Enhanced heavy metals removal without phosphorus loss from anaerobically digested sewage sludge

Heavy metals removal without phosphorus loss from anaerobically digested sewage sludge was investigated by conducting batch experiments using hydrogen peroxide and/or iron sulphate under acidified conditions at pH 3. The addition of hydrogen peroxide to the sludge improved the elution efficiencies of As, Cd, Cu and Zn with phosphorus loss from the sludge. The optimum initial concentrations of hydrogen peroxide were. Respectively. 0.1% for As, Cd, Mn and Zn and 0.5% for Cu and Ni. The combined process of 0.1% hydrogen peroxide and 1 g Fe/L ferric sulphate enhanced the initial elution rate of Cu and Cr compared to the addition of either ferric sulphate or hydrogen peroxide, indicating that oxidants stronger than hydrogen peroxide were produced in the sludge. Furthermore, the combined process immobilised phosphorus in the sludge due to co-precipitation with ferric hydroxide or precipitation as ferric phosphate. It was concluded that there is a possibility that the combined process could remove heavy metals effectively without phosphorus loss from anaerobically digested sewage sludge.     

羟基磷酸钙结晶法回收大型水生植物发酵液中磷酸盐研究

为有效回收大型水生植物发酵液中磷,选择挺水植物西伯利亚鸢尾(Iris sibirica L.)和圆币草(Hydrocotyle vulgaris)进行发酵试验,分析不同pH值下发酵液中磷回收的效率和纯度,探索羟基磷酸钙(hydroxyapatite,HAP)结晶法回收水生植物发酵液中磷酸盐的可能性。结果表明:西伯利亚鸢尾和圆币草发酵液中钙磷摩尔数比分别为2.7和10,镁磷比分别为1.4和1.6,适合采用HAP法回收磷酸盐。不同水生植物发酵液调节pH值回收磷曲线相似,在pH为8.5时西伯利亚鸢尾和圆币草发酵液磷酸盐回收率分别达到89%和91%,产生的羟基磷酸钙沉降性能良好。X射线荧光光谱分析分析结果表明pH为8.5时沉淀物中P2O5质量分数超过25%,羟基磷酸钙为主要成分。pH调节超过8.5后沉淀物中碳酸钙含量会随着pH上升而不断增加,影响羟基磷酸钙的纯度,因此,回收磷酸盐适合的pH值为8.5。     

Operation of a new sewage treatment process with technologies of excess sludge reduction and phosphorus recovery.

This paper shows the potential application of a new sewage treatment process with technologies of excess sludge reduction and phosphorus recovery. The process incorporated ozonation for excess sludge reduction and crystallisation process for phosphorus recovery to a conventional anaerobic/oxic (A/O) phosphorus removal process. A lab-scale continuous operation experiment was conducted with the ratio of sludge flow rate to ozonation tank of 1.1% of sewage inflow under 30 to 40 mgO3/gSS of ozone consumption and with sludge wasting ratio of 0.34% (one-fifth of a conventional A/O process). Throughout the operational experiment, a 60% reduction of excess sludge production was achieved in the new process. A biomass concentration of 2300 mg/L was maintained, and the accumulation of inactive biomass was not observed. The new process was estimated to give a phosphorus recovery degree of more than 70% as an advantage of excess sludge reduction. The slight increase in effluent COD was observed, but the process performance was maintained at a satisfactory level. These facts demonstrate an effectiveness of the new process for excess sludge reduction as well as for phosphorus recovery.     

Ammonia recovery from anaerobically digested cattle manure by steam stripping.

Ammonia recovery from anaerobically digested cattle manure effluents through steam stripping was studied at a stripping tower temperature of 98-99 degrees C and a steam-water ratio approximately 56-72 g/L. The digested manure effluents were first treated by microfiltration and then the permeate was used as feed in steam stripping. The stripping performance was evaluated under different feed pH values, ammonia concentrations and temperatures. The increase of the initial feed pH does not significantly improve ammonia stripping efficiency due to the fact that the stripped effluent pH is increased during steam stripping. This suggests that steam stripping of anaerobically digested manure effluents for ammonia recovery may not need pre-raised pH. In contrast, the pH value of the synthetic ammonia wastewater containing NH4Cl dramatically decreases after steam stripping. Increasing the feed temperature slightly improves ammonia stripping efficiency, but reduces the concentration of the recovered ammonia in the condensate due to an increased condensate volume at a higher feed temperature. Therefore, the feed temperature should be controlled at an optimum point that can compromise the condensate ammonia concentration and the ammonia stripping efficiency. Experimental results indicate that recovery of ammonia from anaerobically digested cattle manure effluents as NH4OH is technically feasible.     

Full-scale application of anaerobic digestion process with partial ozonation of digested sludge.

For improving sludge digestion and biogas recovery, a new anaerobic digestion process combined with ozonation was tested at a full-scale unit for 2 years and its performance was compared with a simultaneously operated conventional anaerobic digestion process. The new process requires two essential modifications, which includes ozonation for enhancing the biological degradability of sludge organics and concentrating of solids in the digester through a solid/liquid separation for extension of SRT. These modifications resulted in high VSS degradation efficiency of ca. 88%, as much as 1.3 times of methane production and more than 70% reduction in dewatered sludge cake production. Owing to accumulation of inorganic solids in the digested sludge, water content of the dewatered sludge cake also reduced from 80% to 68%. An energy analysis suggested that no supplemental fuel was necessary for the subsequent incineration of the cake from the new process scheme. The process is suitable to apply to a low-loaded anaerobic digestion tank, where power production is used.     

A novel process for organic acids and nutrient recovery from municipal wastewater sludge.

In this paper, a novel process for organic acids and nutrient recovery from municipal sludge was introduced and evaluated based on laboratory-scale studies. An economical estimation for its practical application was also performed by mass balance in a full-scale plant (Q=158,000 m3 d(-1)). This novel process comprises an upflow sludge blanket-type high performance elutriated acid fermenter (5d of SRT) for organic acids recovery followed by an upflow-type crystallisation (3 h of HRT) reactor using waste lime for nutrient recovery. In the system, the fermenter is characterised by thermophilic (55 degrees C) and alkaline conditions (pH 9), contributing to higher hydrolysis/acidogenesis (0.18 g VFA(COD) g(-1) VSS(COD), 63.3% of VFA(COD)/COD produced, based on sludge characteristics of the rainy season) and pathogen-free stabilised sludge production. It also provides the optimal condition for the following crystallisation reactor. In the process, the waste lime, which is an industrial waste, can be used for pH control and cation (Ca and Mg) sources for crystallisation reaction. A cost estimation for full-scale application demonstrates that this process has economic benefits (about 67 dollars per m3 of wastewater except for the energy expense) even in the rainy season.     

Resource recovery from excess sludge by subcritical water combined with magnesium ammonium phosphate process.

The amount of excess sludge produced in municipal wastewater treatment plants in Japan is increasing every year as the urban population increases. Phosphorus in excess sludge could be a potential phosphorus resource since at present, phosphate rock is being exhausted all over the world. Every year, Japan imports large quantities of phosphorus from abroad but much is discharged as excess sludge. Therefore, the solubilization process, one method of recovering phosphorus from sludge, could be a promising solution. In this study, a subcritical water process, a new technology that solubilizes sludge under subcritical conditions, was applied before the phosphorus in sludge was recovered with the magnesium ammonium phosphate (MAP) process. As a result, the solubilization rate of excess sludge achieved approximately 80% and about 94-97% of the phosphorus could be recovered.     

Concentration of nutrients from urine and reject water from anaerobically digested sludge.

Experiments with concentration of nutrients from source separated urine and reject water from digestion of sludge in sewage treatment plants (STP) have been performed in laboratory and pilot scale. The methods tested were membrane filtration with reverse osmosis (RO), evaporation, and precipitation of phosphorus and distillation of ammonia. In membrane filtration, pre-filtration with particle separation at 5-10 microm was enough to avoid clogging of the membranes. Separation of phosphorus (P), potassium (K) and sulphur (S) was almost 100%, while separation of nitrogen (N) was dependent on pH. The capacity of flux increased with temperature and pressure. In evaporation, all P, K and S were still in the concentrate, while pH had to be decreased to 4.5 to avoid significant loss of N. In precipitation and distillation, about 90% of P could be recovered from urine as magnesium ammonium phosphate (MAP) just by adding MgO. For the reject water pH was first increased by aeration to remove CO2. Ammonium can be distilled from the water phase after precipitation of MAP, without further increase of pH. At least 80-90% of N can be distilled in 5-10% of the total volume. The article also discusses the quality of different products, cost of separation, and energy and chemical demand.     

Recovery of phosphorus and aluminium from sewage sludge ash by a new wet chemical elution process (SESAL-Phos-recovery process)

The potential of a new wet chemical process for phosphorus and aluminium recovery from sewage sludge ash by sequential elution with acidic and alkaline solutions has been investigated: SESAL-Phos (sequential elution of sewage sludge ash for aluminium and phosphorus recovery). Its most innovative aspect is an acidic pre-treatment step in which calcium is leached from the sewage sludge ash. Thus the percentage of alkaline soluble aluminium phosphates is increased from 20 to 67%. This aluminium phosphate is then dissolved in alkali. Subsequently, the dissolved phosphorus is precipitated as calcium phosphate with low heavy metal content and recovered from the alkaline solution. Dissolved aluminium is recovered and may be reused as a precipitant in wastewater treatment plants.     

Hydrolytic activity of alpha-amylase in anaerobic digested sludge.

Hydrolysis is usually considered to be a rate-limiting step in anaerobic digestion. For improving anaerobic solid waste treatments, it is essential to elucidate the mechanism of hydrolysis. In this study, alpha-amylase, one of the hydrolytic enzymes, was investigated for the elucidation of more precise mechanism of hydrolysis. Alpha-amylase activity of solid starch-degrading bacteria (SDB) was estimated through batch experiments with several different substrates and with distinction between cell-bound and cell-free alpha-amylase. Monitoring of newly isolated strains of SDB was done by fluorescence in situ hybridization. Results indicated that cell-bound alpha-amylase is chiefly responsible for the hydrolysis in the digested sludge, providing very useful information that the contact between microbial cells and solids is significantly important. The activity of alpha-amylase of the digested sludge remained quite low when not required, but increased as they recognized appropriate substrates. Several-fold higher activity was obtained for starch or maltose as compared to glucose only.     

Nitrogen removal from digested manure in a simple one-stage process

A process based on partial nitrification and recirculation into the anaerobic digester was studied to remove nitrogen from digested manure and thus reduce enhanced gaseous ammonia emissions due to on-farm biogas production. An anaerobic reactor representing an anaerobic manure digester was fed with a nitrite solution and digested manure liquor. Nitrite was efficiently removed from the influent and ammonium formation was observed first. Ammonium was subsequently eliminated up to a maximum of 90% of the influent concentration, indicating anaerobic ammonium oxidation activity. This activity, however, decreased again and was lost at the end of the 4-month operation period. In a 1.5 L aerobic CSTR that was fed with digested manure liquor, ammonium was efficiently removed from the influent. Nitrite and nitrate formation was observed but mass balances indicated significant N-removal. Accumulation of suspended solids was observed at the end of the experiment suggesting presence of oxygen-free environments. In a second test in a 15 L CSTR where suspended solids sedimentation could be avoided, low N-removal rates were observed in the absence of biofilm carrier elements whereas high N-removal rates were achieved in their presence. A simple one-stage process based on immobilized biomass could therefore be installed downstream of agricultural anaerobic digesters in order to mitigate undesirable gaseous ammonia emissions.     

Recovering phosphorus as struvite from the digested swine wastewater with bittern as a magnesium source

Recovering nitrogen and phosphorus through struvite (MgNH4PO4 6H2O) crystallization from swine wastewater has gained increasing interest. However, swine wastewater contains complex compositions, which may hinder the formation of struvite crystal and affect the purity of the precipitates by forming other insoluble minerals. In this work, experiments were carried out to evaluate struvite precipitation in the anaerobically digested swine wastewater, with dosing bittern as a low-cost magnesium source. Exceeded 90% phosphate removal and 23-29% ammonium reduction were obtained. FTIR, XRD and mass balance analysis were combined to analyze the species of precipitated minerals. Results showed that the precipitates were struvite, mixed with amorphous calcium phosphate (ACP) and brucite. The presence of Ca2+ diminished the percentage of struvite and gave rise to ACP formation. Controlling pH below 9.5 and bittern dosage above 1% (w/w) could inhibit ACP precipitation and harvest a highly pure struvite crystal product.     

Dewatered alum sludge: a potential adsorbent for phosphorus removal.

Alum sludge refers to the by-product from the processing of drinking water in water treatment works. In this study, groups of batch experiments were designed to identify the characteristics of dewatered alum sludge for phosphorus adsorption. Air-dried alum sludge (moisture content 10.2%), which was collected from a water treatment works in Dublin, was subjected to artificial P-rich wastewater adsorption tests using KH2PO4 as a model P source. Adsorption behaviours were investigated as a function of amount and particle size of alum sludge, pH of solution and adsorption time. The results have shown that pH plays a major role not only in the adsorption process but also in the adsorption capacity. With regard to adsorption capacity, this study reveals the Langmuir adsorption isotherm being the best fit with experimental data (R2 = 0.98-0.99). The maximum adsorption capacities range from 0.7 to 3.5 mg-P/g when the pH of the synthetic P solution was varied from 9.0 to 4.3, accordingly. The outcome of this study indicated that alum sludge is suitable for use as an adsorbent for removal of phosphate from wastewater.     

Influence of ORP variation, carbon source and nitrate concentration on denitrifying phosphorus removal by DPB sludge from dephanox process.

The effect of added carbon source and nitrate concentration on the denitrifying phosphorus removal by denitrifying phosphorus removal bacteria sludge was systematically studied using batch experiments, at the same time the variation of ORP was investigated. Results showed that the denitrifying and phosphorus uptake rate in the anoxic phase increased with the high initial anaerobic carbon source addition. However, once the initial COD concentration reached a certain level, which was in excess of the PHB saturation of Poly-p bacteria, residual COD carried over to the anoxic phase inhibited the subsequent denitrifying phosphorus uptake. This was equal to supplementing the external carbon source to the anoxic phase, furthermore the higher the external carbon source concentration the more powerful the inhibition caused. High nitrate concentration in the anoxic phase increased the initial denitrifying phosphorus rate. Oncethe nitrate was exhausted, phosphate uptake changed to phosphate release. Moreover, the time of this turning point occurred later with the higher nitrate addition. On the other hand, through on-line monitoring the variation of the ORP with different initial COD concentration, it was found that ORP could be used as a control parameter for phosphorus release, but it is impossible to utilize ORP for controlling the dinitrification and anoxic phosphorus uptake operations.     

Analysis of phosphorus removal and anaerobic selector performance in a full-scale activated sludge process in Singapore.

This paper analyses the performance of the anaerobic selector (A/O process) in a full-scale activated sludge process receiving mostly industrial sewage discharge (> 60%) in Singapore. In addition to the sludge settleability, enhanced biological phosphorus removal (EBPR) was studied. The sludge volume index (SVI) reduced from 200 to 80 ml g(-1) and foaming was suppressed significantly, indicating the effectiveness of the anaerobic selector in improving sludge settleability. The phosphorus removal efficiency was 66%, and 7.5 mg HAc-COD was consumed per mg PO4(3-) -P removed. In the anaerobic compartment, 31% of the SCOD and 73% of the acetic acid in the settled sewage were removed with PO4(3-) -P release of 14.1 mg PO4(3-)-P l(-1). The linear correlation between PO4(3-) -P release in the anaerobic compartment and PO4(3-) -P uptake in the aerobic compartment indicates that there is about 0.8 mg PO4(3-) -P release in the anaerobic compartment per mg PO34(3-) -P uptake in the aerobic compartment. The fates of volatile fatty acids (VFAs) and its short chain acids (SCAs) in the process were studied and discussed.     

Application of the flotation process to thicken the sludge from a DAF plant.

Dissolved air flotation (DAF) was evaluated for thickening of the sludges from a water treatment plant which uses DAF. Solid flux theory for gravity thickening was applied to the solid flux of DAF sludge. The higher the polymer dosage, at fixed solid concentration, the greater the rising velocity becomes. When applied with solid flux equations, a similar relationship to that of gravity thickening has been found. However, the values were much higher than in gravity thickening, because both the inflow solid concentration and the floating velocity were higher than for settled sludge. With this result, the proper dosage of polymer could be derived from the relationship between total solid flux and withdrawal velocity of DAF sludge.     

Potentials of using nanofiltration to recover phosphorus from sewage sludge.

Due to the depletion of mineral phosphorus resources there is an increasing demand for efficient phosphorus recovery technologies. In this study the potential of nanofiltration to recover phosphorus from pre-treated sewage sludge is investigated. The efficiency of three commercial nanofiltration membranes (Desal 5DK, NP030; MPF34) was tested using model solutions. Desal 5DK showed the best selectivity for phosphorus. A pH of lower than 1.5 was found to be most suitable. Desal 5DK was used on four different sewage sludge ash eluates and on one sewage sludge. In these experiments it was shown that a separation of phosphorus from undesired components such as heavy metals was possible with significant variations in the efficiency for the different ash and sludge types. Additionally the achievable product recovery was investigated with model solutions. A product recovery of 57.1% was attained for pH 1 and 41.4% for pH 1.5.     

Nitrogen removal from sludge reject water by a two-stage oxygen-limited autotrophic nitrification denitrification process.

Nitrogen removal from sludge reject water was obtained by oxygen-limited partial nitritation resulting in nitrite accumulation in a first stage, followed by autotrophic denitrification of nitrite with ammonium as electron donor (similar to anaerobic ammonium oxidation) in a second stage. Two membrane-assisted bioreactors (MBRs) were used in series to operate with high sludge ages and subsequent high volumetric loading rates, achieving 1.45 kg N m(-3) day(-1) for the partial nitritation MBR and 1.1 kg N m(-3) day(-1) for the anaerobic ammonium oxidation MBR. Biomass retention in the nitritation stage ensured flexibility towards loading rate and operating temperature. Nitrite oxidisers were out-competed at low oxygen and high free ammonia concentration. Biomass retention in the second MBR prevented wash-out of the slowly growing bacteria. Nitrite and ammonium were converted to dinitrogen gas in a reaction ratio of 1.05, thereby maintaining nitrite limitation to assure process stability. The anoxic consortium catalysing the autotrophic denitrification process consisted of Nitrosomonas-like aerobic ammonium oxidizers and anaerobic ammonium oxidizing bacteria closely related to Kuenenia stuttgartiensis. The overall removal efficiency of the combined process was 82% of the incoming ammonium according to a total nitrogen removal rate of 0.55 kg N m(-3) day(-1), without adding extra carbon source.     

The REAL process--a process for recycling sludge from water works.

In order to produce drinking water, coagulants--such as aluminium salts--are widely used for precipitation and separation of impurities from raw water. The residual from the process is sludge, which presents a disposal problem. The REAL process is a method for recycling the aluminium from the sludge. In a first step, the aluminium hydroxide is dissolved in sulphuric acid. In a second step, an ultra filtration will separate all suspended matter and large molecules, leaving a concentrate of 15-20% dry solids. The permeate will contain the trivalent aluminium ions together with 30-50% of the organic contaminants. In a third step, by concentrating the permeate in a nano filter, the concentration of aluminium will be high enough to, in a fourth step, be precipitated with potassium sulphate to form a pure crystal: potassium aluminium sulphate. The potassium aluminium sulphate is comparable to standard aluminium sulphate. The process will give a residual in form of a concentrate from the ultra filtration, representing a few per cent of the incoming volume. This paper presents the results from a long time pilot-scale continuous test run at V?ster?s water works in Sweden, as well as calculations of costs for full-scale operations.     

Energy and nutrient recovery from sewage sludge via pyrolysis.

Energy recovery and nutrient reuse from sewage sludge has traditionally been achieved via anaerobic digestion/power generation with land application of the biosolids. By contrast, thermal processes such as pyrolysis have typically been used only for energy recovery. One such technology has demonstrated at commercial scale that all of the energy in sludge can be beneficially recovered and reused. No attempt was however made to recover and reuse sludge nutrients. There are many potential benefits of using pyrolysis for both energy and nutrient recovery. Firstly, unlike digestion, the principal energy product is oil, which can readily be stored and used when required, ensuring that energy recovery is maximised. Secondly is that the sludge nutrients are recovered in the pyrolysis char. Laboratory soil incubation studies using char from the Subiaco demonstration plant were conducted over an eight-week period to confirm nutrient availability. Results from this study showed that the phosphorus in the char is plant available although the nitrogen was insoluble. Based on these results it appears that there is potential to use pyrolysis as an effective means to recover and reuse both the energy and the very valuable phosphorus present in sewage sludges.