Search

Wastewater sludge drying and incineration are conventional solids handling processes that are sometimes employed in water resource reclamation facilities. However, these two processes generate byproducts, sludge drying chaff and sludge incinerator ash, which are landfilled without taking advantage of their value. To gain value from these byproducts, a new synergistic catalytic pyrolysis process using chaff and ash was investigated in this study to improve energy production (i.e. generating a high yield pyrolysis gas) and generate useful products. Ash was used as a catalyst to decrease bio-oil that is corrosive and challenging for combustion in standard equipment, while increasing pyrolysis gas yield and energy for easier energy recovery. Ash increased the pyrolysis gas yield by 50% and product energy by nearly two-fold at the highest ash loading. The bio-oil volume was greatly reduced and contained fewer constituents based on GC-MS and GC-FID analyses. The product energy shifted from bio-oil to pyrolysis gas, which is relatively clean and easier for onsite energy recovery. Ca and Fe content in ash likely plays the catalytic role.

Wastewater resource recovery facilities produce wastewater solids that offer potential for energy recovery. This opinion article provides a perspective on state-of-the-art technologies to recover energy from sludge (unstabilized wastewater residual solids) and biosolids (stabilized wastewater solids meeting criteria for application on land). The production of biodiesel fuel is an emerging technology for energy recovery from sludge, whereas advancements in pretreatment technologies have improved energy recovery from anaerobic digestion of sludge. Incineration is an established technology to recover energy from sludge or biosolids. Gasification, and to a greater extent, pyrolysis are emerging technologies well-suited for energy recovery from biosolids. While gasification produces high-energy gases, pyrolysis has the benefit of producing biochar in addition to pyrolysis gas. Research on the use of pyrolysis liquids, however, must proceed to advance pyrolysis implementation efforts. Future research on improvements to dewatering and drying of sewage sludge and biosolids will help advance all technologies reviewed.

Pyrolysis is a thermochemical decomposition process that can be used to generate pyrolysis gas (py-gas), bio-oil, and biochar as well as energy from biomass. Biomass from agricultural waste and other plant-based materials has been the predominant pyrolysis research focus. Water resource recovery facilities also produce biomass, referred to as wastewater solids, that could be a viable pyrolysis feedstock. Water resource recovery facilities are central collection and production sites for wastewater solids. While the utilization of biochar from a variety of biomass types has been extensively studied, the utilization of wastewater biochars has not been reviewed in detail. This review compares the characteristics of wastewater biochars to more conventional biochars and reviews specific applications of wastewater biochar. Wastewater biochar is a potential candidate to sorb nutrients or organic contaminants from contaminated wastewater streams. While biochar has been used as a beneficial soil amendment for agricultural applications, specific research on wastewater biochar is lacking and represents a critical knowledge gap. Based on the studies reviewed, if biochar is applied to land it will contain less organic micropollutant mass than conventional wastewater solids, and polycyclic aromatic hydrocarbons are not likely to be a concern if pyrolysis is conducted above 700 °C. Wastewater biochar is likely to serve as a better catalyst to convert bio-oil to py-gas than other conventional biochars because of the inherently higher metal (e.g., Ca and Fe) content. The use of wastewater biochar alone as a fuel is also discussed. Finally, an integrated wastewater treatment process that produces and uses wastewater biochar for a variety of food, energy, and water (FEW) applications is proposed.

Bio-oil and pyrolysis gas (py-gas) are two pyrolysis products available for potential energy recovery. Crude bio-oil, however, is typically corrosive and unstable, requiring special combustion equipment or catalytic upgrading to produce drop-in-grade fuel. In contrast, py-gas is readily useable in standard equipment for energy recovery. Previous research revealed that Ca-impregnated biochar catalyst improved bio-oil to py-gas conversion. Biochar produced from paper mill sludge (p-sludge) has very high Ca content. In this study, the catalytic ability of p-sludge biochar was systematically evaluated for the first time in pyrolysis. P-sludge biochar resulted in higher py-gas yield (40 wt% of total pyrolysis products) and py-gas energy (8400 kJ of py-gas per biosolids pyrolyzed) than other biochar catalysts (e.g. wood and corn stover biochars) and mineral catalysts (e.g. calcined dolomite). Under some conditions (e.g. high temperature and catalyst loading), catalysis completely eliminated the nonaqueous phase condensate. A lower catalyst-to-feedstock ratio was required using p-sludge biochar compared to other biochars for similar performance. P-sludge biochar also had a longer catalyst lifetime based on the effectiveness over five reuse cycles. Bio-oil catalyzed by p-sludge biochar contained fewer organic constituents based on GC-MS and GC-FID analyses (e.g. toluene, ethylbenzene, styrene, phenol, cresol, and indole were not identified after catalysis).

Improving onsite energy generation and recovering value-added products are common goals for sustainable used water reclamation. A new process called autocatalytic pyrolysis was developed at bench scale in our previous work by using biochar produced from the biosolids pyrolysis process itself as the catalyst to enhance energy recovery from wastewater biosolids. The large-scale investigation of this process was used to increase the technical readiness level. A sub-pilot-scale catalytic pyrolytic system was constructed for this scaled-up study. The effects of configuration changes in both pyrolytic and catalytic reactors were investigated as well as the effect of vapor-catalyst contact types (i.e., downstream, in-situ) on product yield and quality. The sub-pilot-scale test with downstream catalysis resulted in higher py-gas yields and lower bio-oil yields when compared to results from a previous batch, bench-scale process. In particular, the py-gas yields increased 2.5-fold and the energy contained in the py-gas approximately quadrupled compared to the control test without autocatalysis. Biochar addition to the feed biosolids before pyrolysis (in-situ catalysis) resulted in increased py-gas production, but the increase was limited. It was expected that using a higher input pyrolyzer with a better mixing condition would further improve the py-gas yield.

The main goals for sustainable water resource recovery include maximizing energy generation, minimizing adverse environmental impacts, and recovering beneficial resources. Wastewater biosolids pyrolysis is a promising technology that could help facilities reach these goals because it produces biochar that is a valuable soil amendment as well as bio-oil and pyrolysis gas (py-gas) that can be used for energy. The raw bio-oil, however, is corrosive; therefore, employing it as fuel is challenging using standard equipment. A novel pyrolysis process using wastewater biosolids-derived biochar (WB-biochar) as a catalyst was investigated to decrease bio-oil and increase py-gas yield for easier energy recovery. WB-biochar catalyst increased the py-gas yield nearly 2-fold, while decreasing bio-oil production. The catalyzed bio-oil also contained fewer constituents based on GC-MS and GC-FID analyses. The energy shifted from bio-oil to py-gas, indicating the potential for easier on-site energy recovery using the relatively clean py-gas. The metals contained in wastewater biosolids played an important role in upgrading pyrolysis products. The Ca and Fe in WB-biochar reduced bio-oil yield and increased py-gas yield. The py-gas energy increase may be especially useful at water resource recovery facilities that already combust anaerobic digester biogas for energy since it may be possible to blend biogas and py-gas for combined use.

Pyrolysis is a thermal process that converts biosolids into biochar (a soil amendment), py-oil and py-gas, which can be energy sources. The objectives of this research were to determine the product yield of dried biosolids during pyrolysis and the energy requirements of pyrolysis. Bench-scale experiments revealed that temperature increases up to 500 °C substantially decreased the fraction of biochar and increased the fraction of py-oil. Py-gas yield increased above 500 °C. The energy required for pyrolysis was approximately 5-fold less than the energy required to dry biosolids (depending on biosolids moisture content), indicating that, if a utility already uses energy to dry biosolids, then pyrolysis does not require a substantial amount of energy. However, if a utility produces wet biosolids, then implementing pyrolysis may be costly because of the energy required to dry the biosolids. The energy content of py-gas and py-oil was always greater than the energy required for pyrolysis.