Enhancement of struvite pellets crystallization in a full-scale plant using an industrial grade magnesium product

Manufacturing of a Granular Fertilizer Based on Organic Slurry and Hardening Agent

The manufacturing of a granular fertilizer based on organic slurry (OS) and sorptive materials aims to enhance the circular economy. This article describes a technology that was conceived after appraising the chemistry of the anaerobic digestate and wood ash and the synergies of combining both materials. The information available in the literature about similar materials such as cattle slurry and lime was also considered to build a better understanding of the underlying science. The processes and machinery designed were optimized from the points of view of energy and material consumption, cost of storage, transportation and land application. The system was sized to process 1 tonne of OS (97% moisture) in a 10 h batch-shift, consuming 140 kg of wood pellets and 0.55 kW of electricity for the fan blowing preheated air. The results of the market research allowed us to reach the most economically viable routes for the commercialization of granular fertilizers. Based on the financial study, an initial investment of GBP 20,000 is needed to successfully implement the value proposition and business plan. The wide adoption of the composite fertilizer improves the management of the OS and reduces the contamination of air, soil, and water derived from intensive agricultural practices.

Wastewater Valorization: Practice around the World at Pilot- and Full-Scale

Over the last few years, wastewater treatment plants (WWTPs) have been rebranded as water resource recovery facilities (WRRFs), which recognize the resource recovery potential that exists in wastewater streams. WRRFs contribute to a circular economy by not only producing clean water but by recovering valuable resources such as nutrients, energy, and other bio-based materials. To this aim, huge efforts in technological progress have been made to valorize sewage and sewage sludge, transforming them into valuable resources. This review summarizes some of the widely used and effective strategies applied at pilot- and full-scale settings in order to valorize the wastewater treatment process. An overview of the different technologies applied in the water and sludge line is presented, covering a broad range of resources, i.e., water, biomass, energy, nutrients, volatile fatty acids (VFA), polyhydroxyalkanoates (PHA), and exopolymeric substances (EPS). Moreover, guidelines and regulations around the world related to water reuse and resource valorization are reviewed.

Economic Model Predictive Control for optimal struvite recovery

Resource recovery from municipal wastewater has been a prime focus for a decade. Although several recovery processes already exist in the market today, the high cost of material, inherent disturbance in the influent quality, lack of real time monitoring of critical parameters, and lack of a robust automation system may result in suboptimal performance. This work attempts to construct a model based predictive control for optimal operation of a struvite recovery unit in a full scale WRRF. A multi-parameter based predictive control has been developed by implementing an Economic Model Predictive Controller (EMPC) for optimal dosing of magnesium hydroxide in a struvite recovery unit. The EMPC used customized objective function for real-time optimization of performance and economical parameters of the crystallization unit. The effectiveness of the proposed EMPC controller is verified through tests conducted on the Benchmark Simulation Model No. 2 (BSM2d.). The results obtained from the simulator-based evaluation of EMPC demonstrate a significant improvement in resource recovery at reduced operational costs. The economic advantages of implementing an EMPC compared to proportional and constant magnesium dosage has also been enumerated.

Critical conditions of struvite growth and recovery using MgO in pilot scale crystallization plant

The struvite crystallization process can recover struvite crystals as a valuable slow-release fertilizer from the side stream of wastewater treatment plants (WWTPs). The purpose of this study is to demonstrate the crystal growth characteristics and determine the appropriate recovery criteria for a struvite crystallization pilot plant. A pilot plant (8.6 m³/d) was designed with a feeding system of MgO (magnesium oxide), a pH controller, and a hydrocyclone for recovering struvite; the plant was operated for 42 hours at a pH range of 8.25-8.5. The removal efficiencies for PO₄-P and NH₄-N were 82.5-90.7% and 13.4-22.9%, respectively. The struvite recovered from the hydrocyclone was sifted using standard sieves and analyzed by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The dry weight fraction of the precipitate in the 300-600 μm range increased gradually from 7% to 74% in 18 hours. The XRD analysis revealed that the crystalline structure of the precipitate in the 150-600 μm range indicates struvite without any peaks of MgO, Mg(OH)₂, and MgCO₃. This indicates that the critical conditions for recovering struvite from the side-stream of WWTPs are an operation period of 18 hours and a crystal size greater than 300 μm.

Elucidating the impacts of initial supersaturation and seed crystal loading on struvite precipitation kinetics, fines production, and crystal growth

To reduce intra-plant nutrient cycling, and recover phosphorus (P) fertilizers from nutrient-rich sidestreams, wastewater utilities increasingly elect to employ struvite precipitation processes without a clear understanding of the inherent tradeoffs associated with specific design and operating decisions. Specifically, the impact of reactor conditions on struvite crystallization rate, and distribution between formation of fines particles and secondary growth onto large diameter seed crystals represent critical knowledge gaps limiting the predictive capabilities of existing process models. In this work, the relative impacts of initial supersaturation (S_i), and seed loading, on P removal kinetics, and struvite solids distribution were investigated. In experiments conducted at different levels of initial supersaturation (1.7-2.4) and seed loading (0-25 g L^-1), struvite fines represented the majority of phosphate solids formed in 10 of 12 conditions. While total P removal was dependent on S_i, and primarily attributed to formation of fines, the concentration of struvite seed granules had a significant impact on the rate of P removal. Struvite seed granules increased the rate of precipitation by reducing induction time of primary nucleation of struvite fines. Secondary crystal growth represented the majority of struvite solids formed at high seed loading and low S_i, but presented the tradeoff of low total removal and low rate of removal. To convey the significance of these findings on process modeling, we show how a prominent kinetic model with a first-order dependency on solid struvite concentration over-predicts P removal rate when total mass is dominated by large diameter seeds (0.9 mm). This works reveals the critical role of struvite fines in P removal, and highlights the need to account for their production and kinetic importance in struvite process design and operation.