Fuel savings in sewage sludge incineration

As a result of a demonstration project partly sponsored by the United States Environmental Protection Agency in cooperation with the Indianapolis Center for Advanced Research, the City of Indianapolis, Indiana, realized a 34% fuel savings for sewage sludge incineration. At the same time, sludge throughput was increased 10%. In addition to these proven savings, operational downtime for repairs was reduced, maintenance costs were reduced, and air pollution was reduced. The air pollution reduction allowed Indianapolis to cancel a $3,000,000 construction program for air pollution abatement.Other cities incinerating sewage sludge in the United States that have initiated the fuel efficient mode of operation have saved even more fuel than Indianapolis. Nashville, Tennessee, reduced its fuel usage 40%; Buffalo, New York, reduced its fuel usage 47% from design expectations; Hartford, Connecticut, reduced its fuel usage 51 %; and Jacksonville, Florida has reduced its fuel usage over 50%.These savings result from installing additional instrumentation and controls (often not required at newer facilities), modifying the incinerator operating methods, and training the operators to operate the facilities more efficiently. At Indianapolis, it cost $20,000 per incinerator for instrumentation and operator training. This was an older plant and required a maximum amount of new controls and instrumentation; however, the payback for this $20,000 was less than three months due to the reduction in fuel use based on an oil price of $0.264 per litre ($1.00 per gallon). In the other cities where instrumentation controls were adequate, the cost for developing the now operating mode and training the operators averaged $75,000 per city.     

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.     

Chemical states of arsenic contained in sewage sludge incineration ash and insolubilized material

Journal of Material Cycles and Waste Management - The chemical states of arsenic contained in 4 kinds of sewage sludge incineration ash and insolubilized materials are analyzed using a leaching...     

Fixation and partitioning of heavy metals in slag after incineration of sewage sludge

Fixation of heavy metals in the slag produced during incineration of sewage sludge will reduce emission of the metals to the atmosphere and make the incineration process more environmentally friendly. The effects of incineration conditions (incineration temperature 500-1100°C, furnace residence time 0-60min, mass fraction of water in the sludge 0-75%) on the fixation rates and species partitioning of Cd, Pb, Cr, Cu, Zn, Mn and Ni in slag were investigated. When the incineration temperature was increased from 500 to 1100°C, the fixation rate of Cd decreased from 87% to 49%, while the fixation rates of Cu and Mn were stable. The maximum fixation rates for Pb and Zn and for Ni and Cr were reached at 900 and 1100°C, respectively. The fixation rates of Cu, Ni, Cd, Cr and Zn decreased as the residence time increased. With a 20min residence time, the fixation rates of Pb and Mn were low. The maximum fixation rates of Ni, Mn, Zn, Cu and Cr were achieved when the mass fraction of water in the sludge was 55%. The fixation rate of Cd decreased as the water mass fraction increased, while the fixation rate of Pb increased. Partitioning analysis of the metals contained in the slag showed that increasing the incineration temperature and residence time promoted complete oxidation of the metals. This reduced the non-residual fractions of the metals, which would lower the bioavailability of the metals. The mass fraction of water in the sludge had little effect on the partitioning of the metals. Correlation analysis indicated that the fixation rates of heavy metals in the sludge and the forms of heavy metals in the incinerator slag could be controlled by optimization of the incineration conditions. These results show how the bioavailability of the metals can be reduced for environmentally friendly disposal of the incinerator slag.     

垃圾焚烧发电厂渗滤液处理站污泥危险特性研究

通过对一例垃圾焚烧发电厂渗滤液处理站污泥进行鉴定,表明该部分污泥不属于危险固废,可以纳入焚烧炉与生活垃圾一起处理.鉴别结果为促进固体废物循环利用及同类企业合理处置渗滤液处理站污泥提供了借鉴.     

Integrated drying and incineration of wet sewage sludge in combined bubbling and circulating fluidized bed units

An original integrated drying and incineration technique is proposed to dispose of sewage sludge with moisture content of about 80% in a circulating fluidized bed. This system combines a bubbling fluidized bed dryer with a circulating fluidized bed incinerator. After drying, sewage sludge with moisture less than 20% is transported directly and continuously from the fluidized bed dryer into a circulating fluidized bed incinerator. Pilot plant results showed that integrated drying and incineration is feasible in a unique single system. A 100 t/d Sewage Sludge Incineration Demonstration Project was constructed at the Qige sewage treatment plant in Hangzhou City in China. The operational performance showed that the main operation results conformed to the design values, from which it can be concluded that the scale-up of this technique is deemed both feasible and successful.     

Influence of calcium chloride on the thermal behavior of heavy and alkali metals in sewage sludge incineration

In order to separate and reuse heavy and alkali metals from flue gas during sewage sludge incineration, experiments were carried out in a pilot incinerator. The experimental results show that most of the heavy and alkali metals form condensed phase at temperature above 600 degrees C. With the addition of 5% calcium chloride into sewage sludge, the gas/solid transformation temperature of part of the metals (As, Cu, Mg and Na) is evidently decreased due to the formation of chloride, while calcium chloride seems to have no significant influence on Zn and P. Moreover, the mass fractions of some heavy and alkali metals in the collected fly ash are relatively high. For example, the mass fractions for Pb and Cu in the fly ash collected by the filter are 1.19% and 19.7%, respectively, which are well above those in lead and copper ores. In the case of adding 5% calcium chloride, the heavy and alkali metals can be divided into three groups based on their conversion temperature: Group A that includes Na, Zn, K, Mg and P, which are converted into condensed phase above 600 degrees C; Group B that includes Pb and Cu which solidify when the temperature is above 400 degrees C; and Group C that includes As, whose condensation temperature is as low as 300 degrees C.     

Environmental and economic life cycle assessment for sewage sludge treatment processes in Japan

Life cycle assessment for sewage sludge treatment was carried out by estimating the environmental and economic impacts of the six alternative scenarios most often used in Japan: dewatering, composting, drying, incineration, incinerated ash melting and dewatered sludge melting, each with or without digestion. Three end-of-life treatments were also studied: landfilling, agricultural application and building material application. The results demonstrate that sewage sludge digestion can reduce the environmental load and cost through reduced dry matter volume. The global warming potential (GWP) generated from incineration and melting processes can be significantly reduced through the reuse of waste heat for electricity and/or heat generation. Equipment production in scenarios except dewatering has an important effect on GWP, whereas the contribution of construction is negligible. In addition, the results show that the dewatering scenario has the highest impact on land use and cost, the drying scenario has the highest impact on GWP and acidification, and the incinerated ash melting scenario has the highest impact on human toxicity due to re-emissions of heavy metals from incinerated ash in the melting unit process. On the contrary, the dewatering, composting and incineration scenarios generate the lowest impact on human toxicity, land use and acidification, respectively, and the incinerated ash melting scenario has the lowest impact on GWP and cost. Heavy metals released from atmospheric effluents generated the highest human toxicity impact, with the effect of dioxin emissions being significantly lower. This study proved that the dewatered sludge melting scenario is an environmentally optimal and economically affordable method.     

Comparative assessment of municipal sewage sludge incineration,gasification and pyrolysis for a sustainable sludge-to-energy management in Greece

For a sustainable municipal sewage sludge management, not only the available technology, but also other parameters, such as policy regulations and socio-economic issues should be taken in account. In this study, the current status of both European and Greek Legislation on waste management, with a special insight in municipal sewage sludge, is presented. A SWOT analysis was further developed for comparison of pyrolysis with incineration and gasification and results are presented. Pyrolysis seems to be the optimal thermochemical treatment option compared to incineration and gasification. Sewage sludge pyrolysis is favorable for energy savings, material recovery and high added materials production, providing a ‘zero waste’ solution. Finally, identification of challenges and barriers for sewage sludge pyrolysis deployment in Greece was investigated.     

Mathematical modelling of sewage sludge incineration in a bubbling fluidised bed with special consideration for thermally-thick fuel particles

Fluidised bed combustor (FBC) is one of the key technologies for sewage sludge incineration. In this paper, a mathematical model is developed for the simulation of a large-scale sewage sludge incineration plant. The model assumes the bed consisting of a fast-gas phase, an emulsion phase and a fuel particle phase with specific consideration for thermally-thick fuel particles. The model further improves over previous works by taking into account throughflow inside the bubbles as well as the floating and random movement of the fuel particles inside the bed. Validation against both previous lab-scale experiments and operational data of a large-scale industrial plant was made. Calculation results indicate that combustion split between the bed and the freeboard can range from 60/40 to 90/10 depending on the fuel particle distribution across the bed height under the specific conditions. The bed performance is heavily affected by the variation in sludge moisture level. The response time to variation in feeding rate is different for different parameters, from 6min for outlet H(2)O, 10min for O(2), to 34min for bed temperature.     

Behavior of PAHs from sewage sludge incinerators in Korea

Although production of sewage sludge increases every year, its proper treatment has only been recently raised as a new issue, as current landfill and ocean dumping arrangements are expected to become increasingly difficult to manage in the future. The Korean Ministry of Environment plans to diversify its processing facilities and expand its processing systems by 2011, with the purpose of processing all sludge produced in Korea. According to this plan, incineration (including incineration of municipal wastes) will process 30% of the entire sewage sludge throughout the country in 2011. This study reviews the characteristics of PAH, which is one of the organic substances found in sewage sludge during the incinerating process. The total amount of PAH produced from sewage sludge incineration was found to be 6.103 mg/kg on average, and investigation performed on 16 PAHs of inlets and outlets of the air control devices at five full-scale incineration facilities showed that concentrations of the PAHs on the inlet and on the outlet ranged from 3.926 to 925.748 microg/m(3) and from 1.153 to 189.449 microg/m(3), respectively. In the case of the incineration facility fed with municipal waste (95%) and sewage sludge (5%), the total of the PAH emissions concentration was higher than that found at the incineration facilities used exclusively to treat sewage. The combustion of waste vinyl and plastics contained in municipal waste fed into the facility might contribute to the high levels of PAHs in the stack gas. However more investigation is needed on the production mechanism of PAHs at different operating conditions of the incineration facilities, such as the types of waste, and other relevant factors.     

Recovery of biomass cellulose from waste sewage sludge

In our previous work, the primary sludge from wastewater treatment plants was shown to contain a considerable amount of cellulose (about 20%, based on suspended solids) owing to the discharge of toilet paper. For the purpose of using the cellulose as a biomass resource, this study examined a simple method for its recovery. When fibrous cellulose was suspended in 0.3% sulfuric acid and autoclaved at 130°C for 60 min, 85%–88% of the initial solids remained without dissolving. Under these conditions, an activated sludge sample not containing cellulose was strongly hydrolyzed and only 7% of the initial solids remained. The prescribed amounts of cellulose added to the activated sludge sample were quantitatively recovered by the autoclaving treatment. In the treatment of primary sludge containing >20% cellulose, residual solids with relatively high levels of cellulose (>69%) could be obtained. The results indicate that the method proposed here could recover cellulose practically from waste sewage sludge for biomass utilization. Received: July 17, 2000 / Accepted: July 4, 2001     

Acidic bioleaching of heavy metals from sewage sludge

The overall objective of this study was to evaluate the use of controlled bio-acidification prior to land application as a decontamination process to remove heavy metals from sludge. The sulfur-oxidizing bacteria were naturally available in the sludge samples and were activated by providing sulfur and aeration at 28°C–30°C. Activation resulted in bio-acidification to pH 2 within 5–11 days. Successive inoculation of fresh sludges with 5% acidified samples reduced the acidification time to 2–3 days in most samples. Bio-acidification resulted in dissolving significant quantities of heavy metals from all sludge types tested. The maximum solubilization results were: 86%–97% for Ni; 48%–98% for Pb; 26%–71% for Cr; 18%–91% for Zn; 16%–90% for Cu; 7%–60% for Cd. Limited metal solubilization results were observed in the various control samples that accompanied the bio-acidified samples. The leaching results in the control samples were limited to 2%–19% for Ni, 0%–7% for Pb, 0%–5% for Cr, 0.3%–4% for Zn, 0.2%–4% for Cu and 0%–3% for Cd. The results confirmed that Ni and Pb were the easiest metals to dissolve from the various sludge types. On the other hand, the lowest solubilization results were observed for Cu and Cd, and moderate solubilization results were achieved for Cr. The bio-acidification process resulted in moderate gains in terms of improving the suitability of tested sludges for land application. Received: April 19, 1999 / Accepted: November 4, 1999     

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.     

Lightweight aggregate made from sewage sludge and incinerated ash

In this study, sewage sludge ash (SSA), with similar characteristics to expansive clay, was used as the principal material and sewage sludge (SS) as the admixture to sinter lightweight aggregate and to study the influences of raw material composition on pelletising, sintering effect and aggregate properties. Results showed that both SS and SSA could be sintered to produce synthetic aggregates individually or mixed. Increasing the amount of SS would decrease the pelletising ratio. Under the consideration of energy saving, the mixture of SSA was better for sintering normal weight aggregate. On the contrary, the mixture that added 20-30% of SS was more adequate to make lightweight aggregates. Adding SS would enhance the oxidation-reduction reaction and lower the bulk density and sintering temperature of aggregates to save energy. Sintering temperature affected the properties of sewage sludge ash lightweight aggregate (SSALA) more than retention period did. Prolonging the retention period could improve bloating effect.     

Phosphate fertilizer from sewage sludge ash (SSA)

Ashes from sewage sludge incineration are rich in phosphorus content, ranging between 4% and 9%. Due to the current methods of disposal used for these ashes, phosphorus, which is a valuable plant nutrient, is removed from biological cycling. This article proposes the possible three-stage processing of SSA, whereby more than 90% of phosphorus can be extracted to make an adequate phosphate fertilizer. SSA from two Swiss sewage sludge incinerators was used for laboratory investigations. In an initial step, SSA was leached with sulfuric acid using a liquid-to-solid ratio of 2. The leaching time and pH required for high phosphorus dissolution were determined. Inevitably, dissolution of heavy metals takes place that would contaminate the fertilizer. Thus in a second step, leach solution has to be purified by having the heavy metals removed. Both ion exchange using chelating resins and sulfide precipitation turned out to be suitable for removing critical Cu, Ni and Cd. Thirdly, phosphates were precipitated as calcium phosphates with lime water. The resulting phosphate sludge was dewatered, dried and ground to get a powdery fertilizer whose efficacy was demonstrated by plant tests in a greenhouse. By measuring the weight of plants after 6 weeks of growth, fertilized in part with conventional phosphate fertilizer, fertilizer made from SSA was proven to be equal in its plant uptake efficiency.     

RecoPhos: Full-scale fertilizer production from sewage sludge ash

The substitution potential of sewage sludge for German primary phosphate imports has been estimated as 40%. Yet, a marketable option for the full scale recovery has been lacking. This study focuses on a full-scale process for the manufacture of a P-fertilizer from sewage sludge ash (SSA) adapted from the production of Triple Superphosphate. Given (i) conformity of the input with phosphate ores mined from sedimentary deposits, (ii) comparability of the product with a commercially available P-fertilizer regarding contaminant levels, P-fractionation and yield effects, and (iii) compliance of the output with the German Fertilizer Ordinance the RecoPhos P 38 fertilizer was discharged from the waste legislation regime. The fertilizer is currently being produced at a rate of 1000 tonnes per month and sold at a competitive price.     

Gasification and its emission characteristics for dried sewage sludge utilizing a fluidized bed gasifier

Various research has attempted to determine the proper treatment of sewage sludge, including thermal technologies. Efficient thermal technologies have been focused on because of their energy saving/energy recovery. Gasification technology can be considered one of these approaches. In this study, the characteristics of gasification reactions were investigated with the aim of finding fundamental data for utilizing sewage sludge as an energy source. For the experiments on sewage sludge gasification reaction characteristics, a laboratory-scale experimental apparatus was set up with a fluidizing bed reactor of 70-mm inner diameter and 600-mm total height using an electric muffle furnace. The experimental materials were prepared from a sewage treatment plant located in Seoul. The reaction temperature was varied from 630 to 860°C, and the equivalence ratio from 0.1 to 0.3. The gas yields, compositions of product gas, and cold gas efficiencies of product gas were analyzed by GC/TCD and GC/FID installed with a carboxen-1000 column. The experimental results indicated that 800°C, ER 0.2 was an optimum condition for sewage sludge gasification. The maximum yield of product gas was about 44%. Producer gas from experiments was mainly composed of hydrogen, carbon monoxide, carbon dioxide, and methane. The cold gas efficiency of sewage sludge gasification was about 68%. The H₂/CO ratio and CO/CO₂ ratio were about 1.1 and 1.4, respectively, in optimum reaction conditions. Gaseous pollutants such as SO₂, HCl, NH₃, H₂S, and NO₂ were also analyzed at various gasification/combustion conditions, and their gaseous products were compared, showing significantly different oxidized product distributions.     

Humic substances in composted sewage sludge

Humic acids obtained from sewage sludge both before and after composting were characterized, and the influence of composting on the formation of more stable and polycondensed structures was studied. These humic acids showed an aliphatic character and although no great differences between humic acids from uncomposted and composted sewage sludge were observed, data from elemental analysis, E₄/E₅ ratio, filtration through Sephadex G-100 gel and infra-red spectra seemed to demonstrate that more polycondensed structures and hence a more stable organic matter, was obtained with the composting process.