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Paper des Monats
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Phase formation and evolution was investigated in the CaO–SiO2 system in the range of 70–80 mol% CaO. The samples were container-less processed in an aerodynamic levitation system and crystallization was followed in situ by synchrotron x-ray diffraction at the beamline P21.1 at the German electron synchrotron (DESY). Modification changes of di- and tricalcium silicate were observed and occurred at lower temperatures than under equilibrium conditions. Despite deep sample undercooling, no metastable phase formation was observed within the measurement timescale of 1 s. For the given cooling rates ranging from 300 K s−1 to about 1 K s−1, no decomposition of tricalcium silicate was observed. No differences in phase evolution were observed between reducing and oxidizing conditions imposed by the levitation gas (Ar and Ar + O2). We demonstrate that this setup has great potential to follow crystallization in refractory oxide liquids in situ. For sub-second primary phase formation faster detection and for polymorph detection adjustments in resolution have to be implemented.
There is an ongoing debate on European scale concerning the criticality of phosphorus. In Switzerland and Germany, phosphorus recovery from phosphorus-rich waste streams will become obligatory. Sewage sludge ash is rich in phosphorus and may become an important secondary feedstock. Thermochemical treatment of sewage sludge ash with sodium sulphate under reducing conditions was shown to remove heavy metals from the solid product and produce the fully plant available crystalline phase CaNaPO4. Pilot-scale experiments in a rotary kiln were carried out at temperatures between 750 and 1000 °C and were compared to laboratory-scale experiments with crucibles. Process upscaling was successfully demonstrated but a series of differences were noticed: In comparison to laboratory-scale, solubility of phosphorus in samples from pilot-scale experiments was lower at all chosen treatment temperatures because of shorter retention time and incomplete decomposition of sodium sulphate. X-ray diffraction analysis revealed remaining phase fractions of whitlockite (Ca3-x(Mg,Fe)x(PO4)2) and sodium sulphate from the starting materials in products and thus indicated incomplete reaction. In contrast to the results of laboratory-scale experiments, the crystalline phase CaNaPO4 was clearly absent in the products from the rotary kiln but instead a Mg-bearing phase (Ca,Mg)NaPO4 was formed. Laboratory-scale experiments confirmed (Ca,Mg)NaPO4 is an intermediate phase between whitlockite and CaNaPO4. However, both crystalline phases are characterized by high plant availability. It was shown that heavy metal removal increased at higher temperatures whereas solubility and thus plant availability of phosphorus already reached its maxima at temperatures of 950 °C in pilot-scale and 875 °C in laboratory-scale experiments.
One of the key elements in the transformation towards a circular economy (CE) is providing more sustainable practices for resources and waste management. Improvement actions focused on transformation towards a CE should be targeted at all groups of materials and waste. As water is essential for human survival and well-being and plays a significant role in sustainable development (SD), the actions related to the reuse of water and the recovery of raw materials from wastewater and other water-based waste should be taken. The paper presents a proposition for a new CE model framework in the water and wastewater sector, which includes the six following actions: reduction—prevent wastewater generation in the first place by the reduction of water usage and pollution reduction at source; reclamation (removal)—an application of effective Technologies for the removal of pollutants from water and wastewater; reuse—reuse of wastewater as an alternative source of water supply (non-potable usage), recycling—recovery of water from wastewater for potable usage; recovery—recovery of resources such as nutrients and energy from water-based waste, and rethink—rethinking how to use resources to create a sustainable economy, which is `free` of waste and emissions. The novelty of the proposed CE model framework is that it presents possible ways of implementing CE principles in the water and wastewater sector, with a strong emphasis not only technological but also organisational and societal changes. Application of the proposed model may help to further transform the European economy to the CE model. Moreover, the indicated model can be significant tool supporting an assessment of local or regional progress towards CE in the water and wastewater sector and further environmental management and planning.
The use of highly water-soluble phosphorus (P) fertilizers can lead to P fixation in the soil, reducing fertilization efficiency. Waste-derived, low water-solubility sources can potentially increase sugarcane’s P uptake compared to triple superphosphate by reducing adsorption to the soil.
Aims:We aimed to test struvite, hazenite, and AshDec® for their agronomic potential as recycled fertilizers for sugarcane production in a typical tropical soil.We hypothesize that these sources can reduce P fixation in the soil, increasing its availability and sugarcane’s absorption.
Methods: In a greenhouse pot experiment, two consecutive sugarcane cycles, 90 days each, were conducted in a Ferralsol. The recovered sources struvite, hazenite, AshDec®, and the conventional triple superphosphate were mixed in the soil in three P doses (30, 60, and 90 mg kg–1), aside a control (nil-P). At both harvests, sugarcane number of sprouts, plant height, stem diameter, dry mass yield, shoot phosphorus, and soil P fractionation were investigated.
Results: At 90 days, struvite and hazenite performed better for dry mass yield (70.7 and 68.3 g pot–1, respectively) than AshDec® and triple superphosphate (59.8 and 57.4 g pot–1, respectively) and for shoot P, with 98.1, 91.6, 75.6, and 66.3 mg pot–1, respectively. At 180 days, struvite outperformed all treatments for dry mass yield (95.3 g pot–1) and AshDec® (75.5 mg pot–1) for shoot P. Struvite was 38% and hazenite 21% more efficient than triple superphosphate in P uptake, while AshDec® was 6% less efficient. Soil had higher labile P under struvite, hazenite, and AshDec® than triple superphosphate by the end of the first cycle, while only the later increased nonlabile P by the end of the experiment (180 days).
Conclusions:Waste-derived P sources were more efficient in supplying P for sugarcane and delivering labile P in 180 days than triple superphosphate.
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.
Conventional phosphate fertilizers are usually highly water-soluble and rapidly solubilize when moistened by the soil solution. However, if this solubilization is not in alignment with plants demand, P can react with the soil colloidal phase, becoming less available over time. This is more pronounced in acidic, oxidic tropical soils, with
high P adsorption capacity, reducing the efficiency of P fertilization. Furthermore, these fertilizers are derived from phosphate rock, a non-renewable resource, generating an environmental impact. To assess these concerns, waste-recycled P sources (struvite, hazenite and AshDec®) were studied for their potential of reducing P Fixation by the soil and improving the agronomic efficiency of the P fertilization. In our work, we compared the solubilization dynamics of struvite, hazenite, AshDec® to triple superphosphate (TSP) in a sandy clay loam Ferralsol, as well as their effect on solution pH and on soil P pools (labile, moderately-labile and non-labile) via an incubation experiment. Leaching columns containing 50 g of soil with surface application of 100 mg per column (mg col 1) of P from each selected fertilizer and one control (nil-P) were evaluated for 60 days. Daily leachate samples from the column were analyzed for P content and pH. Soil was stratified in the end and submitted to P
fractionation. All results were analyzed considering p < 0.05. Our findings showed that TSP and struvite promoted an acid P release reaction (reaching pHs of 4.3 and 5.5 respectively), while AshDec® and hazenite reaction was alkaline (reaching pHs of 8.4 and 8.5 respectively). Furthermore, TSP promoted the highest P release among all sources in 60 days (52.8 mg col 1) and showed rapid release dynamic in the beginning, while struvite and hazenite showed late release dynamics and lower total leached P (29.7 and 15.5 mg col 1 P respectively). In contrast, no P-release was detected in the leachate of the AshDec® over the whole trial period. Struvite promoted
the highest soil labile P concentration (7938 mg kg 1), followed by hazenite (5877 mg kg 1) and AshDec® (4468 mg kg 1), all higher than TSP (3821 mg kg 1), while AshDec® showed high moderately-labile P (9214 mg kg 1), reaffirming its delayed release potential.
Future nutrient recovery from sewage sludge regarding three different scenarios - German case study
(2022)
Agricultural sewage sludge utilization becomes less important in Germany. In 2017, new fertilizer and waste laws caused the agricultural sewage sludge utilization to collapse by more than a quarter. From 2029, German wastewater treatment plants (WWTPs) must recover phosphorus (P) from sewage sludge if it contains more than 2 wt % P. Agricultural utilization will be prohibited for large WWTPs >100,000 population equivalents (pe) from 2029 and >50,000 pe from 2032. In Germany, each federal state must annually report amounts and quality of agriculturally utilized sewage sludge which was 16% of the total disposal in 2019. The reports of 10 states were evaluated for 2016 and 2017 representing approx. 60% of the total agriculturally used sludge volume. In 2016, 60% of the WWTPs’ sludges exceeded the recovery limit of 2 wt % P which is 70% of the amount of sludge and 85% of the phosphorus load. Other nutrients are not affected by the recovery obligation. However, many P recovery processes recover other nutrients, too. Considering three different scenarios for future German sewage sludge disposal shows that 70–77% of the P load in sewage sludge will probably be recovered in the future. At the same time, this applies for about 0–16% nitrogen, 36–52% of calcium, 31–53% of potassium, and 40–52% of magnesium. However, these recovered nutrients loads can substitute only 1% or less of the commercial fertilizer demand except from phosphorus which is up to 43% of the demand.
Gypsum is widely used in the construction sector and its worldwide consumption has been increasing for several decades. Depending on the life-time of the used gypsum products, an increase of gypsum in construction and demolition waste follows. Especially against the background of a circular economy, the recycling of waste gypsum is of growing importance. However, the use of recycled gypsum makes only sense if it is environmentally friendly. Therefore, an evaluation of the environmental impacts of an industrial-scale processing for the recycling of post-consumer gypsum waste was conducted. The evaluation was performed with an established life cycle assessment software. Original data provided by industry and complementary data from a database for life cycle assessments were used for the calculations. Two scenarios for recycled gypsum with different transportation distances were calculated. These results are compared with results of the environmental evaluation of gypsum derived from coal-fired power plants (FGD gypsum) and natural gypsum. The results show that utilization of recycled gypsum can be environmentally advantageous compared to the use of natural gypsum or FGD gypsum, especially in the impact categories land transformation and resource consumption (abiotic depletion potential). For most environmental impact categories the specific transportation distances have a strong influence.
Treatment and reusing of hazardous wastes have become significant issues of modern societies. Blast furnace sludge (BFS) and electric arc furnace dust (EAFD) are such typical wastes, because they usually contain high amounts of undesirable elements such as zinc (Zn) and lead (Pb).
These elements can cause operational problems in reusing of BFS and EAFD. In this study, the Ferro Duo GmbH and the Federal Institute for Materials Research and Testing have investigated a novel approach for eliminating and/or recovering Zn and Pb from both wastes. Applied was a selective chlorination and volatilization of Zn and Pb as chlorides at temperatures between 500 °C and 1100 °C. Both product obtained, Zn and Pb in the form of ZnCl2 and PbCl2 and the purified solid mineral compound are attractive materials for further use. Hydrochloric acid and iron(II) chloride were used as chlorination agents. Exceptionally high Zn and Pb removal efficiencies of >99.5 % could be achieved with both chlorination agents, whereby iron(II) chloride exhibited better performance.
In Denmark, increasing amounts of woody biomass are being used for the production of renewable energy, resulting in more wood ashes being generated. While these materials have been mainly landfilled, wood ashes may also be utilised for fertilizing and liming purposes on top of soils. Pre-treatments involving hardening or granulation may be carried out prior to soil application. In this study, two Danish wood ash samples were hardened and/or granulated. Lab-hardening induced rapid changes in the shape of the acid neutralisation capacity curve of the ashes. Up-flow column tests, assuming local equilibrium conditions, were employed to investigate the leaching from pre-treated ashes. Granules and loose ashes demonstrated similar leaching behaviours, indicating that similar geochemical processes were governing their leaching. In comparison with untreated fresh ashes, the hardened ashes demonstrated reduced leaching of Ca, Ba, Pb and Zn with concentration levels generally below or close to the analytical limits of quantification; to the contrary, the leaching of As, P, Sb, Si, V and Mg was enhanced in the hardened ashes. The release of alkalinity was reduced by hardening. In general, all granules were barely breakable by finger-pinching and they could withstand one month of continuous leaching, preserving their overall shape. The solubility of phosphorous in neutral ammonium citrate indicated that about 30–51% of the total P content in the ash samples was released, suggesting that the ashes could be potentially valuable as P-fertiliser if applied onto soil.
AbstractRed mud is the waste of bauxite refinement into alumina, the feedstock for aluminium production1. With about 180 million tonnes produced per year1, red mud has amassed to one of the largest environmentally hazardous waste products, with the staggering amount of 4 billion tonnes accumulated on a global scale1. Here we present how this red mud can be turned into valuable and sustainable feedstock for ironmaking using fossil-free hydrogen-plasma-based reduction, thus mitigating a part of the steel-related carbon dioxide emissions by making it available for the production of several hundred million tonnes of green steel. The process proceeds through rapid liquid-state reduction, chemical partitioning, as well as density-driven and viscosity-driven separation between metal and oxides. We show the underlying chemical reactions, pH-neutralization processes and phase transformations during this surprisingly simple and fast reduction method. The approach establishes a sustainable toxic-waste treatment from aluminium production through using red mud as feedstock to mitigate greenhouse gas emissions from steelmaking.
Re-melting of scrap in an electric arc furnace (EAF) results in the accumulation of filter dust from off-gas treatment that predominantly consists of iron and zinc oxides. Filter dust is classified as hazardous waste due to its high contents of potentially toxic or ecotoxic elements such as Pb, Cr, Cd, and As. A promising processing route for this waste is selective chlorination, in which the non-ferrous metal oxides are chlorinated and selectively evaporated in form of their respective chlorides from the remaining solids via the process gas flow. Here, we investigate stepwise thermochemical treatment of EAF dust with either waste iron(II) chloride solution or hydrochloric acid at 650, 800, and 1100 ◦C. The Zn and Pb contents of the thermochemically processed EAF dust could be lowered from 29.9% and 1.63% to 0.09% and 0.004%, respectively. Stepwise heating allowed high separation between zinc chloride at the 650 ◦C step and sodium-, potassium-, and lead-containing chlorides at higher temperatures. Furthermore, the lab-scale results were transferred to the use of an experimental rotary kiln highlighting the possibilities of upscaling the presented process. Selective chlorination of EAF dust with liquid chlorine donors is, therefore, suggested as a potential recycling method for Zn-enriched steelworks dusts.
Sugarcane bagasse is commonly combusted to generate energy. Unfortunately, recycling strategies rarely consider the resulting ash as a potential fertilizer. To evaluate this recycling strategy for a sustainable circular economy, we characterized bagasse ash as a fertilizer and measured the effects of co-gasification and co-combustion of bagasse with either chicken manure or sewage sludge: on the phosphorus (P) mass fraction, P-extractability, and mineral P phases. Furthermore, we investigated the ashes as fertilizer for soybeans under greenhouse conditions. All methods in combination are reliable indicators helping to assess and predict P availability from ashes to soybeans. The fertilizer efficiency of pure bagasse ash increased with the ash amount supplied to the substrate. Nevertheless, it was not as effective as fertilization with triple-superphosphate and K<sub>2</sub>SO<sub>4</sub>, which we attributed to lower P availability. Co-gasification and co-combustion increased the P mass fraction in all bagasse-based ashes, but its extractability and availability to soybeans increased only when co-processed with chicken manure, because it enabled the formation of readily available Ca-alkali phosphates. Therefore, we recommend co-combusting biomass with alkali-rich residues to increase the availability of P from the ash to plants.
For the first time evidence is provided that a nanocrystalline and stacking-disordered, chemically stabilized β-cristobalite form of AlPO4 occurs in a sewage sludge ash (SSA). This proof is based on a combined X-ray powder diffraction and X-ray fluorescence investigation of an SSA produced at a large-scale fluidized bed incineration facility serving a catching area with a population of 2 million. The structural and chemical characterization was carried out on 'as received' SSA samples as well as on solid residues remaining after leaching this SSA in sodium hydroxide solution. Thus, it was ascertained that the observed nanocrystalline and stacking-disordered cristobalite-like component belongs to the aluminum phosphate component of this SSA, rather than to its silicon dioxide component. In addition, a direct proof is presented that the chemically stabilized β-cristobalite form of AlPO4 does crystallize from X-ray amorphous precursors under conditions that mimic the huge heating rate and short retention time (just seconds at T ≈ 850°C), typical for fluidized bed incinerators.
Evidence is provided that the tridymite component observed in the X-ray diffraction patterns of some sewage sludge ashes (SSAs) should not be interpreted as the tridymite modification of SiO2 but as the tridymite form of AlPO4. This proof is based on a combined X-ray Powder Diffraction (XRD), X-ray fluorescence (XRF) and Mossbauer spectroscopy investigation of two SSAs produced at two fluidized bed incineration facilities, located in different municipalities and operated differently. The structural and chemical characterization was carried out on the 'as received' SSA samples as well as on the residues of these two SSAs pretreated by leaching in citric acid. In addition, direct proof is presented that the tridymite form of AlPO4 does crystallize from X-ray amorphous precursors under conditions that mimic the huge heating rate and short retention time (just seconds at T ≈ 850 °C) typical for fluidized bed incinerators.
Slags from the production of high-alloyed steel contain both chemically bound chromium (mainly as Cr2O3) in the mineral fraction and elemental chromium in the metallic remainders. Thermochemical post treatment of the slag in an electric arc furnace under reducing conditions enables the nearly complete recovery of the total amount of chromium in form of a metallic alloy. The best results were achieved by resistance melting (submerged electrodes) with addition of a reducing agent into the melt. The efficiencies of the reducing agents carbon, aluminium, silicon (as ferrosilicon) and silicon carbide were investigated and compared. As aluminium is the strongest reducing agent, it is less selective and reduces much more SiO2 than Cr2O3. While SiC shows only low reactivity because of its high thermal resistance, carbon and silicon had the highest reducing potentials: More than 97% of the chemically bound chromium can be recovered by application of these reducing agents. Due to the high temperature required for the reduction of the chromium compounds, the reduction of SiO2 as an undesired side reaction cannot be avoided. However, compared with mechanical procedures that are limited to the recovery of the metallic remainders, the total chromium recovery can be significantly increased by the described reductive melting procedure.