Machine learning for municipal sludge recycling by thermochemical conversion towards sustainability

The sustainable disposal of high-moisture municipal sludge (MS) has received increasing attention. Thermochemical conversion technologies can be used to recycle MS into liquid/gas bio-fuel and value-added solid products. In this review, we compared energy recovery potential of common thermochemical technologies (i.e., incineration, pyrolysis, hydrothermal conversion) for MS disposal via statistical methods, which indicated that hydrothermal conversion had a great potential in achieving energy recovery from MS. The application of machine learning (ML) in MS recycling was discussed to decipher complex relationships among MS components, process parameters and physicochemical reactions. Comprehensive ML models should be developed considering successive reaction processes of thermochemical conversion in future studies. Furthermore, challenges and prospects were proposed to improve effectiveness of ML for energizing thermochemical conversion of MS regarding data collection and preprocessing, model optimization and interpretability. This review sheds light on mechanism exploration of MS thermochemical recycling by ML, and provide practical guidance for MS recycling.

Integral evaluation of effective conversion of sewage sludge from WWTP into highly porous activated carbon

Urban sewage sludge (SL) is a major concern due to the number of environmental problems it causes. Its application for different purposes is strictly regulated, limiting the possibilities of recycling and reusing this material. Thus, in this work, a complete study of a simple method to convert SL into activated carbon (AC) was carried out. The comprehensive study involves an evaluation of the main process parameters, such as the activating agent (AA) content (25 %, 33 %, 50 %), using the lowest amount of AA as novelty, different pyrolysis temperatures (600 and 800 °C), and purification conditions (6 M HCl:AC ratio, v:w). Under controlled and optimised conditions and through a single combined activation and pyrolysis step followed by acid purification, ACs with well-developed porosity can be obtained. Surface area values of around 870 m2/g and over 60 % carbon content were achieved, demonstrating that the prepared ACs could have applications in a wide variety of fields as high-value products. As an innovative aspect in this research, the gases streams and liquid effluents generated during the global process were analysed, achieving elimination of over 63 % of the concentration of the chemical elements contained in the SL during the chemical purification stage. Finally, mass, energy, and economic balances were carried out to estimate the production cost of AC derived from SL (<€ 8/kg AC).

A thematic review on livestock manure treatment strategies focusing on thermochemical conversion

Livestock manure (LSM) management is emerging as a challenge due to increasing livestock consumption. Owing to the decreased agricultural land area, it is necessary to ensure LSM utilization in non-agricultural fields. LSM can be a valuable resource if managed as a circulating resource. This study discusses research trends based on a literature review and classifies LSM treatments. The analysis of each treatment is presented according to research trends, and implications for the future LSM processing are discussed. "Biological treatment" accounted for the largest portion at 48%, "manure management," which suggests improvement in manure treatment through systematic thinking or LSM management practices, accounted for 16%, and "thermochemical conversion" accounted for 11%. In addition, "life cycle assessment (LCA) research," "solid-liquid separation approach," and "nutrient-recovery/losses" were derived. Studies on biological treatments are increasing. Although anaerobic digestion (AD) is the most used method, it has the disadvantages of long processing time and waste generation after processing. As a key supplement, thermochemical conversion (TCC) technology, which could overcome the disadvantages of AD, was reviewed.

A review on the thermochemical treatments of biomass: Implications for hydrochar production and rare earth element recovery from hyperaccumulators

Phytomining is a promising method that employs hyperaccumulators to concentrate metals from various substrates. Many studies on phytomining have been reported in the literature, while how to recover metals from hyperaccumulators has not been well resolved, which is critical for developing a complete phytomining-based metal recovery process. The most straightforward approach is to combust hyperaccumulators and recover metals from the combustion residue. However, the combustion process results in significant waste and carbon emissions. In contrast to combustion, thermochemical treatments can convert the biomass of hyperaccumulators to valuable products, such as biochar, hydrochar, biocrudes, and biogas. Therefore, it is more sustainable to develop a process that combines thermochemical treatments for metal recovery from hyperaccumulators. To achieve this objective, a systematic and comprehensive understanding of product characteristics and metal fate during thermochemical processing is required. In this article, three emerging thermochemical technologies, i.e., microwave-assisted pyrolysis, hydrothermal processing, and microwave-assisted hydrothermal treatment, are systematically reviewed in terms of conversion mechanisms, merits, demerits, product characteristics, and metal fate. Significant findings reported in the literature on the effects of operating parameters on product characteristics and metal fate during thermochemical treatment of waste biomass, especially those from hyperaccumulators, were summarized. Due to limited studies on thermochemical treatments of rare earth element hyperaccumulators, this review is expanded to include hyperaccumulators of any metal species. Based on comparisons among the three emerging thermochemical treatment technologies, microwave-assisted hydrothermal pyrolysis is identified as the most promising approach that favors carbon product obtainment and REE recovery from hyperaccumulators.

Catalytic hydrothermal carbonization of wet organic solid waste: A review

Hydrothermal carbonization has gained attention in converting wet organic solid waste into hydrochar with many applications such as solid fuel, energy storage material precursor, fertilizer or soil conditioner. Recently, various catalysts such as organic and inorganic catalysts are employed to guide the properties of the hydrochar. This review presents a summarize and a critical discussion on types of catalysts, process parameters and catalytic mechanisms. The catalytic impact of carboxylic acids is related to their acidity level and the number of carboxylic groups. The catalysis level with strong mineral acids is likely related to the number of hydronium ions liberated from their hydrolysis. The impact of inorganic salts is determined by the Lewis acidity of the cation. The metallic ions in metallic salts may incorporate into the hydrochar and increase the ash of the hydrochar. The selection of catalysts for various applications of hydrochars and the environmental and the techno-economic aspects of the process are also presented. Although some catalysts might enhance the characteristics of hydrochar for various applications, these catalysts may also result in considerable carbon loss, particularly in the case of organic acid catalysts, which may potentially ruin the overall advantage of the process. Overall, depending on the expected application of the hydrochar, the type of catalyst and the amount of catalyst loading requires careful consideration. Some recommendations are made for future investigations to improve laboratory-scale process comprehension and understanding of pathways as well as to encourage widespread industrial adoption.

Hydrothermal carbonization combined with thermochemical treatment of sewage sludge: Effects of MgCl2 on the migration of phosphorus and heavy metal

Phosphorus (P) is a non-regenerative and finite raw material. Due to its decreasing availability, and to protect the environment, recycling methods are needed. With the focus on closing nutrient cycles, sewage sludge (SS) is a potential source for P recovery. The objective of this study was to produce a mineral P-reach fertilizer. For this purpose, the treatment of SS in a multi-stage process, consisting of a hydrothermal carbonization (HTC) and thermochemical post-treatment was examined and compared with a direct thermochemical treatment. The focus was on the transformation of P and the migration of the heavy metals during the processes. In addition, the role of MgCl₂ as an additive was examined. During the HTC, most of the P remained in the HTC-char, so that the P content increased in the HTC-char compared with the SS. The addition of MgCl₂ to the process resulted in lower transportation rates of P in the liquid phase and higher P solubilities in water, citric acid, and alkalic ammonium citrate out of the solid phase. The thermochemical treatment of SS and the HTC-chars further concentrated P in the ash. Retention rates of >97% were achieved, and P₂O₅ contents in the ash were as high as ∼16 wt-%. The presence of the additive resulted in (i) higher retention rates of P in the ashes (ii) higher P-solubility and (iii) higher removal rates of easily volatile heavy metals such as Pb and Zn, and the treatment of HTC-char favored these effects compared with the direct treatment of SS.

Management of university solid waste in China through gasification technology: An analysis of waste composition and energy potential

This study explored the composition and energy potential of university solid waste (USW) in China. Five combustible components, namely hard plastics (HP), paper (PP), soft plastics (SP), biomass (BM), and rubber (RB), were screened with the compositions 51%, 29%, 9%, 4%, and 3%, respectively. Each USW sample was gasified using a thermogravimetric analyzer (TGA) coupled with mass spectrometry (MS) at the heating rates of 5, 10, and 15 ℃/min and a final process temperature of 900 ℃. Thermal weight loss (TG) curves exposed the degradation in the order HP > SP > RB > BM > PP. Derivative thermogravimetric (DTG) peaks revealed that HP, PP, BM, and SP were degraded in three temperature-oriented phases in the range 172-731 ℃. The RB took an additional phase in the range 584-660 ℃. Major released gases, H₂, CH₄, CO, and CO₂, were detected using MS via mass-to-charge (m/z) ratios. Higher H₂ and total gas yield produced in the case of the HP dominated other materials at the lower heating rate of 5 ℃/min. Validation of data was assessed by equating experimental and calculated curves; therefore, the regression coefficient (R²) ranged between 0.884 and 0.997. The kinetics of the process were estimated by applying the Flynn-Wall-Ozawa (FWO) model at the conversion rates (α) of 0.2, 0.5, and 0.8, which presented reasonable results. Overall, the lower heating rates supported higher thermal conversion and a high quantity of gaseous products for all the components.

Thermochemical conversion of heavy metal contaminated biomass: Fate of the metals and their impact on products

With the rapid depletion of fossil energy and increasingly severe environmental pollution, the development of biomass resources for biorefineries has become a new research focus. However, heavy metals may be released during the thermochemical treatment when the biomass materials used in biomass conversion are contaminated by heavy metals. This can cause secondary environmental pollution or transference to the target products, reducing product quality. Therefore, having a systematic understanding of the fate of heavy metals in biomass conversion is necessary for alleviating potential risks. This study presents the current status of contaminated biomass and conversion products involving thermochemical processes, the migration, transformation, and impact of heavy metals in biomass conversion was investigated, and the utilization of heavy metals in contaminated biomass was briefly outlined. This review aims to link biomass conversion to the fate of heavy metals, avoid existing risks as much as possible to produce cleaner products efficiently, and promote the sustainable development of heavy metal contaminated biomass resources.

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.

Molecular characterization and environmental impacts of water-soluble organic compounds of bio-oil from the thermochemical treatment of domestic sewage sludge

Water-soluble organic compounds derived from bio-oil (WOCB) are regarded as potential risk sources of sludge thermochemical treatment. This study showed that 10.35 mg of water-soluble organic carbon and 1.32 mg of water-soluble organic nitrogen were released per gram of sludge when the final temperature of thermochemical treatment was 600 °C. WOCB was mainly formed at 300-500 °C. Furthermore, FT-ICR MS results indicated that high temperatures promoted deamination reactions, and low molecular weight (LMW) compounds with low oxygen number polymerized into aromatic compounds with increasing temperature. Noteworthily, WOCB released at 20-600 °C showed strong phytotoxicity to wheat. LMW compounds with lignin/carboxylic rich alicyclic molecules (CRAM)-like structures derived from low temperatures (200-400 °C) induced this inhibitory effect, but lipids containing nitrogen and sulfur from high temperatures (400-600 °C) can act as nutrients to promote wheat growth. This study provides theoretical support for the risk control and benefits assessments of sludge thermochemical treatment.

Fate of heavy metals and polycyclic aromatic hydrocarbons (PAH) in sewage sludge carbonisates and ashes - A risk assessment to a thermochemical phosphorus-recycling process

In the near future, phosphorus (P) recycling will gain importance in terms of decreasing primary resources. Sewage sludge (SSL) is an adequate secondary P-resource for P-fertilizer production but it is also a sink for heavy metals and organic pollutants. The present study is an investigation on thermochemical P-recycling of SSL. Various temperatures and amendments were tested regarding their performance to remove heavy metals and polycyclic aromatic hydrocarbons (PAH) and simultaneous increase of the plant-availability of P. The investigations were carried out on two types of SSL originating from wastewater treatment plants with chemical P-precipitation and enhanced biological P-removal, respectively. The results show that thermochemical treatment with chlorine donors is suitable to remove the majority of heavy metals and that a combination of a gaseous chlorine donor (HCl) and sodium additives leads to both high heavy metal removal and high plant availability of P. Furthermore, plant experiments show that almost all investigated thermochemical treatments can significantly reduce the bioavailability and plant uptake of heavy metals. Furthermore, PAHs are secondarily formed during low-temperature treatments (400-500 °C), but can be significantly reduced by using sodium carbonate as an additive.

Addendum to "Process development for elemental recovery from PGM tailings by thermochemical treatment: Preliminary major element extraction studies using ammonium sulphate as extracting agent" [Waste Manage. 50 (2016) 334-345]

In a recent paper, a promising two-stage process for the extraction of major elements from Platinum Group Metals (PGM) was presented (Mohamed et al., 2016). This process involved solid-solid thermochemical treatment of tailings with ammonium sulphate (stage one), followed by an optimised acid dissolution step (stage two). The inclusion of a control experiment for the optimal dissolution procedure was however overlooked. The new set of data delivered by the control experiment reveals that (i) most of the silicon and calcium are extracted via the acid leaching step, (ii) aluminium and magnesium are extracted at each stage of the process, and (iii) the thermochemical step is the main contributor to chromium and iron extraction. The conclusion of the previous paper (Mohamed et al., 2016), whereby thermochemical treatment with ammonium sulphate represents a promising technology for extracting valuable elements from South African PGM tailings, withstands.

Effect of various types of thermochemical processing of sewage sludges on phosphorus speciation, solubility, and fertilization performance

Sewage sludge has one of the highest phosphorus (P) recovery potentials of all waste materials. Therefore, P-recycling from sewage sludge could contribute to closing the P-cycle. Recently, various thermal processes for P-recovery have been developed, but there is still a demand for information on the effect of different process parameters (e.g. additives and temperature) on P-speciation and especially on the fertilization performance. In the present study, two common methods (low-temperature conversion at 400-500°C and thermochemical treatment at 950°C) were investigated and combined to produce highly bioavailable P-fertilizers from two different types of sewage sludge based on chemical phosphorus precipitation (Chem-P) and enhanced biological phosphorus removal (Bio-P). The results of P-fractionation, X-ray diffraction analysis, and pot experiments with maize showed that Bio-P sludges attain high P-plant-availability after treatment at low temperatures (400°C). In contrast, Chem-P sludges can adequately be treated at higher temperatures under reductive conditions with sodium additives to form highly bioavailable calcium-sodium-phosphate. Additionally, also highly heavy-metal contaminated sludges can be thermochemically treated at high temperatures to achieve the legal requirements for fertilizers.

Process development for elemental recovery from PGM tailings by thermochemical treatment: Preliminary major element extraction studies using ammonium sulphate as extracting agent

Mine tailings can represent untapped secondary resources of non-ferrous, ferrous, precious, rare and trace metals. Continuous research is conducted to identify opportunities for the utilisation of these materials. This preliminary study investigated the possibility of extracting major elements from South African tailings associated with the mining of Platinum Group Metals (PGM) at the Two Rivers mine operations. These PGM tailings typically contain four major elements (11% Al2O3; 12% MgO; 22% Fe2O3; 34% Cr2O3), with lesser amounts of SiO2 (18%) and CaO (2%). Extraction was achieved via thermochemical treatment followed by aqueous dissolution, as an alternative to conventional hydrometallurgical processes. The thermochemical treatment step used ammonium sulphate, a widely available, low-cost, recyclable chemical agent. Quantification of the efficiency of the thermochemical process required the development and optimisation of the dissolution technique. Dissolution in water promoted the formation of secondary iron precipitates, which could be prevented by leaching thermochemically-treated tailings in 0.6M HNO3 solution. The best extraction efficiencies were achieved for aluminium (ca. 60%) and calcium (ca. 80%). 35% iron and 32% silicon were also extracted, alongside chromium (27%) and magnesium (25%). Thermochemical treatment using ammonium sulphate may therefore represent a promising technology for extracting valuable elements from PGM tailings, which could be subsequently converted to value-added products. However, it is not element-selective, and major elements were found to compete with the reagent to form water-soluble sulphate-metal species. Further development of this integrated process, which aims at achieving the full potential of utilisation of PGM tailings, is currently underway.

Sewage sludge ash--A promising secondary phosphorus source for fertilizer production

Sewage sludge incineration is extensively practiced in some European countries such as the Netherlands, Switzerland, Austria and Germany. A survey of German sewage sludge ash showed that the recovery potential is high, approx. 19,000 t of phosphorus per year. However, the survey also discovered that the bioavailability of phosphorus in the sewage sludge ash is poor and that more than half of the ashes cannot be used as fertilizers due to high heavy metal content. A new thermochemical process for sewage sludge ash treatment was developed that transforms the ash into marketable fertilizer products. Sewage sludge ash was thermochemically treated with sodium and potassium additives under reducing conditions, whereby the phosphate-bearing mineral phases were transformed into plant available phosphates. High P-bioavailability was achieved with a molar Na/P ratio >1.75 in the starting materials. Sodium sulfate, carbonate and hydroxide performed comparably as additives for this calcination process. Potassium carbonate and -hydroxide have to be added in a molar K/P ratio >2.5 to achieve comparable P-solubility. The findings of the laboratory scale investigations were confirmed by an industrial demonstration trial for an ash treatment with sodium sulfate. Simultaneously, the volatile transition metal arsenic (61% removal) as well as volatile heavy metals such as cadmium (80%), mercury (68%), lead (39%) and zinc (9%) were removed via the off-gas treatment system. The product of the demonstration trial is characterized by high bioavailability and a toxic trace element mass fraction below the limit values of the German fertilizer ordinance, thus fulfilling the quality parameters for a P-fertilizer.

An evaluation of tannery industry wastewater treatment sludge gasification by artificial neural network modeling

This paper reports on the calorific value of synthetic gas (syngas) produced by gasification of dewatered sludge derived from treatment of tannery wastewater. Proximate and ultimate analyses of samples were performed. Thermochemical conversion alters the chemical structure of the waste. Dried air was used as a gasification agent at varying flow rates, which allowed the feedstock to be quickly converted into gas by means of different heterogeneous reactions. A lab-scale updraft fixed-bed steel reactor was used for thermochemical conversion of sludge samples. Artificial neural network (ANN) modeling techniques were used to observe variations in the syngas related to operational conditions. Modeled outputs showed that temporal changes of model predictions were in close accordance with real values. Correlation coefficients (r) showed that the ANN used in this study gave results with high sensitivity.