Carbonization of johkasou sludge using batch-type equipment

The carbonization of dehydrated johkasou sludge was examined using batch-type equipment. Based on the temperature changes in the carbonization room and the gas combustion room, the carbonization process was divided into three phases: phase I, drying the sludge; phase II, thermal decomposition of the dried sludge; phase III, after phase II. The times required for phases I and II were strongly correlated with the amounts of water and solid matter, respectively, in dehydrated sludge. The reduction rate of the sludge on completion of phase I was about 90% on average, and the decomposition rate of solid matter increased with time during phase II or phase II plus phase III until it reached about 50%. TOC concentration of the eluate from the carbonized sludge was used as an index to evaluate the progress of the carbonization process, and the highest temperature in the carbonization room was recognized as an important operational factor. The specific surface area and pore volume of carbonized sludge were smaller than those of charcoals and activated carbons by 1–3 orders of magnitude and 1–2 orders of magnitude, respectively. No elution of heavy metals was observed from any of the carbonized sludges examined. The reduced amount of carbon in dehydrated johkasou sludge was estimated to be about 25% of the decomposed organic matter.     

Drying characteristics of sewage sludge using vacuum evaporation and frying

This study was performed to investigate the possibility of utilizing sewage sludge as a fuel. The drying characteristics of sewage sludge were examined by using vacuum evaporation and fry-drying technology in a batch-type rotary evaporator. In addition, the optimal drying conditions of sludge in the vacuum evaporator were investigated in terms of the vacuum pressure, temperature, and oil dosage ratio, etc. Experimental results showed that the moisture content in the sludge decreased with increases in oil/sewage sludge ratio and temperature. Dried sludge fuel (SDF) product could be obtained with on average less than 5% moisture content and a lower heating value of more than 4000 kcal/kg. Considering energy efficiency, we suggest that the optimal operating condition for drying sludge is ?450 mmHg of vacuum, a temperature of 100°C, a drying time of 90 min, and a sludge/oil ratio of 1:1. The SDF product was shaped as granules and fluff-type particles. Evaluated from the perspective of the energy balance and economic considerations, this sludge drying system with vacuum fry drying could be used for effective sludge treatment and the production of SDF.     

Analysis of the combustion of sewage sludge-derived fuel by a thermogravimetric method in China

The treatment and disposal of sewage sludge are significant environmental problems in China. The reuse of sewage sludge for fuel could be an effective solution. The aim of this study was to characterize the behavior of sludge-derived fuel during combustion by a thermogravimetric method. The combustion profiles obtained showed four obvious weight loss regions. The results of dynamics analysis showed that first-order reactions together with Arrhenius’ law explained reasonably well the different stages of weight loss in the samples. Three temperature regions (162–327 °C, 367–445 °C, and 559–653 °C for sawdust and 162–286 °C, 343–532 °C, and 609–653 °C for coal) in each derivative thermogravimetry (DTG) curve corresponded well with the Arrhenius equation. The reactivity of sludge was lower than that of samples containing sawdust, but higher than that of coal-containing samples. These data demonstrate that sludge-derived fuel has better combustion characteristics than sludge, sawdust, or coal.     

Adsorption removal of pollutants by active cokes produced from sludge in the energy recycle process of wastes

This study proposes a recycling system of sludge into active cokes and the fundamental examinations for the application were carried out. In the system, active cokes were produced by carbonizing pellets of sludge in a steam stream. Pyrolysis gas yielded by carbonization can be available to a fuel for a steam generation boiler. The exhaust heat from the boiler is used sequentially for drying of sludge. The active cokes are applied to the adsorbent for dioxin removal in exhaust gas from incinerators of wastes, or for purification of gas obtained in a gasification process of wastes, particularly removal of H2S. The used adsorbent is not recycled, but incinerated in the furnace without a desorption process to decompose adsorbed dioxin or to oxidize H2S for a sequential desulfurization process of SO2. Dry pellets of sludge were carbonized in a quartz tube reactor under various atmospheres. The micro pore structure and the adsorption performance of the cokes produced without activation process were examined. The micro pore structure was influenced by the temperature, the sort of flow gas (N2, CO2 and steam) and carbonization time, and the active cokes produced under the condition of the temperature 823 K for 60 min in the steam atmosphere had a largest specific surface area in the diameter less than 5 nm. The amount of benzene adsorption as an alternative substance of dioxin into the active cokes had a similar quality to a commercial active char produced from coal if it was evaluated by adsorption per a unit specific surface area. This fundamental knowledge must be reflected to an optimum design for development of a simple continuous process to produce the active cokes by a fluidized bed type of the carbonization furnace.     

Study on the co-combustion process and mercury emission characteristics of sewage sludge-coal slime coupled fuel

Journal of Material Cycles and Waste Management - To realize the clean and efficient resource utilization of sewage sludge (SS) and coal slime (CS), single-component and coupled fuels were...     

Characterization of char derived from various types of solid wastes from the standpoint of fuel recovery and pretreatment before landfilling

Carbonization is a kind of pyrolysis process to produce char from organic materials under an inert atmosphere. In this work, chars derived from various solid wastes were characterized from the standpoint of fuel recovery and pretreatment of waste before landfilling. Sixteen kinds of municipal and industrial solid wastes such as residential combustible wastes, non-combustible wastes, bulky wastes, construction and demolition wastes, auto shredder residue, and sludges were carbonized at 500 degrees C for 1h under nitrogen atmosphere. In order to evaluate the quality of char as fuel, proximate analysis and heating value were examined. The composition of raw waste had a significant influence on the quality of produced char. The higher the ratio of woody biomass in waste, the higher heating value of char produced. Moreover, an equation to estimate heating value of char was developed by using the weight fraction of fixed carbon and volatile matter in char. De-ashing and chlorine removal were performed to improve the quality of char. The pulverization and sieving method seems to be effective for separation of incombustibles such as metal rather than ash. Most char met a 0.5 wt% chlorine criterion for utilization as fuel in a shaft blast furnace after it was subjected to repeated water-washing. Carbonization could remove a considerable amount of organic matter from raw waste. In addition, the leaching of heavy metals such as chrome, cadmium, and lead appears to be significantly suppressed by carbonization regardless of the type of raw waste. From these results, carbonization could be considered as a pretreatment method for waste before landfilling, as well as for fuel recovery.     

Characterization of dried sewage sludge for co-firing in coal power plant by using thermal gravimetric analysis

This research studied the characteristics of dried sewage sludge using TGA to co-fire dried sewage sludge with coal in power plants. The sewage sludges that were discharged from Daejeon, Korea were dried and examined fundamental properties to use them as a fuel. Also, the properties of bituminous coal and wood pellet, which are used in domestic coal power plants, were analyzed and compared with them of sewage sludges and non-isothermal analyses of dried sewage sludges were performed at the heating rates of 5, 10, 20, and 30C /min using TG analyzer to investigate the basic combustion characteristics. As a results of these TGA/DTG analyses, sewage sludges showed its primary peak at the temperature of 250–500?°C, which overlapped with main peak of wood and secondary peak at around 500–600?°C, which overlapped with main peak of coals. Also for the interpretation by Friedman method, the activation energies in the section of highest weight loss were 525.16 kJ/mole for dried digested sewage sludge, 544.88 kJ/mole for dried excess sewage sludge, 203.86 kJ/mole for wood pellet and 146.4585 kJ/mole for bituminous coal. The reaction orders for dried digested excess sewage sludge, dried excess sewage sludge, wood pellet and bituminous coal were 28.775, 24.319, 18.398 and 9.1005, respectively, and the frequency factors were 5.89?\(\times \hspace{0.17em}\)10²⁸, 1.65?\(\times \hspace{0.17em}\)10^24,, 9.59?\(\times \hspace{0.17em}\)10¹⁶ and 1.77?\(\times \hspace{0.17em}\)10⁸ for each, respectively.     

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.     

Characterizations of biochar from hydrothermal carbonization of exhausted coffee residue

The aim of this study was to produce renewable energy from exhausted coffee residue, which is a form of biomass. As coffee preference continues to increase, the importation of coffee beans has been increasing sharply. However, the amount of coffee that is actually consumed is only about 0.2% of coffee beans, while the spent coffee beans are discarded in the form of exhausted coffee residue. Hydrothermal carbonization is a method of producing an improved fuel from renewable energy sources by changing the physical and chemical properties of biochars. Biochars were obtained from a variety of reaction temperatures during hydrothermal carbonization and analyzed using elemental analysis, ultimate analysis, and calorific value measurement. The atomic C/O and C/H ratios of all obtained biochars decreased and were found to be similar to those of lignite and sub-bituminous coal. The highest energy recovery efficiency of biochar indicates that the optimum reaction temperature for hydrothermal carbonization was between 210 and 240 °C, which produced biochars with calorific value of approximately 26–27 MJ/kg. The spectra of biochars obtained from Fourier transform infrared spectroscopy (FTIR) showed fewer C–O and aliphatic C–H functional groups, but more carbonyl C=O functional groups and aliphatic CH _x groups. The results of this study indicate that hydrothermal carbonization can be used as an effective means to generate highly energy-efficient renewable fuel resources from coffee residue. The thermogravimetric analysis provided the changing combustion characteristics due to increased fixed carbon content.     

Effect of mixing ratio of woody waste and food waste on the characteristics of carbonization residue

Biomass such as woody waste and food waste can be converted to a renewable energy source by means of carbonization processes. The basic characteristics of woody waste and food waste, such as proximate analysis and heating value, were evaluated before carrying out carbonization tests. Carbonization tests were carried out to obtain the basic characteristics of carbonization residue on changing the proportion of food waste from 0% to 30% in the mixture of woody waste and food waste. The effect of the food waste was estimated by basic characteristics of the residue such as the heating value, yield, and fuel ratio. As increased the food waste content, the bulk density, yield and chlorine content of the carbonization residue increased, but fuel ratio, the carbon content and heating value of the residue decreased. From the results of the basic characteristics of the residue, the optimum food waste content in carbonization tests was found to be 20%. Even if food waste is combined with woody waste at levels up to 30%, the sulfur and chlorine concentrations in the residue were much lower than the regulatory standard levels. From the results for the fuel ratio and heating value of the residue, the carbonization residue is suitable for use as a renewable energy source and can be categorized by the second grade level of solid fuel products.     

Gasification characteristics of sewage sludge combined with wood biomass

The gas products from gasification processes have been considered to have some limitations in gas composition and heating value from the previous studies. Gasification characteristics of sewage sludge and wood mixture were investigated using different mixing ratios with the purpose of better quality of gas product suitable for energy/power generation. The gasification experiment was performed by an indirectly heated fluidized bed reactor. As reaction temperature increased from 600 to 900 °C, the yield of gas product increased with higher generation of CO, H₂ and CH₄ by more activated gas conversion reactions. As the equivalence ratio increased from 0.2 to 0.4, composition ratio of CO₂ increased while CO, CH₄, H₂ decreased as expected. Several operating variables including mixing ratio of wood with dried sludge were also tested. From this initial stage of experiment, optimal operating conditions for the bubbling fluidized bed gasifier, could be considered 900 °C in temperature; 0.2 in equivalence ratio and 40 % in wood mixing ratio within test variables range. These results will be more thoroughly investigated for the application to the larger scale pilot system.     

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.     

Pore structure and adsorption properties of carbonized material prepared from waste paper

We have already reported the adsorptivity and pore structure of activated carbon made from waste newspaper in order to use the waste paper for purposes other than paper-making stock. However, manufacturing the activated carbon may not necessarily be an advantageous method based on environmental concerns and the effective use of the resource because the reaction during the activating process is endothermic and the amount of carbon consumed is significant. Here, we examine the pore structure and adsorption properties of waste newspaper used as an adsorbent in the form of a carbonized material. Waste newspaper was carbonized for 2 h in the temperature range 400°–1000°C. The specific surface area of the carbonized material obtained, 418 m²/g, was highest for the sample carbonized at 800°C, which was equal to or greater than that of commercially available charcoal. Moreover, the iodine adsorption number of 581 mg/g was the highest and the rate of adsorption was the fastest for the sample carbonized at 800°C. However, the humidity control capability was highest for the material carbonized at 600°–700°C. It has been determined that it is advantageous to carbonize waste paper at 800°C in order to use the carbonized material as an adsorbent, while carbonization at 600°–700°C is more advantageous for use as a humidity control material. Received: June 23, 2000 / Accepted: January 17, 2001     

Evaluation of bangkok sewage sludge for possible agricultural use.

Bangkok (Thailand) covers more than 1500 km2 and has 10 million inhabitants. The disposal of wastewater is creating huge problems of pollution. The estimated amount of sewage sludge was estimated to be around 108 tonnes dry matter (DM) per day in 2005. In order to find a lasting way of disposal for this sewage sludge, the suitability of the sludge produced from three waste-water treatment plants for use as fertilizing material was investigated. Monthly samplings and analysis of sewage sludge from each plant showed that the composition of sludge varied according to the area of collection and period of sampling, and there was no link to rainfall cycle. Plant nutrient content was high (i.e. total N from 19 to 38 g kg(-1) DM) whereas organic matter content was low. The concentrations of heavy metals varied between sludge samples, and were sometimes higher than the E.U. or U.S. regulations for sewage sludge use in agriculture. Faecal coliforms were present in the sludge from one of the plants, indicating a possible contamination by night soil. In order to decrease this potentially pathogenic population the sewage sludge should be heated by composting. As the C/N ratio of sewage sludge was low (around 6) some organic by-products with high carbon content could be added as structural material to enhance the composting.     

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.     

Co-combustion of dried sewage sludge and coal in a pulverized coal boiler

More than 1.1 million tons of municipal and industrial sewage sludge is produced annually in Poland. Most of this sewage sludge is landfilled or used for recultivation and fertilization of soil. After accession of Poland to the EU, large investments are planned for wastewater treatment, so it is expected that the amount of sewage sludge produced in Poland will grow in the near future. It is well known that the combustion of sewage sludge is becoming a more and more popular utilization method of such waste. Unfortunately, the current situation in Poland makes it impossible to incinerate the sewage sludge because of a lack of incinerators. One possible solution for Poland is the co-firing of dried sewage sludge in existing coal-fired utility boilers. This article presents results of initial Polish industrial trials of dried municipal sewage sludge and hard coal co-combustion in an OP-230 pulverized coal boiler. Such a solution was shown to be technically viable and not to require changes to the existing technological system. Cocombustion of sewage sludge with coal in power plants seems to be the best solution for sludge utilization in the near future in Poland.     

Characteristic of heavy metals in biochar derived from sewage sludge

This study investigates the characteristic of heavy metals (Pb, Zn, Cu, Cd, Cr, Ni and As) in biochar derived from sewage sludge at different pyrolysis temperatures (300, 400, 500, 600 and 700 °C). The heavy metal concentrations, chemical speciation distribution, leaching toxicity, and bio-available contents were investigated using ICP-OES after microwave digestion, a sequential extraction procedure recommended by the Community Bureau of Reference (BCR), an improved nitric acid–sulphuric acid method, and diethylenetriamine pentaacetic acid (DTPA) extraction method, respectively. The results showed that a great percentage of the heavy metals remained in biochar, the concentrations of heavy metals in biochar (except Cd in B7) were higher than that in sludge, and the enrichment of the heavy metals in biochar enhanced with the pyrolysis temperature. Although the effect of pyrolysis temperature on the chemical speciation distribution, the leaching toxicity and the bio-available contents of heavy metals in biochar was inconsistent, the potential risk of biochar on soil and groundwater contamination was lower than sewage sludge.     

Leaching characteristics and phytotoxic effects of sewage sludge biochar

Biochar was prepared via the pyrolysis of sewage sludge at temperatures ranging from 300 to 900 °C and the physical–chemical compositions of the biochars obtained were analyzed. Leaching tests were conducted using the biochars to investigate the release of the constituents and their phytotoxic effects on wheat (Triticum aestivum) seeds in a germination test. Multivariate analyses were used to evaluate the contributions of the constituents to the germination index (GI). The results showed that the biochars were rich in micronutrient contents and they improved the germination of wheat. The heavy metal contents were higher in the biochars than the sewage sludge and their levels increased with the pyrolysis temperature, but they were within the acceptable limits for land application, thereby suggesting that sewage sludge is suitable for use as a biochar substrate. The different components of the biochar leachates could promote and inhibit the germination of wheat seeds, where the GI was promoted at lower concentrations but inhibited at higher concentrations. Our results suggest that biochar is an effective and environmentally friendly fixative for the immobilization of heavy metals in sewage sludge when applied to land or disposed of in landfill, but its ecotoxicity needs to be assessed to ensure its environmental safety.     

Legislative and environmental issues on the use of ash from coal and municipal sewage sludge co-firing as construction material

For the economy of any co-firing process, it is important that the common waste management options of ash remain practical. Ash from bituminous coal combustion is typically handed to the construction industry. This paper describes the current European legislation on use of ash for construction purposes. Also, it presents an experimental study on the suitability of fly ash from combustion of mixtures of bituminous coal and municipal sewage sludge as additive to cement and concrete, and for use in open-air construction works, based on the ash chemical composition and the characteristics of the extract of the ash. Presently, two European standards forbid the use of ash from co-firing as additive to cement or concrete. This study shows that ash derived from coal and sewage sludge co-firing contains generally less unburned carbon, alkali, magnesium oxide, chlorine, and sulfate than coal ash. Only the concentration of free lime in mixed ash is higher than in coal, even though, at least up to 25% of the thermal input, still below the requirements of the standards. This ash also meets the requirements for the use of fly ash in open-air construction works--concentration and mobility of few elements--although this management option is forbidden to ash from co-firing. The leaching of Cd, Cr, Cu, Ni, Pb and Zn was investigated with three leaching tests. The concentration of these metals in the extracts was below the detection limit in most cases. The concentration of Cu and Zn in the extract from fly ash was found to increase with increasing share of sewage sludge in the fuel mixture. However, the concentration of these two metals in the extract is not regulated. This study indicates that excluding a priori the use of ash from co-firing as a suitable additive for construction material could cause an unnecessary burden on the environment, since probably ash would have to be disposed of in landfill. However, allowing this requires the modification of current European standards to include limitations on all elements and compounds, absent in coal but which might be present in other fuels, that are deleterious for the quality of construction materials.     

Comprehensive temperature monitoring in an in-vessel forced-aeration static-bed composting process

Comprehensive temperature monitoring was done in an in-vessel forced-aeration static-bed composting process using sewage sludge. The three layers that divided the compost pile horizontally showed different temperature distributions. The temperature of the top layer appeared not to be influenced by the ambient temperature. The temperature of the center area of the top layer was taken to be the representative temperature for evaluating composting start-up performance. The temperature of the bottom layer was strongly influenced by the ambient temperature, and the temperature of the center area of the bottom layer was taken to be the representative temperature for pathogen control as it was the minimum temperature in the reactor. Composting start-up performance was influenced by several factors when the ambient temperature was either below or above 20°C. When the ambient temperature was below 20°C, the time taken to reach 65°C (T ₆₅) was influenced by the temperature of inflowing air, but when the temperature was higher than 20°C, it was influenced by the ratio of sewage sludge to seed compost (F/S). T ₆₅ was least when F/S was 1–2. Received: January 9, 2001 / Accepted: October 10, 2001