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.     

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.     

Phosphorus recovery from sewage sludge ash through an electrodialytic process

The electrodialytic separation process (ED) was applied to sewage sludge ash (SSA) aiming at phosphorus (P) recovery. As the SSA may have high heavy metals contents, their removal was also assessed. Two SSA were sampled, one immediately after incineration (SA) and the other from an open deposit (SB). Both samples were ED treated as stirred suspensions in sulphuric acid for 3, 7 and 14 days. After 14 days, phosphorus was mainly mobilized towards the anode end (approx. 60% in the SA and 70% in the SB), whereas heavy metals mainly electromigrated towards the cathode end. The anolyte presented a composition of 98% of P, mainly as orthophosphate, and 2% of heavy metals. The highest heavy metal removal was achieved for Cu (ca. 80%) and the lowest for Pb and Fe (between 4% and 6%). The ED showed to be a viable method for phosphorus recovery from SSA, as it promotes the separation of P from the heavy metals.     

Crystalline phase analysis and phosphorus availability after thermochemical treatment of sewage sludge ash with sodium and potassium sulfates for fertilizer production

Phosphorus rich sewage sludge ash is a promising source to produce phosphorus recycling fertilizer. However, the low plant availability of phosphorus in these ashes makes a treatment necessary. A thermochemical treatment (800–1000 °C) with alkali additives transforms poorly plant available phosphorus phases to highly plant available calcium alkali phosphates (Ca,Mg)(Na,K)PO₄. In this study, we investigate the use of K₂SO₄ as additive to produce a phosphorus potassium fertilizer in laboratory-scale experiments (crucible). Pure K₂SO₄ is not suitable as high reaction temperatures are required due to the high melting point of K₂SO₄. To overcome this barrier, we carried out series of experiments with mixtures of K₂SO₄ and Na₂SO₄ resulting in a lower economically feasible reaction temperature (900–1000 °C). In this way, the produced phosphorus potassium fertilizers (8.4 wt.% K, 7.6 wt.% P) was highly plant available for phosphorus indicated by complete extractable phosphorus in neutral ammonium citrate solution. The added potassium is, in contrast to sodium, preferably incorporated into silicates instead of phosphorus phases. Thus, the highly extractable phase (Ca,Mg)(Na,K)PO₄ in the thermochemical products contain less potassium than expected. This preferred incorporation is confirmed by a pilot-scale trial (rotary kiln) and thermodynamic calculation.

     

Development of lightweight aggregate from dry sewage sludge and coal ash

In this study, dry sewage sludge (DSS) as the principal material was blended with coal ash (CA) to produce lightweight aggregate. The effects of different raw material compositions and sintering temperatures on the aggregate properties were then evaluated. In addition, an environmental assessment of the lightweight aggregate generated was conducted by analyzing the fixed rate of heavy metals in the aggregate, as well as their leaching behavior. The results indicated that using DSS enhanced the pyrolysis–volatilization reaction due to its high organic matter content, and decreased the bulk density and sintering temperature. However, the sintered products of un-amended DSS were porous and loose due to the formation of large pores during sintering. Adding CA improved the sintering temperature while effectively decreasing the pore size and increasing the compressive strength of the product. Furthermore, the sintering temperature and the proportion of CA were found to be the primary factors affecting the properties of the sintered products, and the addition of 18–25% of CA coupled with sintering at 1100 °C for 30 min produced the highest quality lightweight aggregates. In addition, heavy metals were fixed inside products generated under these conditions and the As, Pb, Cd, Cr, Ni, Cu, and Zn concentrations of the leachate were found to be within the limits of China’s regulatory requirements.     

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 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.     

污泥灰中磷的湿化学法回收技术研究进展

从污泥灰中磷的提取、磷与重金属的分离和磷产品的制备3方面综述了国内外湿化学法回收污泥灰中磷的研究进展,重点分析了磷提取过程中的各种影响因素,并对今后污泥灰中磷的湿化学法回收技术的研究方向进行了展望。指出:利用萃取的方法将提取液中的无机强酸萃取出来并回收重复利用,可大幅降低酸的消耗量;在回收磷的同时可研究回收不同种类金属的方法,尤其是价值较大的重金属,以进一步提高污泥灰资源的回收价值。     

Tar-free fuel gas production from high temperature pyrolysis of sewage sludge

Pyrolysis of sewage sludge was studied in a free-fall reactor at 1000–1400 °C. The results showed that the volatile matter in the sludge could be completely released to gaseous product at 1300 °C. The high temperature was in favor of H₂ and CO in the produced gas. However, the low heating value (LHV) of the gas decreased from 15.68 MJ/N m³ to 9.10 MJ/N m³ with temperature increasing from 1000 °C to 1400 °C. The obtained residual solid was characterized by high ash content. The energy balance indicated that the most heating value in the sludge was in the gaseous product.     

Mechanical and physical properties of cement blended with sewage sludge ash

The aim of this paper is to evaluate the compatibility of sewage sludge ash (SSA) with various types of commercially available cements (CEM I and CEM II types, cements with several proportions of clinker). The behaviour of mortars fabricated with various percentages (10-30% by weight) of the cement replaced by SSA has been analyzed in terms of workability, mechanical strength, porosity and shrinkage/expansion. SSA exhibits moderate pozzolanic activity; the highest compressive strengths were obtained with 10% of the cement replaced by SSA. The CEM II/B-M (V-LL) 42.5R cement is considered ideal for preparing mortars containing SSA. Shrinkage data demonstrate that sulphates present in SSA are not reactive towards cement.     

Foamed lightweight materials made from mixed scrap metal waste powder and sewage sludge ash.

The porous properties and pozzolanic effects of sewage sludge ash (SSA) make it possible to produce lightweight materials. This study explored the effects of different metallic foaming agents, made from waste aluminium products, on the foaming behaviours and engineering characteristics, as well as the microstructure of sewage sludge ash foamed lightweight materials. The results indicated that aluminium powder and mixed scrap metal waste powder possessed similar chemical compositions. After proper pre-treatment, waste aluminium products proved to be ideal substitutes for metallic foaming agents. Increasing the amount of mixed scrap metal waste by 10-15% compared with aluminium powder would produce a similar foaming ratio and compressive strength. The reaction of the metallic foaming agents mainly produced pores larger than 10 microm, different from the hydration reaction of cement that produced pores smaller than 1 microm mostly. To meet the requirements of the lightweight materials characteristics and the compressive strength, the amount of SSA could be up to 60-80% of the total solids. An adequate amount of aluminium powder is 0.5-0.9% of the total solids. Increasing the fineness of the mixed scrap metal waste powder could effectively reduce the amount required and improve the foaming ratio.     

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.     

Lightweight aggregates from incinerated sludge ash

A range of artificial aggregates has been developed from incinerated sewage sludge ash. The ash is either pelletized or slabbed and subsequently fired until it sinters and expands to form lightweight products which are later graded for use as aggregates in concrete. From the standard tests conducted on size grading, bulk density, absorption and fracture strength, it appears that both the pellets and slabs are potentially suitable as lightweight aggregates in concrete. Preliminary studies on concrete incorporating these aggregates support this hypothesis. No studies of potential containment release at high temperature was made during these studies.     

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.     

Experimental study of the bio-oil production from sewage sludge by supercritical conversion process

Environment-friendly treatment of sewage sludge has become tremendously important. Conversion of sewage sludge into energy products by environment-friendly conversion process, with its energy recovery and environmental benefits, is being paid significant attention. Direct liquefaction of sewage sludge into bio-oils with supercritical water (SCW) was therefore put forward in this study, as de-water usually requiring intensive energy input is not necessary in this direct liquefaction. Supercritical water may act as a strong solvent and also a reactant, as well as catalyst promoting reaction process. Experiments were carried out in a self designed high-pressure reaction system with varying operating conditions. Through orthogonal experiments, it was found that temperature and residence time dominated on bio-oil yield compared with other operating parameters. Temperature from 350 to 500 °C and reaction residence time of 0, 30, 60 min were accordingly investigated in details, respectively. Under supercritical conversion, the maximum bio-oil yield could achieve 39.73%, which was performed at 375 °C and 0 min reaction residence time. Meanwhile, function of supercritical water was concluded. Fuel property analysis showed the potential of bio-oil application as crude fuel.     

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...     

烧结机头除尘灰生产复合肥的研究

通过系统分析烧结机头除尘灰的成分和化学结构,研究制定了利用烧结除尘灰生产复合肥的配方和工艺,该研究为烧结除尘灰的利用开发了新的用途。     

Increasing biogas production from sewage sludge anaerobic co-digestion process by adding crude glycerol from biodiesel industry

In an effort to convert waste streams to energy in a green process, glycerol from biodiesel manufacturing has been used to increase the gas production and methane content of biogas within a mesophilic anaerobic co-digestion process using primary sewage sludge. Glycerol was systematically added to the primary digester from 0% to 60% of the organic loading rate (OLR). The optimum glycerol loading range was from 25% to 60% OLR. This resulted in an 82–280% improvement in specific gas production. Following the feeding schedule described, the digesters remained balanced and healthy until inhibition was achieved at 70% glycerol OLR. This suggests that high glycerol loadings are possible if slow additions are upheld in order to allow the bacterial community to adjust properly. Waste water treatment plant operators with anaerobic digesters can use the data to increase loadings and boost biogas production to enhance energy conversion. This process provides a safe, environmentally friendly method to convert a typical waste stream to an energy stream of biogas.     

Co-digestion of sewage sludge with glycerol to boost biogas production

The feasibility of adding crude glycerol from the biodiesel industry to the anaerobic digesters treating sewage sludge in wastewater treatment plants was studied in both batch and continuous experiments at 35 °C. Glycerol addition can boost biogas yields, if it does not exceed a limiting 1% (v/v) concentration in the feed. Any further increase of glycerol causes a high imbalance in the anaerobic digestion process. The reactor treating the sewage sludge produced 1106 ± 36 ml CH₄/d before the addition of glycerol and 2353 ± 94 ml CH₄/d after the addition of glycerol (1% v/v in the feed). The extra glycerol-COD added to the feed did not have a negative effect on reactor performance, but seemed to increase the active biomass (volatile solids) concentration in the system. Batch kinetic experiments showed that the maximum specific utilization rate (μ_max) and the saturation constant (K_S) of glycerol were 0.149 ± 0.015 h^?1 and 0.276 ± 0.095 g/l, respectively. Comparing the estimated values with the kinetics constants for propionate reported in the literature, it can be concluded that glycerol uptake is not the rate-limiting step during the process.     

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.