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.     

Production of technical grade phosphoric acid from incinerator sewage sludge ash (ISSA)

The recovery of phosphorus from sewage sludge ash samples obtained from 7 operating sludge incinerators in the UK using a sulfuric acid washing procedure to produce a technical grade phosphoric acid product has been investigated. The influences of reaction time, sulfuric acid concentration, liquid to solid ratio and source of ISSA on P recovery have been examined. The optimised conditions were the minimum stoichiometric acid requirement, a reaction time of 120 min and a liquid to solid ratio of 20. Under these conditions, average recoveries of between 72% and 91% of total phosphorus were obtained. Product filtrate was purified by passing through a cation exchange column, concentrated to 80% H₃PO₄ and compared with technical grade H₃PO₄ specifications. The economics of phosphate recovery by this method are briefly discussed.     

Recycling and recovery routes for incinerated sewage sludge ash (ISSA): A review

The drivers for increasing incineration of sewage sludge and the characteristics of the resulting incinerated sewage sludge ash (ISSA) are reviewed. It is estimated that approximately 1.7 million tonnes of ISSA are produced annually world-wide and is likely to increase in the future. Although most ISSA is currently landfilled, various options have been investigated that allow recycling and beneficial resource recovery. These include the use of ISSA as a substitute for clay in sintered bricks, tiles and pavers, and as a raw material for the manufacture of lightweight aggregate. ISSA has also been used to form high density glass–ceramics. Significant research has investigated the potential use of ISSA in blended cements for use in mortars and concrete, and as a raw material for the production of Portland cement. However, all these applications represent a loss of the valuable phosphate content in ISSA, which is typically comparable to that of a low grade phosphate ore. ISSA has significant potential to be used as a secondary source of phosphate for the production of fertilisers and phosphoric acid. Resource efficient approaches to recycling will increasingly require phosphate recovery from ISSA, with the remaining residual fraction also considered a useful material, and therefore further research is required in this area.     

Co-digestion of grease trap sludge and sewage sludge

Redirection of organic waste, from landfilling or incineration, to biological treatment such as anaerobic digestion is of current interest in the Malmö-Copenhagen region. One type of waste that is expected to be suitable for anaerobic digestion is sludge from grease traps. Separate anaerobic digestion of this waste type and co-digestion with sewage sludge were evaluated. The methane potential was measured in batch laboratory tests, and the methane yield was determined in continuous pilot-scale digestion. Co-digestion of sludge from grease traps and sewage sludge was successfully performed both in laboratory batch and continuous pilot-scale digestion tests. The addition of grease trap sludge to sewage sludge digesters was seen to increase the methane yield of 9–27% when 10–30% of sludge from grease traps (on VS-basis) was added. It was also seen that the grease trap sludge increases the methane yield without increasing the sludge production. Single-substrate digestion of grease trap sludge gave high methane potentials in batch tests, but could not reach stable methane production in continuous digestion.     

Biodegradability of blends of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with cellulose acetate esters in activated sludge

Blends of the bacterially produced polyester poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) with cellulose acetate esters (CAE) further substituted with propionyl or butyryl groups (degree of substitution: 2.60 propionyl and 0.36 acetyl or 2.59 butyryl and 0.36 acetyl, respectively) were exposed for 4 months to activated sludge to determine their biodegradability. Samples of such blends made by solution-mixing and solvent-casting had complex morphologies in which both individual components as well as a miscible blend phase were present. Additionally, the two opposite surfaces of solvent-cast films showed both physical and chemical differences. After 2 months, samples of pure PHBV had degraded by more than 98% (15 mg/cm² of surface area), whereas a pure CAE sample had degraded less than 1% (<0.2 mg/cm²). Samples containing 25% CAE lost less than 40% of their initial weights (6 mg/cm²) over the total 4-month period. Samples with 50% CAE lost up to 16% weight (2 mg/cm²), whereas those containing 75% CAE lost only slightly more weight than corresponding sterile control samples (1 mg/cm²). NMR results confirm that weight loss from samples containing 25% CAE resulted only from degradation of PHBV and that the surface of samples became enriched in CAE. Solvent-cast film samples containing equal amounts of PHBV and CAE degraded preferentially on the surface which formed at the polymer-air interface. Scanning electron microscopy and attenuated total reflectance infrared spectroscopy revealed this surface to have a rougher texture and a greater PHBV content.     

Sources and behaviour of polybrominated diphenyl ethers (PBDEs), polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) in Spanish sewage sludge

Presence, sources and behaviour of polybrominated diphenyl ethers (PBDEs) and polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) were evaluated in Spanish sewage sludge. A total of 120 samples were seasonally collected from October 2005 to September 2006 at 31 urban wastewater treatment plants (WWTPs). Concentrations of PBDEs (ranging between 57.5 and 2606 ng/g dry weight) were two to three orders of magnitude higher than those obtained for PCDDs (0.17-5.03 ng/g d.w.) and PCDFs (0.05-3.07 ng/g d.w.). All the samples presented International Toxicity Equivalents (I-TEQ) levels (ranging between 2.06 and 44.4 ng/kg d.w.) below the limit values proposed by European Union for land application. Congener patterns evaluation revealed that the use of Deca-BDE commercial mixture seems to be the major source of PBDEs in the sludge. Nevertheless, origin of PCDD/Fs should be related to atmospheric deposition, faeces and presence of PCDD/Fs precursors such as pentachlorophenol in the sludge. No correlations (p > 0.05) were found between pollutant concentrations (PBDEs and PCDD/Fs) and wastewater treatment plant (WWTP) characteristics (capacity nor sludge rate). Lower levels of PBDEs and PCDFs were found in WWTPs using biological nitrogen and phosphorous elimination, suggesting that these compounds are susceptible of microbial elimination. According to our knowledge, this is the first work comparing together both PBDEs and PCDD/Fs sludge patterns.     

Sewage sludge ash to phosphorus fertiliser (II): Influences of ash and granulate type on heavy metal removal

Ashes from monoincineration of sewage sludge suggest themselves as an ideal base for inorganic fertiliser production due to their relatively high phosphorus (P)-content. However, previously they need to be detoxified by reducing their heavy metal content. The core process considered in this paper consists of three steps: mixing of the ashes with suitable chlorine-containing additives, granulation of the mixture and thermochemical treatment in a rotary kiln. Here relevant heavy metal compounds are first transformed into volatile species with the help of the additives and then evaporated from the granules.In this study two chemically different ashes and their mixture were agglomerated to two different granulate types, briquettes and rolled pellets. The resulting six different materials were subjected to thermal treatment at different temperatures. The heavy metals examined were Cu and Zn due to their strong dependence on treatment conditions and their relevance concerning thermal treatment of sewage sludge ashes. Besides, the behaviour of Cl and K was monitored and evaluated.The experiments showed that ash type and temperature are more influential on Cl and heavy metal chemistry than granulate type. Temperature is a primary variable for controlling removal in both cases. Cu removal was less dependent on both ash and granulate type than Zn. The Cl utilization was more effective for Cu than for Zn. Depending on the treatment conditions some K could be retained, whereas always all P remained in the treated material. This satisfies the requirement for complete P recycling.     

Priority and emerging pollutants in sewage sludge and fate during sludge treatment

This paper aims at characterizing the quality of different treated sludges from Paris conurbation in terms of micropollutants and assessing their fate during different sludge treatment processes (STP). To achieve this, a large panel of priority and emerging pollutants (n = 117) have been monitored in different STPs from Parisian wastewater treatment plants including anaerobic digestion, thermal drying, centrifugation and a sludge cake production unit. Considering the quality of treated sludges, comparable micropollutant patterns are found for the different sludges investigated (in mg/kg DM – dry matter). 35 compounds were detected in treated sludges. Some compounds (metals, organotins, alkylphenols, DEHP) are found in every kinds of sludge while pesticides or VOCs are never detected. Sludge cake is the most contaminated sludge, resulting from concentration phenomenon during different treatments. As regards treatments, both centrifugation and thermal drying have broadly no important impact on sludge contamination for metals and organic compounds, even if a slight removal seems to be possible with thermal drying for several compounds by abiotic transfers. Three different behaviors can be highlighted in anaerobic digestion: (i) no removal (metals), (ii) removal following dry matter (DM) elimination (organotins and NP) and iii) removal higher than DM (alkylphenols – except NP – BDE 209 and DEHP). Thus, this process allows a clear removal of biodegradable micropollutants which could be potentially significantly improved by increasing DM removal through operational parameters modifications (retention time, temperature, pre-treatment, etc.).     

Waste paper and clinoptilolite as a bulking material with dewatered anaerobically stabilized primary sewage sludge (DASPSS) for compost production

Environmental problems associated with sewage sludge disposal have prompted strict legislative actions over the past few years. At the same time, the upgrading and expansion of wastewater treatment plants have greatly increased the volume of sludge generated. The major limitation of land application of sewage sludge compost is the potential for high heavy metal content in relation to the metal content of the original sludge. Composting of sewage sludge with natural zeolite (clinoptilolite) can enhance its quality and suitability for agricultural use. However, the dewatered anaerobically stabilized primary sewage sludge (DASPSS) contained a low concentration of humic substances (almost 2%), and the addition of the waste paper was necessary in order to produce a good soil conditioner with high concentrations of humics. The final results showed that the compost produced from DASPSS and 40-50% w/w of waste paper was a good soil fertilizer. Finally, in order to estimate the metal leachability of the final compost product, the generalized acid neutralization Capacity (GANC) procedure was used, and it was found that by increasing the leachate pH, the heavy metal concentration decreased. The application of the sequential chemical extraction indicated that metals were bound to the residual fraction characterized as a stabilize fractions.     

Reuse of sewage sludge ashes (SSA) in cement mixtures: the effect of SSA on the workability of cement mortars

The influence of sewage sludge ash (SSA) on workability of cement mortars has been studied. The irregular morphology of SSA particles produced a decrease of mortar workability. A nonlinear reduction of workability in mortars containing SSA was observed, but when SSA content in mortars was increased the workability reduction was less significant. A superplasticizer is used in order to compensate the decrease of workability produced by SSA. When SSA sized fractions were used, only significant differences in workability for mortars prepared with high water volumes or with the presence of superplasticizer were observed.     

Self-heating of dried wastewater sludge

We experimentally studied the occurrence of spontaneous self-heating of sludge after drying, to understand its nature, course and remediation. The sludge originates from primary and biological treatment of both municipal and industrial wastewater, the latter largely dominant (approx. 90% total organic carbon, mainly from local tanneries). Dried sludge is collected into big–bags (approx. 1.5 m³) and landfilled in a dedicated site. After several years of regular operation of the landfill, without any management or environmental issue, indications of local warming emerged, together with smoke and smelling emissions, and local subsidence. During a two year monitoring activity, temperatures locally as high as 80 °C have been detected, 6–10 m deep. Experiments were carried out on large quantities of dried sludge (～1 t), monitoring the temperature of the samples over long periods of time (months), aiming to reproduce the spontaneous self-heating, under different conditions, to spot enhancing and damping factors. Results demonstrate that air is a key factor to trigger and modulate the self-heating. Water, in addition to air, supports and emphasizes the heating. Unusual drying operation was found to affect dramatically the self-heating activity, up to spontaneous combustion, while ordinary drying conditions yield a sludge with a moderate self-heating inclination. Temperature values as well as heating time scales suggest that the exothermic process nature is mainly chemical and physical, while microbiological activity might be a co-factor.     

Compost detoxification of vegetable-tannery sludge

The disposal problem represented by vegetable-tannery sludge is of great and ever-increasing concern in Italy. Such sludge is of a highly polluting nature and therefore, requires a reliable and safe treatment to make it harmless before release into the environment. Vegetable-tannery sludge contains some very toxic compounds, mainly polyphenols (i.e. tannins) and sulphides, that are hazardous to biological systems. This paper deals with experiments evaluating the feasibility of vegetable-tannery sludge management and recycling by an integrated composting process. Static windrow technique with forced air and temperature feedback has been adopted for composting a mixture of vegetable-tannery sludge and organic biodegradable fraction of municipal solid waste (MSW) as bulking agent. Physico-chemical, microbiological and phytotoxicological aspects of this compost production from vegetable-tannery sludge are here emphasized along with some technological details.     

Stabilization of sewage sludge in the presence of nanoscale zero-valent iron (nZVI): abatement of odor and improvement of biogas production

The potential benefits of nanoscale zero-valent iron (nZVI) on sludge stabilization, either the abatement of odor or the improvement of biogas production, were investigated in this study. Two commercial-grade microscale iron powders were also utilized for comparison. Adding 0.10 wt% of nZVI in sludge during anaerobic incubation significantly reduced the concentration of H₂S in biogas by 98.0 % (96.2–98.9 %), probably attributed by reactions between sulfides and the neo-formed hydrous Fe(II)/Fe(III) oxides layer at the surface of ZVI nanoparticles. Meanwhile, the percentage of P in bioavailable fractions decreased from 76.8 to 52.5 %, possibly due to the formation of vivianite [Fe₃(PO₄)₂]. Furthermore, 0.10 wt% of nZVI in anaerobic digestion for 17 days enhanced the concentration of CH₄ in biogas by 5.1–13.2 % and improved the production of biogas and methane by 30.4 and 40.4 %, respectively. The amendment of iron nanoparticles during anaerobic digestion can not only effectively reduce H₂S in biogas, but also potentially boost methane production significantly.     

Influence of sludge characteristics on coagulant recovery from water treatment sludge: a preliminary study

Journal of Material Cycles and Waste Management - This study investigated the effect of raw water quality and coagulant type and dosage on the efficiency of aluminium recovery from water treatment...     

Copper stabilization in beneficial use of waterworks sludge and copper-laden electroplating sludge for ceramic materials

A promising strategy for effectively incorporating metal-containing waste materials into a variety of ceramic products was devised in this study. Elemental analysis confirmed that copper was the predominant metal component in the collected electroplating sludge, and aluminum was the predominant constituent of waterworks sludge collected in Hong Kong. The use of waterworks sludge as an aluminum-rich precursor material to facilitate copper stabilization under thermal conditions provides a promising waste-to-resource strategy. When sintering the mixture of copper sludge and the 900 °C calcined waterworks sludge, the CuAl₂O₄ spinel phase was first detected at 650 °C and became the predominant product phase at temperatures higher than 850 °C. Quantification of the XRD pattern using the Rietveld refinement method revealed that the weight of the CuAl₂O₄ spinel phase reached over 50% at 850 °C. The strong signals of the CuAl₂O₄ phase continued until the temperature reached 1150 °C, and further sintering initiated the generation of the other copper-hosting phases (CuAlO₂, Cu₂O, and CuO). The copper stabilization effect was evaluated by the copper leachability of the CuAl₂O₄ and CuO via the prolonged leaching experiments at a pH value of 4.9. The leaching results showed that the CuAl₂O₄ phase was superior to the CuAlO₂ and CuO phases for immobilizing hazardous copper over longer leaching periods. The findings clearly indicate that spinel formation is the most crucial metal stabilization mechanism when sintering multiphase copper sludge with aluminum-rich waterworks sludge, and suggest a promising and reliable technique for reusing both types of sludge waste for ceramic materials.     

Alum-based sludge (AbS) recycling for turbidity removal in drinking water treatment: an insight into statistical,technical, and health-related standpoints

This study aimed to evaluate the feasibility of recycling alum-based sludge (AbS) generated from drinking water treatment facility for turbidity removal. A response surface methodology (RSM)-based modeling and factor analysis were first implemented for assessing the optimal conditions of four independent factors, such as initial turbidity concentration, humic acid (HA) concentration, pH, and AbS dose on the water turbidity removal via the use of AbS as a coagulant agent. The optimum values of the four main variables were determined as initial turbidity concentration?=?59.65 NTU, pH?=?5.56, AbS dose?=?19.71 g/L, and HA concentration?=?12.28 mg/L, and at the optimum conditions, the percentage of turbidity removal was obtained as 94.81 (±?1.01)% for real water. At the optimum conditions of AbS usage as a coagulant for real water samples, monitoring of water quality parameters of the process indicated no health-related concerns in terms of hardness (all types), alkalinity, pH, residual aluminum, and even bacteriological (fecal and total coliforms) contamination. The results indicated a potential for AbS recycling in the treatment plant as a coagulant agent, although some requirements should be fulfilled before full-scale application.