Synergistic application of alum sludge and sequential extraction for phosphorus recovery from sewage sludge char.

[Display omitted] • P recovery from SS char in amended process was 48 % higher than control process. • SS amendment led to AP to NAIP conversion which enhanced P recovery from char. • Higher P recovery from chars prepared at 400 °C than at 600 °C and 900 °C. • Excess Al inhibited the formation of less soluble P species in amended process. • Immobilization of P in the carbon matrix of char prepared at ≥ 600 °C. Phosphorus (P) recovery from sewage sludge (SS) (or its ash/char) is challenging due to the presence of heavy metals (HMs) in SS. This study proposed the integration of SS, alum sludge (AS), sequential wet extraction, and pyrolysis for P recovery without simultaneous HM extraction. SS + AS mixture (P:Al molar ratio = 3:1) was first acid pretreated to obtain amended SS, then pyrolyzed, and finally, P was extracted from the char using an alkali. Pyrolysis was conducted at low (400 °C), medium (600 °C), and high (900 °C) temperatures. The highest alkaline P recovery efficiency was 88 % from the amended SS char, while 32 % from the unamended SS char (both prepared at 400 °C). Overall, the highest P recovery in the amended process was 48 % higher than the unamended process despite 11 % P loss during acidic pretreatment. Standards measurements and testing (SMT) protocol and solid-state NMR (31P and 27Al) analyses revealed that acidic pretreatment of SS with AS induced apatite phosphate (AP) to non-apatite inorganic phosphate (NAIP) conversion in SS. As NAIP is more soluble in alkali than AP and HMs, higher alkaline P recovery was achieved for amended SS char than unamended SS char, without HM contamination. However, higher pyrolytic temperatures impaired P recovery due to the immobilization of P in the char carbon matrix and the formation of recalcitrant P phases. These findings were corroborated by complementary characterization techniques such as XPS, XRD, and FTIR. Some major HMs in SS and AS were concentrated in char, except Zn, which partially volatilized above 600 °C. This study demonstrated the applicability of AS for extracting P from SS, offering a potential pathway for the synergistic management of sludge waste streams. [ABSTRACT FROM AUTHOR]