Oxygen-enriched air for co-incineration of organic sludges with municipal solid waste: a pilot plant experiment

Pilot-plant experiments were performed to evaluate the effect of oxygen enrichment on the co-incineration of MSW and organic sludge from a wastewater treatment facility. Combustion chamber temperatures, stack gas concentrations, i.e., CO(2) and CO, and the residual oxygen were measured. The maximum ratio of organic sludge waste to total waste input was 30 wt.%. Oxygen-enriched air, 22 vol.% (dry basis) oxygen, was used for stable combustion. As the co-incineration ratio of the sludge increased, the primary and secondary combustion chamber temperatures were decreased to 900 and 750 degrees C, respectively, approximately 100 degrees C below the proper incineration. However, if the supplied air was enriched with 22 vol.% (dry basis) oxygen content, the incinerator temperature was high enough to burn the waste mixture containing 30 wt.% moisture sludge, with an estimated heating value of 6.72 MJ/kg. There are two main benefits of using oxygen enrichment in the co-incineration. First, the sensible heat can be reduced as the quantity of nitrogen in the flue gas will be decreased. Second, the unburned carbon formation is reduced due to the oxygen-enriched burning of the waste, despite an increase in the sludge co-incineration ratio.     

Life cycle assessment of sewage sludge co-incineration in a coal-based power station

A life cycle assessment was conducted to evaluate the environmental and economic effects of sewage sludge co-incineration in a coal-fired power plant. The general approach employed by a coal-fired power plant was also assessed as control. Sewage sludge co-incineration technology causes greater environmental burden than does coal-based energy production technology because of the additional electricity consumption and wastewater treatment required for the pretreatment of sewage sludge, direct emissions from sludge incineration, and incinerated ash disposal processes. However, sewage sludge co-incineration presents higher economic benefits because of electricity subsidies and the income generating potential of sludge. Environmental assessment results indicate that sewage sludge co-incineration is unsuitable for mitigating the increasing pressure brought on by sewage sludge pollution. Reducing the overall environmental effect of sludge co-incineration power stations necessitates increasing net coal consumption efficiency, incinerated ash reuse rate, dedust system efficiency, and sludge water content rate.     

Environmental assessment of supercritical water oxidation and other sewage sludge handling options.

Sustainable development relies on the eco-efficient use of all flows in society; more value created out of each resource unit. Supercritical water oxidation (SCWO) can be used for treatment of wet organic waste. The technology has been under development for over 20 years but has not yet been fully commercialized. SCWO allows for complete oxidation of all organics in sewage sludge and almost complete recovery of the inherent energy, essentially without harmful emissions. In this paper, a life-cycle assessment (LCA) of sewage sludge SCWO (Aqua-Critox) is presented and the results are compared with LCA results for other sludge handling options: agricultural use, co-incineration with municipal solid waste, incineration with subsequent phosphorus extraction (Bio-Con) and sludge fractionation with phosphorus recovery (Cambi-KREPRO). For SCWO, beneficial utilization of the heat of reaction is of crucial importance for the outcome. The electricity consumed by pumping and the nitrous oxide produced are other important parameters. The best sludge handling option from an environmental point of view depends on what aspect is considered more important in the impact assessment. Regarding global warming, the energy recovery methods perform better than agricultural use.     

The important role of microwave receptors in bio-fuel production by microwave-induced pyrolysis of sewage sludge

Microwave receptor plays an important role in the microwave pyrolysis of sewage sludge in view of its significant influence on the yield and property of bio-fuel products. The yield and the chemical compositions of bio-fuels (gases and oils) obtained from sewage sludge mixed with different receptors (graphite, residue char, active carbon or silicon carbide) were investigated in this study by Gas Chromatography (GC), Gas Chromatography-Mass Spectrometry (GC-MS), and Fourier Transform Infrared Spectroscopy (FTIR). The results showed that the use of silicon carbide gave rise to the highest final temperature of 1130 °C, resulting in the highest yield of gas fraction (up to 63.2 wt.%). The low heating rate (200 °C/min) which was attributed to the addition of residue char promoted condensation reactions and resulted in an increase in solid yield. The existence of active carbon could prolong the resistance time of volatiles in the hot zone owing to its porous structure, generating the maximum concentration of H₂ + CO (60%) in the pyrolysis gas. When graphite was used, the final low temperature favoured the cyclization of the alkenes, giving rise to a higher concentration of mononuclear aromatics in the pyrolysis oils. The model established in this study revealed that the quantity and quality of the products obtained from the microwave pyrolysis highly depended on the process conditions, which were influenced by the receptor significantly.     

Limitations for heavy metal release during thermo-chemical treatment of sewage sludge ash

Phosphate recycling from sewage sludge can be achieved by heavy metal removal from sewage sludge ash (SSA) producing a fertilizer product: mixing SSA with chloride and treating this mixture (eventually after granulation) in a rotary kiln at 1000 ± 100 °C leads to the formation of volatile heavy metal compounds that evaporate and to P-phases with high bio-availability. Due to economical and ecological reasons, it is necessary to reduce the energy consumption of this technology. Generally, fluidized bed reactors are characterized by high heat and mass transfer and thus promise the saving of energy. Therefore, a rotary reactor and a fluidized bed reactor (both laboratory-scale and operated in batch mode) are used for the treatment of granulates containing SSA and CaCl₂. Treatment temperature, residence time and - in case of the fluidized bed reactor - superficial velocity are varied between 800 and 900 °C, 10 and 30 min and 3.4 and 4.6 m s⁻¹. Cd and Pb can be removed well (>95 %) in all experiments. Cu removal ranges from 25% to 84%, for Zn 75-90% are realized. The amount of heavy metals removed increases with increasing temperature and residence time which is most pronounced for Cu.In the pellet, three major reactions occur: formation of HCl and Cl₂ from CaCl₂; diffusion and reaction of these gases with heavy metal compounds; side reactions from heavy metal compounds with matrix material. Although, heat and mass transfer are higher in the fluidized bed reactor, Pb and Zn removal is slightly better in the rotary reactor. This is due the accelerated migration of formed HCl and Cl₂ out of the pellets into the reactor atmosphere. Cu is apparently limited by the diffusion of its chloride thus the removal is higher in the fluidized bed unit.     

Moisture retention of municipal solid waste mixed with sewage sludge and ash in a semi-arid climate.

Mechanisms involved in moisture storage in refuse are explored using data from four sets of experiments in a semi-arid climate. Two laboratory series of experiments contained municipal solid waste (MSW) amended with sewage sludge, one with higher proportions of ash in the MSW than the other. Outdoor experiments contained waste streams with different proportions of ash. Field cells compared moisture retention of refuse and MSW co-disposed with sewage sludge. Sewage sludge at high loads was found to increase the moisture storage relative to unamended MSW. Belt-pressed sludge retained water as bound water that was released by decay and changing pH. Sun-dried sludge also retained more moisture than MSW alone. In gravimetric terms, ash reduced the storage potential of MSW, in laboratory and outdoor experiments. However, outdoor experiments released less leachate from ash-rich refuse than middle-income waste with no ash fraction.     

Modeling of the reburning process using sewage sludge-derived syngas

Gasification of sewage sludge can provide clean and effective reburning fuel for combustion applications. The motivation of this work was to define the reburning potential of the sewage sludge gasification gas (syngas). A numerical simulation of the co-combustion process of syngas in a hard coal-fired boiler was done. All calculations were performed using the Chemkin programme and a plug-flow reactor model was used. The calculations were modelled using the GRI-Mech 2.11 mechanism. The highest conversions for nitric oxide (NO) were obtained at temperatures of approximately 1000-1200 K. The combustion of hard coal with sewage sludge-derived syngas reduces NO emissions. The highest reduction efficiency (>90%) was achieved when the molar flow ratio of the syngas was 15%. Calculations show that the analysed syngas can provide better results than advanced reburning (connected with ammonia injection), which is more complicated process.     

The effect of bed properties on methane removal in an aerated biofilter--model studies

The capacity of laboratory-scale aerated biofilters to oxidize methane was investigated. Four types of organic and mineral-organic materials were flushed with a mixture of CH₄, CO₂ and air (1:1:8 by volume) during a six-month period. The filter bed materials were as follows: (1) municipal waste compost, (2) an organic horticultural substrate, (3) a composite of expanded perlite and compost amended with zeolite, and (4) the same mixture of perlite and compost amended with bentonite. Methanotrophic capacity during the six months of the experiment reached maximum values of between 889 and 1036 g m⁻² d⁻¹. Batch incubation tests were carried out in order to determine the influence of methane and oxygen concentrations, as well as the addition of sewage sludge, on methanotrophic activity. Michaelis constants K_M for CH₄ and O₂ were 4.6-14.9%, and 0.7-12.3%, respectively. Maximum methanotrophic activities V_max were between 1.3 and 11.6 cm³ g⁻¹ d⁻¹. The activity significantly increased when sewage sludge was added. The main conclusion is that the type of filter bed material (differing significantly in organic matter content, water-holding capacity, or gas diffusion coefficient) was not an important factor in determining methanotrophic capacity when oxygen was supplied to the biofilter.     

Characteristics of carbonized sludge for co-combustion in pulverized coal power plants

Co-combustion of sewage sludge can destabilize its combustion profile due to high volatility, which results in unstable flame. We carried out fuel reforming for sewage sludge by way of carbonization at pyrolysis temperature of 300-500 °C. Fuel characteristics of carbonized sludge at each temperature were analyzed. As carbonization temperature increased, fuel ratio increased, volatile content reduced, and atomic ratio relation of H/C and O/C was similar to that of lignite. The analysis result of FT-IR showed the decrease of aliphatic C-H bond and O-C bond in carbonization. In the analysis result of TG-DTG, the thermogravimetry reduction temperature of carbonized sludge (CS400) was proven to be higher than that of dried sludge, but lower than that of sub-bituminous coal. Hardgrove grindability index increased in proportion to fuel ratio increase, where the carbonized sludge value of 43-110 was similar or higher than the coal value of 49-63. As for ash deposits, slagging and fouling index were higher than that of coal. When carbonized sludge (CS400) and coal were co-combusted in 1-10% according to calorific value, slagging tendency was low in all conditions, and fouling tendency was medium or high according to the compositions of coal.     

Evaluation of a lime-mediated sewage sludge stabilisation process. Product characterisation and technological validation for its use in the cement industry

This paper describes an industrial process for stabilising sewage sludge (SS) with lime and evaluates the viability of the stabilised product, denominated Neutral, as a raw material for the cement industry. Lime not only stabilised the sludge, raised the temperature of the mix to 80-100 °C, furthering water evaporation, portlandite formation and the partial oxidation of the organic matter present in the sludge.Process mass and energy balances were determined. Neutral, a white powder consisting of portlandite (49.8%), calcite (16.6%), inorganic oxides (13.4%) and organic matter and moisture (20.2%), proved to be technologically apt for inclusion as a component in cement raw mixes. In this study, it was used instead of limestone in raw mixes clinkerised at 1400, 1450 and 1500 °C. These raw meals exhibited greater reactivity at high temperatures than the limestone product and their calcination at 1500 °C yielded clinker containing over 75% calcium silicates, the key phases in Portland clinker. Finally, the two types of raw meal (Neutral and limestone) were observed to exhibit similar mineralogy and crystal size and distribution.     

Reduction of tar using cheap catalysts during sewage sludge gasification

Solid-fuel conversion or gasification study of sewage sludge and energy recovery has become increasingly important because energy recovery and climate change are emerging issues. Various types of catalysts, such as dolomite, steel slag and calcium oxide, were tested for tar reduction during the sewage sludge gasification process. For the experiments on sewage sludge gasification reactions and tar reduction using the catalysts, a fixed bed of laboratory-scale experimental apparatus was set up. The reactor was made of quartz glass using an electric muffle furnace. The sewage sludge samples used had moisture contents less than 6%. The experimental conditions were as follows: sample weight was 20 g and reaction time was 10 min, gasification reaction temperature was from 600 to 800°C, and the equivalence ratio was 0.2. The quantity of catalysts was 2–6 g, and temperatures of catalyst layers were 500–700°C. As the reaction temperature increased up to 800°C, the yields of gaseous products and liquid products increased, whereas char and tar products decreased, showing effects on gas product compositions. These results were considered to be due to the increase of the water-gas reaction and Boudouard reaction. In the case of experiments with catalysts, dolomite (4 g), steel slag (6 g) and calcium oxide (6 g) were used. When the temperature of catalysts increased, the weight of the tar produced decreased with different cracking performances by different catalysts. Reforming reactions were considered to occur on the surface of dolomite, steel slag and calcium oxide, causing cracking of the hydrocarbon structure, which eventually showed reduced tar generation.     

Food waste impact on municipal solid waste angle of internal friction

The impact of food waste content on the municipal solid waste (MSW) friction angle was studied. Using reconstituted fresh MSW specimens with different food waste content (0%, 40%, 58%, and 80%), 48 small-scale (100-mm-diameter) direct shear tests and 12 large-scale (430 mm × 430 mm) direct shear tests were performed. A stress-controlled large-scale direct shear test device allowing approximately 170-mm sample horizontal displacement was designed and used. At both testing scales, the mobilized internal friction angle of MSW decreased considerably as food waste content increased. As food waste content increased from 0% to 40% and from 40% to 80%, the mobilized internal friction angles (estimated using the mobilized peak (ultimate) shear strengths of the small-scale direct shear tests) decreased from 39° to 31° and from 31° to 7°, respectively, while those of large-scale tests decreased from 36° to 26° and from 26° to 15°, respectively. Most friction angle measurements produced in this study fell within the range of those previously reported for MSW.     

Incorporation of sewage sludge in clay brick and its characterization.

This study reports the use of sewage sludge generated from sewage treatment plant (STP) as raw material in a clay brick-making process. The physico-chemical and mineralogical characterization of the sewage sludge and clay were carried out in order to identify the major technological constraints and to define the sludge pretreatment requirements if necessary. Moreover, the effects on processing conditions and/or on changes of typical final characteristics are also evaluated. Bricks were produced with sewage sludge additions ranging from 10 to 40% by dry weight. The texture and finishing of the surface of sludge-amended clay bricks were rather poor. As for the physical and chemical properties, bricks with a sludge content of up to 40 wt.% were capable of meeting the relevant technical standards. However, bricks with more than 30 wt.% sludge addition are not recommended for use since they are brittle and easily broken even when handled gently. A tendency for a general degradation of brick properties with sludge additions was observed due to its refractory nature. Therefore, sludge bricks of this nature are only suitable for use as common bricks, which are normally not exposed to view, because of poor surface finishing.     

Anaerobic digestion of chicken feather with swine manure or slaughterhouse sludge for biogas production

Biogas production from anaerobic digestion of chicken feathers with swine manure or slaughterhouse sludge was assessed in two separate experiments. Ground feathers without any pre-treatment were added to 42-L digesters inoculated with swine manure or slaughterhouse sludge, representing 37% and 23% of total solids, respectively and incubated at 25 °C in batch mode. Compared to the control without feather addition, total CH₄ production increased by 130% (P < 0.001) and 110% (P = 0.09) in the swine manure and the slaughterhouse sludge digesters, respectively. Mixed liquor NH₄N concentration increased (P < 0.001) from 4.8 and 3.1 g/L at the beginning of the digestion to 6.9 and 3.5 g/L at the end of digestion in the swine manure and the slaughterhouse sludge digesters, respectively. The fraction of proteolytic microorganisms increased (P < 0.001) during the digestion from 12.5% to 14.5% and 11.3% to 13.0% in the swine manure and the slaughterhouse sludge digesters with feather addition, respectively, but decreased in the controls. These results are reflective of feather digestion. Feather addition did not affect CH₄ yields of the swine manure digesters (P = 0.082) and the slaughterhouse sludge digesters (P = 0.21), indicating that feathers can be digested together with swine manure or slaughterhouse sludge without negatively affecting the digestion of swine manure and slaughterhouse sludge.     

Comparison of coal/solid recovered fuel (SRF) with coal/refuse derived fuel (RDF) in a fluidized bed reactor

An experimental study was undertaken to compare the differences between municipal solid waste (MSW) derived solid recovered fuel (SRF) (complying with CEN standards) and refuse derived fuel (RDF). Both fuels were co-combusted with coal in a 50 kW fluidised bed combustor and the metal emissions were compared. Synthetic SRF was prepared in the laboratory by grinding major constituents of MSW such as paper, plastic, textile and wood. RDF was obtained from a local mechanical treatment plant. Heavy metal emissions in flue gas and ash samples from the (coal + 10% SRF) fuel mixture were found to be within the acceptable range and were generally lower than that obtained for coal + 10% RDF fuel mixture. The relative distribution of heavy metals in ash components and the flue gas stream shows the presence of a large fraction (up to 98%) of most of the metals in the ash (except Hg and As). Thermo-gravimetric (TG) analysis of SRF constituents was performed to understand the behaviour of fuel mixtures in the absence and presence of air. The results obtained from the experimental study will enhance the confidence of fuel users towards using MSW-derived SRF as an alternative fuel.     

Combustion kinetics of sewage sludge and combustible wastes

This study estimated the kinetics of the mono- and co-combustion of sewage sludge pellets and combustible wastes such as municipal solid waste (MSW) and refuse-derived fuel (RDF). Sewage sludge was manufactured into pellets with a diameter of 8, 12, or 16 mm and a length of 30 mm. The RDF was composed of paper and plastics and was formed into pellets with a diameter of 8 mm and a length of 30 mm. MSW samples were synthesized using combustible wastes such as garbage, paper, plastics, and wood. The MSW was adjusted to have a moisture content of around 40% after shredding to under 10 mm. A laboratory-scale batch type stoker incinerator was used for the combustion and the gas composition of the flue gas was measured. The activation energy was calculated using the experimental results, and then the relation of the decomposition rate and reaction time was evaluated using the shrinking core model. The decomposition rate of the sludge pellets decreased as their diameter and moisture content increased, and the co-combustion of sludge pellets and combustible waste was affected by the amount of combustible waste. The individual combustion rates of the cylindrical sludge pellets or RDF were mainly controlled by the chemical reaction, but in the case of shredded MSW it was mostly influenced by gas diffusion. The rate for the co-combustion of sludge pellets and combustible wastes was mainly determined by the combustion rate of the combustible waste. The activation energy of the 8-mm-diameter sludge pellets was between 6.70 and 10.0 kcal/mol, according to the moisture content, but it was lower for MSW and RDF. In the case of MSW co-combustion, the reaction rate accelerated as the moisture content of the sludge pellets decreased, but it was markedly increased by the addition of RDF, regardless of the sludge moisture content.     

Reduction of hazardous elements contained in sewage sludge incineration ash

Research and experimental studies were carried out in relation to reduction of hazardous elements contained in sewage sludge incineration ash. A questionnaire survey was conducted in 69 Japanese municipalities with sewage sludge incineration facilities. Selenium content in bag filter ash and ceramic filter ash was relatively higher than that in ash of cyclone and electrostatic precipitators. It was assumed that selenium vaporized in the furnace was due to adsorb in the fly ash on filter when passing through the low-temperature filter. To reduce high boiling point heavy metals in the ash, sewage sludge and incineration ash were heated up using a small muffle furnace. As the result, the chrome and nickel contents were reduced. A decrease in the surface area of ash and the reduction of elements occurred at the same time in sewage sludge and incineration ashes tested in this study.     

Production of well-matured compost from night-soil sludge by an extremely short period of thermophilic composting

The effect of various operational conditions on the decomposition of organic material during the composting of night-soil treatment sludge was quantitatively examined. The optimum composting conditions were found to be a temperature of ca. 60 °C and an initial pH value of 8. Rapid decomposition of organic matter ceased by the sixth day of composting under these optimum conditions, and the final value of the cumulative emission of carbon (E_C), which represents the degree of organic matter decomposition, was less than 40%, indicating that the sludge contained only a small amount of easily degradable organic material. A plant growth assay using Komatsuna (Brassica campestris L. var. rapiferafroug) in a 1/5000a standard cultivation pot was then conducted for the compost at various degrees of organic matter decomposition: the raw composting material, the final compost obtained on day 6, and the 2 intermediate compost products (i.e., E_C = 10% and 20%). It was found that the larger the E_C, the greater the yield of Komatsuna growth. It was also found that 6 days of composting is sufficient to promote Komatsuna growth at the standard loading level, which is equivalent to a 1.5 g N/pot, since the promotion effect was as high as that obtained using chemical fertilizer. It can therefore be concluded that well-matured compost could be obtained in a short period of time (i.e., as early as 6 days), when night-soil sludge is composted under optimum conditions.     

The toxicity of composts from sewage sludges evaluated by the direct contact tests phytotoxkit and ostracodtoxkit

Limitations relating to permissible standards of undesirable substances in sewage sludges make it necessary to optimize sludge properties. One of the methods to achieve the above goal is the use of a composting process. The aim of this study was to determine the toxicity of composts obtained from sewage sludges composted for 76 days. Dewatered sewage sludges were collected from the four wastewater treatment plants located in the south-eastern part of Poland (Kraśnik, Lublin, Biłgoraj and Zamość). The sludges were mixed with standard OECD soil at doses of 6% and 24%. Phytotoxkit (with Lepidium sativum) and ostracodtoxkit (with Heterocypris incongruens) tests were used to evaluate toxicity. The results obtained showed different toxicity of sewage sludge depending on the sludge dose and bioassay used. H. incongruens mortality ranged from 0% to 90% and depended on the sewage sludge. The greatest inhibition of test organism growth was noted at a level of 55%. In the case of the Phytotoxkit test, a clearly negative influence of the sewage sludges on seed germination was observed at a dose of 24%. Root growth inhibition was noted in the case of most sewage sludges and was at a level of 20–100%. The influence of the composting on the toxicity of biosolids also showed various trends depending on the sludge type. Sludge composting often resulted in a toxicity increase in relation to H. incongruens. In the case of plants (Phytotoxkit test) and most sewage sludges, however, the composting process influenced both the seed germination and root growth in a positive way.     

Recycling of Malaysia’s electric arc furnace (EAF) slag waste into heavy-duty green ceramic tile

Recently, various solid wastes from industry such as glass waste, fly ash, sewage sludge and slag have been recycled into various value-added products such as ceramic tile. The conventional solutions of dumping the wastes in landfills or incineration, including in Malaysia are getting obsolete as the annual huge amount of the solid wastes would boost-up disposal cost and may cause permanent damage to the flora and fauna. This recent waste recycling approach is much better and greener as it can resolve problems associated with over-limit storage of industrial wastes and reduce exploration of natural resources for ceramic tile to continuously sustain the nature. Therefore, in this project, an attempt was made to recycle electric arc furnace (EAF) slag waste, obtained from Malaysia’s steel making industry, into ceramic tile via conventional powder compaction method. The research work was divided into two stages. The first stage was to evaluate the suitability of EAF slag in ceramic tile by varying weight percentage of EAF slag (40 wt.%, 50 wt.% and 60 wt.%) and ball clay (40 wt.%, 50 wt.% and 60 wt.%), with no addition of silica and potash feldspar. In the second stage, the weight percentage of EAF slag was fixed at 40 wt.% and the percentage of ball clay (30 wt.% and 40 wt.%), feldspar (10 wt.% and 20 wt.%) and silica (10 wt.% and 20 wt.%) added was varied accordingly. Results obtained show that as weight percentage of EAF slag increased up to 60 wt.%, the percentage of apparent porosity and water absorption also rose, with a reduction in tile flexural strength and increased porosity. On the other hand, limiting the weight percentage of EAF slag to 40 wt.% while increasing the weight percentage of ball clay led to a higher total percentage of anorthite and wollastonite minerals, resulting in higher flexural strength. It was found that introduction of silica and feldspar further improved the flexural strength due to optimization of densification process. The highest flexural strength, lowest apparent porosity and water absorption of EAF slag based tile was attained at the composition of 40 wt.% EAF slag – 30 wt.% ball clay – 10 wt.% feldspar – 20 wt.% silica. The properties of ceramic tile made with EAF slag waste (up to 40 wt.%), especially flexural strength are comparable to those of commercial ceramic tile and are, therefore, suitable as high flexural strength and heavy-duty green ceramic floor tile. Continuous development is currently underway to improve the properties of tile so that this recycling approach could be one of the potential effective, efficient and sustainable solutions in sustaining our nature.