 14.2%, respectively. In contrast, the effect on volatilization for Ni and Cr was not significant. Additionally, utilizing the NEN 7375 method, the cumulative leaching rates of Ni, Cd, Cr, and Cu over a 64-day experiment under extremely acidic conditions were 0.22%, 7.18%, 0.01%, and 1.46%, respectively. Similarly, higher short-term leaching rates of Cd (4.03%) and Cu (5.73%) than those of Ni (0.94%) and Cr (0.08%) were observed. This finding might be attributed to the lower stability of the Cd and Cu solid phases under acidic environments compared to those of Ni and Cr. Surface wash-off, dissolution, and diffusion were the processes governing HM leaching from bricks. The 10-year projections revealed a minimal release of HMs during future extended leaching, implying the successful S/S of HMs. This study provides a reference for assessing the environmental impacts of brick kiln co-processing of Cl-containing IHWs.

Migration and transformation of trace elements during sewage sludge and coal slime Co-combustion

Co-combustion of sewage sludge (SS) and coal slime (CS) could improve the combustion properties of the two materials, however, high levels of trace elements (TEs) can be released from the two wastes, resulting in secondary pollution. The migration and transformation behavior of As, Cr, Pb, Zn, and Mn during co-combustion is explored in current research. The results showed co-combustion could inhibit the emission of Zn, As, Pb, and Mn, and the effect was more pronounced for Zn, As and Mn. Meanwhile, minerals like kaolinite and gypsum were found to generated in the ash from co-combustion but not solo-combustion. Model experiments demonstrated that kaolinite captured As, Pb and Mn, while gypsum captured Zn, As and Mn but facilitated the emission of Pb and Cr. This well explained the distinct TEs emission characteristics between co-combustion and solo combustion. As the temperature elevated, kaolinite in co-combustion ash decomposed and the generation of gypsum was promoted. In this way, the emission ratios of Zn, As, and Mn initially increased but subsequently decreased between 700 and 1300 °C, whereas Pb and Cr emission ratios increased by twofold within the same temperature range. Leaching characteristics and risk assessment code on co-combustion ashes were also conducted in this study. The results indicated a marginal elevation in the risk associated with trace elements (TEs) following co-combustion, provided that all five TEs remained within the limits of national standards.

A systematic review on tannery sludge to energy route: Current practices, impacts, strategies, and future directions

The growing amount of tannery sludge (TS) generated from leather processing often undergoes uncontrolled landfilling, or open dumping, releasing a significant volume of harmful pollutants, including carcinogenic chromium (Cr) into the air, water, and soil. Therefore, the sustainable TS management through advanced valorization technologies becomes vital to align with the Sustainable Development Goals (SDGs) and mitigate the adverse environmental, health, and social impacts. Moreover, TS, as biomass, can be considered a renewable energy source for bioenergy generation, which could be a viable solution for meeting contemporary environmental standards and expediting transition towards a circular economy. However, TS valorization is sensitive and critical due to the potential risk of transforming Cr(III) to Cr(VI) during the valorization process. Therefore, there is an urgency to consider efficient and holistic TS valorization technologies in the design, implementation, and operations phases to avoid any environmental and health hazards. In pursuit of this goal, this systematic literature review (SLR) comprehensively and critically analyzes the existing TS valorization processes to develop sustainable energy recovery solutions from TS. This SLR contributes uniquely to the existing literature in different ways. Firstly, it provides a critical evaluation of the current TS valorization technologies identifying the available waste-to-energy recovery options. Secondly, the review encompasses extensive research from three reputed databases such as Scopus, Web of Science, and ScienceDirect, without temporal restrictions to offer a comprehensive understanding of current TS management practices and available valorization techniques. Moreover, the review categorized 124 published papers into distinct groups, revealing promising avenues for future research in this field. The findings indicated that most of the work concentrating on Chrome (Cr) recovery, pyrolysis, anaerobic co-digestion, and solidification while gasification and biodiesel or biofuel production from TS remained largely unexplored. Additionally, vital aspects such as process optimization, life cycle assessment of different valorization techniques, environmental, economy, energy, emergy, and exergy (5E) analysis, life cycle energy balance, and techno-economic analysis including exergoeconomic and exergoenvironmental are completely absent in the literature. Future studies need to concentrate on process optimization, exergy and energy analysis, and techno-economic assessment including exergoeconomic and exergoenvironmental analysis to understand the feasibility and environmental benefits of various TS valorization technologies and to develop industry-scale valorization plants for TS management in an economically and ecologically sustainable manner. Moreover, the review will serve as a comprehensive guide for scholars, authorities, and stakeholders to advance research in this field and formulate policies for the eco-friendly management of TS, paving the way towards clean energy solutions.

Trace metal elements vaporization and phosphorus recovery during sewage sludge thermochemical treatment - A review

Phosphorus (P) plays essential roles in crops growth. Natural mineral sources of phosphate are non-renewable, overexploited and unevenly distributed worldwide, making P a strategic resource for agricultural systems. The search for sustainable ways to secure P supply for fertilizer production has therefore become a critical issue worldwide. Sewage sludge (SS) is an organic waste material considered as a key alternative source of P. Switzerland and the European Union are about to make it mandatory to recover P from SS or its treatment residues. Among the many technical options to achieve this objective, SS thermochemical treatments spiked with Cl-donors appear as a promising approach to recover P from SS and separate it from mineral pollutants such as trace metal elements (TME). The purpose of Cl-donor additives is to fix P within the mineral residues, possibly in bioavailable P species forms, while promoting TME vaporization by chlorination mechanisms. This review paper compares the various thermochemical treatments investigated worldwide over the past two decades. The influence of process conditions and Cl-donor nature is discussed. The presented results show that, except for nickel and chromium, most TME can be significantly vaporized during a high temperature treatment (over 900 °C) with Cl addition. In addition, the fixation rate and solubility of P is increased when a Cl-donor such as MgCl₂ is added.

Review on fate of chlorine during thermal processing of solid wastes

Chlorine (Cl) is extensively present in solid wastes, causing significant problems during the thermal conversion of waste to energy or fuels, by combustion, gasification or pyrolysis. This paper introduces the analytical methods for determining the Cl content in solid materials and presents the concentrations of Cl in various types of wastes, as reported in literature. Then, it provides a comprehensive analysis on the Cl emission behavior and Cl species formed during the thermal processing of the inorganic and organic Cl sources. The challenges resulted from the reactions between the formed Cl species and the ferrous metals, the heavy metals and the organic matters are summarized and discussed, e.g., high temperature corrosion, heavy metal evaporation and dioxin formation. The quality degradation of products (oil, char and syngas) by Cl is analyzed. Finally, the available controlling methods of Cl emission, including pre-treatment (water washing, sorting, microwave irradiation and stepwise pyrolysis) and in-furnace (absorbents, co-treatment and catalysts) methods are assessed.

Effects of chlorine on the volatilization of heavy metals during the co-combustion of sewage sludge

To clarify the volatilization of heavy metals (Cu, Ni, Pb, and Zn) in sewage sludge during co-combustion in cement kiln, effects of addition and types of four chlorides and temperature on the volatilization of heavy metals in raw meal with 25wt.% sewage sludge were investigated. The results showed that the volatilization of Cu, Ni, and Pb increased significantly with increase of chlorides addition, while no obvious change in the volatilization of Zn was observed. The effectiveness of chlorides on the volatilization of heavy metals depended on their release capacity of chlorine radicals and the chlorine combined capacity of heavy metals. Higher calcination temperature resulted in dramatically increase in the volatilization of heavy metals due to easier formation of volatile heavy metal chlorides. The results will provide a guideline for co-combusting heavy metals contained solid wastes in cement kiln on the basis of security.

Oxidation behavior of Cr(III) during thermal treatment of chromium hydroxide in the presence of alkali and alkaline earth metal chlorides

The oxidation behavior of Cr(III) during the thermal treatment of chromium hydroxide in the presence of alkali and alkaline earth metal chlorides (NaCl, KCl, MgCl2, and CaCl2) was investigated. The amounts of Cr(III) oxidized at various temperatures and heating times were determined, and the Cr-containing species in the residues were characterized. During the transformation of chromium hydroxide to Cr2O3 at 300 °C approximately 5% of the Cr(III) was oxidized to form intermediate compounds containing Cr(VI) (i.e., CrO3), but these intermediates were reduced to Cr2O3 when the temperature was above 400 °C. Alkali and alkaline earth metals significantly promoted the oxidation of Cr(III) during the thermal drying process. Two pathways were involved in the influences the alkali and alkaline earth metals had on the formation of Cr(VI). In pathway I, the alkali and alkaline earth metals were found to act as electron transfer agents and to interfere with the dehydration process, causing more intermediate Cr(VI)-containing compounds (which were identified as being CrO3 and Cr5O12) to be formed. The reduction of intermediate compounds to Cr2O3 was also found to be hindered in pathway I. In pathway II, the alkali and alkaline earth metals were found to contribute to the oxidation of Cr(III) to form chromates. The results showed that the presence of alkali and alkaline earth metals significantly increases the degree to which Cr(III) is oxidized during the thermal drying of chromium-containing sludge.

The role of temperature on Cr(VI) formation and reduction during heating of chromium-containing sludge in the presence of CaO

In this study, the temperature dependence of Cr(VI) formation and reduction in the presence of CaO was examined during the thermal treatment of sludge that contains chromium. thermogravimetry-differential scanning calorimetry and X-ray diffractometry were used to characterize the thermal behavior and phase transformation, respectively. Na2CO3 leaching procedure was employed to determine the amount of Cr(VI). The result showed that CaO promoted Cr(III) oxidation, however, its influence is very dependent on heating temperature, with the extent of the effect varying with temperature. From 200-400 °C, the presence of CaO facilitated formation of intermediate product Cr2O3+x containing Cr(VI) during dehydration of chromium hydrate, while Cr2O3+x would decompose as temperature over 400 °C, accompanied by part of Cr(VI) being reduced to Cr(III). From 500 to 900 °C, Cr(III) reacted with CaO to form a leachable CaCrO4 product. This product was stable and a prolonged heating time did not reduce the amount of Cr(VI) significantly. At 1000-1200 °C, part of CaCrO4 was reduced to Ca(CrO2)2 in 1h. While extended heating time above 1h resulted in the Ca(CrO2)2 being oxidized reversibly to CaCrO4 at 1200 °C. Since CaCrO4 is thermodynamically less stable over 1000 °C, MgO could induce CaCrO4 to be reduced into MgCr2O4 at around 900 °C, lower than that for the reduction from CaCrO4 into Ca(CrO2)2. It suggested that adding MgO might be a potential approach for inhibiting Cr(VI) formation during heating sludge containing chromium.

An experimental and thermodynamic equilibrium investigation of the Pb, Zn, Cr, Cu, Mn and Ni partitioning during sewage sludge incineration

The effects of different chlorides and operational conditions on the distribution and speciation of six heavy metals (Pb, Zn, Cr, Cu, Mn and Ni) during sludge incineration were investigated using a simulated laboratory tubular-furnace reactor. A thermodynamic equilibrium investigation using the FactSage software was performed to compare the experimental results. The results indicate that the volatility of the target metals was enhanced as the chlorine concentration increased. Inorganic-Cl influenced the volatilization of heavy metals in the order of Pb>Zn>Cr>Cu>Mn>Ni. However, the effects of organic-Cl on the volatility of Mn, Pb and Cu were greater than the effects on Zn, Cr and Ni. With increasing combustion temperature, the presence of organic-Cl (PVC) and inorganic-Cl (NaCl) improved the transfer of Pb and Zn from bottom ash to fly ash or fuse gas. However, the presence of chloride had no obvious influence on Mn, Cu and Ni. Increased retention time could increase the volatilization rate of heavy metals; however, this effect was insignificant. During the incineration process, Pb readily formed PbSiO4 and remained in the bottom ash. Different Pb compounds, primarily the volatile PbCl2, were found in the gas phase after the addition of NaCl; the dominant Pb compounds in the gas phase after the addition of PVC were PbCl2, Pb(ClO4)2 and PbCl2O4.

Effects of hydroxyapatite addition on heavy metal volatility during tannery sludge incineration

The effectiveness of hydroxyapatite (HAP) on volatilization reducing of heavy metals during incineration of tannery sludge was investigated. The tannery sludge was treated through doped with different content of HAP, and then incinerated in the tube furnace at the temperature of 600 °C and 900 °C. The results showed that the volatilization rates decreased by 10.19% for Pb, 10.17% for Zn, 7.40% for Cu and 5.33% for Cr at 600 °C when the HAP content was raised to 20%. At 900 °C, the volatilization rates of Pb, Cr and Cu decreased by about 40.0%, 24.0% and 9.0%, respectively, while volatilization of Zn can be considered nearly unchanged at around 5%. The heavy metals can be stabilized effectively in the incineration after the pyromorphite-like minerals were formed in the sludge doped with HAP.

Studying the influence of operation parameters on heavy and alkali metals partitioning in flue gases

In order to study the distribution and partitioning of heavy and alkali metals in the flue gases of a sewage sludge incinerator, an experiment was carried out in a pilot scale combustor. The results indicated that it was feasible to separate part of metals from flue gases by collecting fly ash at different temperatures. On the basis of their separation temperature, heavy and alkali metals could be divided into three groups: group A included Zn, K and P, which converted from gaseous phase to liquid or solid when temperature was above 600 degrees C. Pb and Cu were the metals of group B, with optimum transformation temperature of 400 degrees C. Na and As belonged to group C, with conversion temperatures of 300 degrees C. Moreover, the effect of temperature gradient on heavy and alkali metal gas-solid transformation was also experimentally investigated. It was observed that the temperature gradient could promote the gas-solid conversion of heavy and alkali metals. However, too high a temperature gradient would suppress the formation of fine particles. The peak of conversion rate for K, Pb and Na occurred at 434 degrees C s(-1), while that of P and Cu was 487 degrees C s(-1).