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Phosphorus Recovery and Recycling from Municipal Wastewater Sludge

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Phosphorus Recovery and Recycling from Municipal Wastewater Sludge Aalto University School of Science and Technology Department of Civil and Environmental Engineering Jenni Nieminen PHOSPHORUS RECOVERY AND RECYCLING FROM MUNICIPAL WASTEWATER SLUDGE A Master of Science thesis Submitted for inspection in Espoo, 7 May 2010 Supervisor: Professor Riku Vahala Instructor: M.Sc. (Tech.) Pirjo Rantanen ABSTRACT OF THE MASTER’S THESIS Author and the name of the thesis: Jenni Nieminen Phosphorus recovery and recycling from municipal wastewater sludge Date: 7 May 2010 Number of pages: 96 Department: Civil and Environmental Professorship: Water and Wastewater Engineering Engineering Supervisor: Professor Riku Vahala Instructor: M.Sc. (Tech.) Pirjo Rantanen Keywords : Phosphorus recovery, phosphorus recycling, municipal wastewater sludge, sewage sludge, crystallization, struvite The past decades have witnessed a rising awareness of the finite phosphorus resources and the importance of phosphorus recovery. The world phosphorus resources are estimated to deplete in 60 to 240 years and the world phosphorus production to peak in 2033, creating a need to discover alternative materials to replace phosphate ore. Municipal wastewater sludge is a phosphorus source worth considering, since modern technologies can transfer over 90% of the phosphorus from the wastewater to the sludge fraction. The aim of this thesis is to discuss and overview the current methods for phosphorus recovery from municipal wastewater sludge, ash from sludge incineration, and the liquid phase after anaerobic treatment containing phosphorus in soluble form. The methods for recovery include crystallization and precipitation, wet chemical methods, and thermo•chemical methods. The crystallization and precipitation methods convert phosphorus into solid form with a chemical dosage and pH adjustment. The wet chemical methods recover the phosphorus bound in sludge or ash by leaching it with acid or base, and recovering the resulting dissolved phosphorus with various methods, the most common being the precipitation. The ash fraction after incineration can be treated with thermo•chemical methods by adding chloride chemical and bringing the ash to temperature higher than the boiling point of the resulted heavy metal chlorides, leading to their evaporation. This study surveys processes based on these methods, both the operational full•scale applications and the pilot•scale and laboratory•scale processes. Most of the operational processes are based on crystallization or precipitation. Precipitation is a widely studied method that has proved to be economical compared to the wet chemical methods. The wet chemical methods require chemicals and offer limited amount of experiences from full•scale. Thermo• chemical methods do not yet have full•scale implementations. ii DIPLOMITYÖN TIIVISTELMÄ Tekijä ja työn nimi: Jenni Nieminen Fosforin kierrätys ja talteenotto yhdyskuntien jätevesilietteestä Päivämäärä: 7.5.2010 Sivumäärä: 96 Tiedekunta: Insinööritieteiden ja Laitos: Yhdyskunta• ja arkkitehtuurin tiedekunta ympäristötekniikan laitos Työn valvoja: Professori Riku Vahala Työn ohjaaja: Diplomi•insinööri Pirjo Rantanen Avainsanat: Fosforin talteenotto, fosforin kierrätys, yhdyskuntien jätevesiliete, struviitti Viime vuosikymmeninä on alettu kiinnittää entistä enemmän huomiota maailman fosforivarojen riittävyyteen ja fosforin kierrätykseen. Arviot taloudellisesti hyödynnettävien fosforiesiintymien riittävyydestä vaihtelevat 60 ja 240 vuoden välillä ja maailman fosforin tuotannon arvioidaan saavuttavan huippunsa vuonna 2033. Tämän jälkeen fosforin tuotannossa on siirryttävä hyödyntämään vaikeammin saavutettavissa olevia ja heikkolaatuisempia malmivaroja. Vaikean saavutettavuuden vuoksi tuotanto hidastuu, ja heikompi laatu hankaloittaa malmin prosessointia. Tuotannon epävarmuus saattaa aiheuttaa nopeitakin heilahteluita fosforin hinnassa. Hupenevia fosforivaroja korvaamaan tarvitaan tulevaisuudessa vaihtoehtoisia fosforinlähteitä. Harkitsemisen arvoinen vaihtoehto on jäteveden puhdistusprosesseissa syntyvä liete, johon prosessin tehokkuudesta riippuen voi päätyä yli 90 % puhdistamolle tulevan jäteveden fosforista. Tämän diplomityön tarkoituksena on tarkastella menetelmiä, jotka on kehitetty fosforin talteenottoon yhdyskuntien jätevesilietteestä, lietteen polton seurauksena syntyvästä tuhkasta sekä nestefaasista, johon fosfori on anaerobisessa käsittelyssä vapautunut. Talteenotto nestefaasista tapahtuu saostus• ja kiteytysmenetelmillä, joissa kemikaaliannostuksen ja pH:n säädön seurauksena liukoinen fosfori saostuu. Tuhkaan ja lietteeseen sitoutuneen fosforin talteenottamiseksi fosfori liuotetaan happo• tai emäskäsittelyllä. Liuenneen fosforin erottamiseen voidaan käyttää esimerkiksi saostusta, ioninvaihtohartseja tai nanosuodatusta. Tuhkan käsittelyyn voidaan soveltaa myös termokemiallisia menetelmiä, joissa tuhkaan lisätään klooriyhdisteitä ja seos kuumennetaan yli raskasmetallikloridien kiehumispisteen, jolloin syntyneet yhdisteet poistuvat kaasuna. Työssä tarkastellaan menetelmiin perustuvia prosesseja: sekä toiminnassa olevia täyden mittakaavan laitoksia että kokeilu• tai laboratoriomittakaavassa olevia prosesseja. Suurin osa täyden mittakaavan sovelluksista perustuu kiteytykseen tai saostukseen. Näitä menetelmiä on kehitetty ja tutkittu eniten ja ne ovat taloudellisempia kuin märkäkemialliset menetelmät, jotka vaativat runsaasti kemikaaleja. Märkäkemiallisiin menetelmiin perustuvista täyden mittakaavan laitoksista on rajallisesti käyttökokemuksia. Termokemiallisia menetelmiä ei ole vielä toteutettu täydessä mittakaavassa. iii ACKNOWLEDGEMENTS This thesis was written at Aalto University between October 2009 and May 2010, and it was funded by Kemira Oyj. Therefore, I want to show my gratitude to Kemira, and thank especially Pentti Pekonen and Timo Härmä for their guidance and providing me with such an interesting topic. From Aalto University, I would like to thank my supervisor professor Riku Vahala for his understanding attitude towards the tight schedule, my instructor Pirjo Rantanen for her support and guiding me into the right direction, and Michela Mulas for her help with the final touch. I would also like to thank my mother for supporting me during the thesis process and my studies. iv TABLE OF CONTENTS 1 INTRODUCTION......................................................................................................................................... 1 2 PHOSPHORUS.............................................................................................................................................. 3 2.1 NATURAL PHOSPHORUS CYCLE.............................................................................................................. 3 2.2 WORLD PHOSPHATE ROCK RESOURCES ................................................................................................. 5 2.3 BASIC CHEMISTRY.................................................................................................................................. 8 2.4 APPLICATIONS ...................................................................................................................................... 10 2.4.1 Fertilizers........................................................................................................................................ 10 2.4.2 Detergents....................................................................................................................................... 10 2.4.3 Other................................................................................................................................................ 11 2.5 PRODUCTION ........................................................................................................................................ 11 2.5.1 Wet chemical process..................................................................................................................... 11 2.5.2 Electro•thermal process................................................................................................................. 12 3 PHOSPHORUS REMOVAL..................................................................................................................... 15 3.1 PHOSPHORUS IN WASTEWATER TREATMENT PLANT ........................................................................... 15 3.2 CHEMICAL PHOSPHORUS REMOVAL..................................................................................................... 16 3.3 BIOLOGICAL PHOSPHORUS REMOVAL .................................................................................................. 18 3.4 SLUDGE TREATMENT............................................................................................................................ 20 3.4.1 Anaerobic digestion........................................................................................................................ 20 3.4.2 Mono•incineration.......................................................................................................................... 21 3.5 PHOSPHORUS RECYCLING .................................................................................................................... 22 3.5.1 Agricultural use .............................................................................................................................. 22 3.5.2 Recycling in phosphate industry.................................................................................................... 23 4 PHOSPHORUS RECOVERY..................................................................................................................
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