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Abstract
The activated sludge (AS) process has had a profound impact on improving the
quality of the water environment, but the process has a high energy consumption
associated with the aeration requirement to support suspended microbial growth.
However, the unique physico-chemical and microbiological/ecological properties
of the process and residual sludge offer significant opportunities for resource
recovery that can offset the energy demand, and can also be exploited to produce
valuable industrial chemicals and feedstocks and other value added outputs. The
disintegration of AS by a pre-treatment technique, to increase biogas production
and energy recovery by optimised sludge anaerobic digestion (AD) processes, can
bring the overall wastewater treatment system close to energy self-sufficiency.
Wastewater treatment and nutrient capture in AS has a critical role in conserving
finite P reserves and the embedded energy from industrial N fixation used in fertiliser
manufacture. Expanding this capacity, by maximising: (a) nutrient transfer to the
solid phase, (b) recycling AS biosolids, and (c) the production of concentrated
mineral nutrients, such as struvite and ammonium sulphate, will become increasingly
necessary to create a circular economy for nutrients for sustainable food
production. The resource potential of AS has yet to be fully exploited and this will be
achieved through an integrated approach involving combinations of energy,
nutrient, industrial chemical and possibly other recovery techniques. Diversifying
resource recovery will also increase the security and resilience of sludge
management routes.
Keywords
Activated sludge, Energy, Industrial chemicals, Nutrients, Resource recovery.
Introduction
The activated sludge (AS) process forms an integral part of conventional urban
wastewater treatment systems. These technologies are designed to meet four main
water pollution control objectives relating to:
Within this framework, the systems employed for wastewater treatment have been
demonstrably successful at improving and protecting the water environment and
thereby benefitting human health and well-being. However, the overall cost and
particularly the energy inputs required to meet ever more stringent wastewater
treatment standards are receiving increasing scrutiny (Georges et al., 2009). The
Water Industry consumes up to 3% of the total energy used (Howe, 2009), is the
fourth most energy intensive sector (POST, 2007) and contributes approximately 1%
of national greenhouse gas (GHG) emissions in the UK (Water UK, 2009); specifically,
wastewater treatment contributes almost 60% of overall GHGs emitted by the
industry (Ainger et al., 2009). Indeed, whilst overall UK GHG emissions have declined,
GHG emissions by the Water Industry have increased by up to 30% over the past 10
years (McAdam et al., 2011). To fulfil its renewable energy and climate change
obligations, the UK Government has committed to achieving 15% of UK total energy
from renewable sources by 2020; in playing its part in contributing to these
objectives, the Water Industry has an aspirational target of 20% renewable energy
generation (Howe, 2009).
The earliest reviews of novel approaches to resource recovery from sewage sludge
were published in the late 1980s (Frost and Campbell, 1986; Webber et al., 1986) and
by Webber (1991). Since then, a proliferation of research and published material in
the area has occurred highlighting the importance of sludge in general, and AS in
particular, as a valuable resource. Indeed, the evidence demonstrates that AS is
currently under-utilised as a resource. Recent reviews by Tyagi and Lo (2013) and Mo
and Zhang (2013) provide particularly useful summaries of some of the recent
developments.
Recycling sludge by land application (for agricultural use or other purposes, such as
restoration), or disposal of sludge in landfill are the two principal, final destination
routes for sewage sludge management in Europe (Figure 3). Separate statistics are
collected on the incineration of sludge, but this is not a disposal route per se;
incineration is effectively a sludge treatment process that achieves the maximum
solids reduction by thermal conversion and the residual ash is disposed of in landfill.
Energy production from sludge incineration processes is consumed for water
evaporation and to meet the parasitic load of the process, therefore, incineration
does not usually contribute to improved energy management (Mininni et al., 1997;
Thierbach and Hanssen, 2002; Kroiss, 2004). In general, the disposal of whole sludge
in landfill is limited and is regarded as unsustainable in the long-term and inconsistent
with EU landfill policy to reduce disposal of biodegradable municipal waste by this
route. Nevertheless, it represents a significant disposal route in some cases. There is
also uncertainty about the final destinations for sludge in some European countries
as suggested by the large others category in some reports (Figure 3). The
assessment of sludge management routes demonstrates that the available options
are limited and potentially vulnerable to future barriers or restrictions. Therefore,
diversification would increase the resilience of sludge management and this can be
achieved by also maximising the resource recovery opportunities from sludge.
12000
Sludge production t/year DS
10000
8000
x1000
6000
4000
2000
0
1980 1985 1990 1995 2000 2005 2010 2015
Year
All EU EU15
Figure 1: Sewage sludge production in the European Union (post 2002 data
extracted and adapted from Eurostat, 2013)
Under typical conditions, AS, which is the biological sludge generated from the
metabolic transformation of biodegradable substrates in wastewater, comprises 50%
of overall sludge production at a WWTP. Activated sludge contains a range of
valuable resources, including a high total organic carbon content, which is a
potential energy source or can be used as a bulky soil improver; the major plant
nutrients: N, P and S; cellulosic fibres; polyhydroxyalkanoate (PHA) polymers, which
are fully biodegradable, renewable polyesters (poly-3-hydroxybutyrate (PHB) is the
most common type); as well as hydrolase enzymes that are produced by
microorganisms to hydrolyse and metabolise the high lipid and protein content in
wastewater. A summary of the chemical composition of AS is presented in (Table 1).
Sewage sludge also contains inorganic and organic contaminants and the source
control of these from industrial and domestic sources is critical to sludge quality for
the major current recycling routes; this is particularly the case for agriculture
application. However, the concentrations of potentially toxic elements (PTEs) and of
a majority of persistent organic pollutants (POPs) and other organic contaminants
(OCs) have decreased with time due to effective source control legislation and
action by the Water Industry (ICON 2001; Smith, 2009). In a time trend analysis,
Olofsson et al. (2012) observed statistically significant changes in the concentrations
of 18 compounds out of 77 examined, and 75% of these were declining. Against this
background, and the implementation of microbiological controls on sludge (ADAS,
2001), comprehensive and quantitative risk assessments of contaminants and
infectious microbes (Gale, 2005; Schowanek et al., 2007; Eriksen et al., 2009),
demonstrate the risks associated with land application of treated sludge are minimal
and provide the technical case and justification supporting the reuse of sludge in
agriculture and for other soil improvement purposes. In future, however, it may be
possible to recover refined nutrient products for agricultural use also with reduced
contaminant concentrations, and at the same time generate renewable energy
and other valuable industrial products by applying a series of recovery stages to the
sludge generated by wastewater treatment.
The Web-of-Science database holds 60,700 records relating to activated sludge for
the period 1950-2014. The level of research activity focussed on resource recovery
from AS has increased markedly in the past 10 years (Figure 4). This remarkable trend
underlines the significance and importance of AS as a resource and the innovative
ways that the process and material can be used, adapted and applied to recover
valuable products and components and to perform critical, environmentally
beneficial functions. Internationally, the main research output is originating from
China (27%) and USA (14%). The UK Water Industry may not be taking full advantage
of the potential benefits that these opportunities offer reflected in the relatively small
volume of UK research output in this area.
(a) Number of publications by year
Energy
Shi (2011) presents a comprehensive assessment of the mass flow and energy
efficiency of municipal WWTP, considering the various options for increasing the
overall energy efficiency of the process, and particularly to offset the aeration
demand of AS. For example, the application of conventional mesophilic AD
combined heat and power (CHP) systems (25 - 30% electricity conversion efficiency)
can increase energy efficiency up to 30%. Energy efficiency can be raised further by
up to 50% by a combination of the following options: (a) improving primary
sedimentation, (b) sludge pre-treatment, or (c) thermophilic digestion. Increasing
the efficiency of primary treatment leads to greater primary solids transfer to, and
biogas production from, conventional AD systems, and also reduces the aeration
demand and biomass production in secondary treatment. However, applying
sludge pre-treatments and improving AD performance to increase VS destruction to
60% in combination with other measures can raise the energy efficiency to 80%.
Research and operational experience demonstrate that, with the integrated
application of appropriate technologies and processes, energy efficiencies
equivalent to 80 - 100% are possible and that a positive energy balance is feasible in
practice.
For recent reviews concerning the recovery of energy from sewage sludge and a
comparison of options, see Rulkens and Bien (2004) and Rulkens (2008).
Anaerobic digestion
Approximately 70% of sewage sludge is treated by AD in the UK (EA, 2014) and in the
US about 50% of sludge production receives AD treatment (NEBRA, 2007). The
scientific literature on the potential contribution of AD to global bioenergy
production and on the application of AD for waste activated sludge (WAS)
treatment specifically was reviewed recently by Appels et al. (2008, 2011).
Producing energy from organic waste materials is regarded as one of the major
future sources of renewable energy and AD processes in particular are expected to
play a critical role in the renewable energy market.
Sewage sludge is one of the most effective substrates for AD and CH4 production
(Figure 5). Conventional mesophilic AD typically achieves ~40% VS destruction and
gas production is equivalent to 0.8-1.1 m3/kg VS destroyed (Tchobanoglous et al.,
2003). However, until recently, little attention was paid to AD process operation to
optimise VS destruction and biogas production, but this is now a priority area for
research and operational action to manage energy consumption and increase
renewable energy generation by the Water Industry. For example, recent studies
have examined the effect of digestion temperature and solids loading rate on VS
destruction and gas production rates by conventional mesophilic AD (Winter et al.,
2012, 2013).
Figure 5: Overview of the average methane yields obtained through anaerobic
digestion of different waste types (Appels et al., 2011)
However, the relatively slow anaerobic digestibility of WAS can be overcome by by-
passing the hydrolysis stage by applying a pre-treatment technique to disrupt the
biomass causing cell lysis and the release of readily degradable organic substrates
for the acidogenic population. Carrre et al. (2010) have reviewed the available
pre-treatment technologies to improve sludge anaerobic degradability. These
include: biological (eg two-stage thermophilic-mesophilic AD is the most common
type), thermal hydrolysis, mechanical (eg ultrasonic, lysis-centrifuge or liquid shear)
and chemical treatments (eg oxidation with ozone, or alkali treatment). Biological,
thermal hydrolysis and mechanical methods are the most widely applied
techniques.
Thermal hydrolysis of sludge is becoming well established for sludge AD pre-
treatment. For example, there are 23 Cambi thermal hydrolysis reference
installations at WWTP internationally and it is particularly pertinent to mention this in
the context of resource recovery from AS because the largest plant is soon to be
commissioned at the Davyhulme Sewage Treatment Works in Manchester
(http://www.cambi.no/wip4/plant.epl?cat=10643&id=463527) where the AS process
was originally developed. The main advantages of the process include: (a) an
increase in biogas production and VS destruction of approximately 60%, (b)
increase in dry solids to 30% after dewatering, and (c) increased solids loading to 5
6 kg VS/m3/day (Carrre et al., 2010). Although thermal hydrolysis increases overall
AD performance and biogas yield, the thermal energy consumption is significant,
therefore, the overall energy balance is neutral. Thermal hydrolysis is also more
capital intensive compared to mechanical options.
Other biofuels
Other strategies to recover liquid or other gaseous fuel resources from sludge
include production of bio-oil or syngas by pyrolysis or gasification processes (Manara
and Zabaniotou, 2012), or biodiesel (Siddiquee and Rohani, 2011). Energy can be
recovered from sludge by advanced oxidation processes, for example, supercritical
wet oxidation (>375 oC and 22.1 MPa) (Rulkens, 2008). The direct production of
electricity from sewage sludge and specifically from WAS using microbial fuel cells is
also technically feasible (Dentel et al., 2004; Linji et al., 2013). However, based on the
current evidence and status, these techniques struggle to compete with well
established AD technologies for the treatment and recovery of energy and other
resources (eg nutrients) from WAS in terms of operational experience, practicability,
cost and energy efficiency (Rulkens, 2008; Tyagi and Lo, 2013).
Nutrients
Given the resource implications associated with the industrial production and
manufacture of conventional fertilisers, rather than using more energy to simply
remove and discard the nutrients contained in wastewater, a more sustainable
strategy would be to focus on the recovery and recycling of these valuable nutrients
as agricultural fertilisers. This approach would conserve both the embedded energy
within the nutrient life-cycle overall and geogenic resources, by assisting the closure
of the nutrient loop (Green Alliance, 2007; McCarty et al., 2011). In future, therefore,
a shift away from current N elimination strategies in wastewater treatment (eg Ahn,
2006; Paredes et al., 2007) may be anticipated with greater emphasis being placed
on the recovery of N as a resource. There are also significant financial advantages
to be gained from this strategy considering the high and increasing cost of fertiliser
materials. Indeed, the approximate value per annum of UK sludge in terms of its total
N and P contents is equivalent to 110 million (assuming UK sludge production is 1.4
Mt/year DS and contains 4.4% and 3.1% of total N and P, respectively (Defra, 2010)).
Nutrient recovery processes from sludge that employ thermal treatments and acidic
or alkaline conditions and/or precipitation reactions (for example: degaard et al.,
2002; Rulkens, 2004; Dichtl et al., 2007), may require high energy and/or chemical
inputs and are not currently considered as cost-effective options (Verstraete et al.,
2009). Nevertheless, further research in this area is necessary and should also focus
on increasing the efficiency of solid-phase N recovery by wastewater treatment.
Fertiliser value
(a) Nitrogen
(b) Phosphorus
Treated sewage sludge typically has a phosphate fertiliser value of 50% (Defra,
2010). However, modifying the AS process for EBPR increases the P content and
raises the availability of P in the residual mixed treated sludge to a level that is at
least as effective as triple superphosphate fertiliser (Smith et al., 2003; Oladeji et al.,
2008; Miller and OConnor, 2009). Indeed, field trials specifically investigating the P
fertiliser value of AS show that the sludge from conventional biological aerobic
wastewater treatment has a large available P content equivalent to 80% relative to
superphosphate fertiliser (ORiordan et al., 1987b).
Nutrient recovery
In principle, sewage sludge ash (SSA) could be applied directly to land as a fertiliser
if it meets the contaminant limits for agricultural fertilisers. For instance, Petzet and
Cornel (2011) suggest that 30% of SSA in Germany could be potentially used directly
for fertiliser manufacture without further processing to reduce contaminant
concentrations. Acid extraction of SSA is generally considered as the most practical
option for P recovery from SSA (for example, see Hong et al., 2005); this approach
allows complete dissolution of P and heavy metal impurities are removed by
precipitation by increasing the pH value, although other more advanced
technologies including: nanofiltration, liquid-liquid extraction, or ion exchange have
also been examined. However, these procedures are either at the developmental
stage or the energy and chemical requirements have prevented their application at
full-scale. Other alternative technologies have been developed for thermal
recovery of P from SSA, but require high temperature treatments in the range 1000
2000oC and therefore also have a significant energy requirement. Consequently,
there are currently few examples where P recovery from SSA is practiced at full-
scale (Stark, 2004; Ptezet and Cornell, 2011). Therefore, until the recovery of P from
SSA becomes economically feasible, the disposal of SSA in mono-landfill is proposed
as a intermediate measure to conserve this important P resource and there are
plans to implement this in Germany (Kroiss, 2004; Petzet and Cornel, 2011).
Kuroda et al. (2002) and Takiguchi et al. (2004) describe a simple method for P
recovery from WAS produced from EBPR processes by heating the sludge to 70oC for
approximately 1 hour and P precipitation with CaCl2, without pH adjustment. The
technique recovered approximately 75% of the total P in the sludge as a high P
content (16%) calcium phosphate mineral. Further advantages included reduced P
release and increased digestion efficiency and methane production during sludge
AD. The treatment conditions are similar to those operating in existing sludge pre-
pasteurisation systems, therefore, there could be potential advantages gained from
integrating a P recovery stage into thermal disinfection processes. However, this
may be less attractive due to the energy input required to heat unthickened liquid
AS compared to struvite crystallisation post AD treatment, which also improves the
overall process N balance.
Anaerobic digestion processes are sensitive to ammonia toxicity and the upper
critical concentration reported for sludge AD at which inhibitory effects may be
detected is approximately 3000 mg/l of total ammonia N (TAN) and 400 mg/l as free
ammonia N (FAN) (Yenign and Demirel, 2013), although, process inhibition has
been observed at TAN concentrations as low as 760 mg/l of TAN (Walker et al.,
2011). Ammonia toxicity is a significant problem for AD of source separated food
waste due to the high N content and biodegradability of the waste (Walker et al.,
2011). However, the expanding application of high intensity pre-treatments, eg
thermal hydrolysis, for biomass disruption to primarily increase digestibility and biogas
yield from AD of WAS could also place sludge AD at potential risk from ammonia
toxicity (Carrre et al., 2010). If the codigestion of sludge with foodwaste were
realised in the future, this would also increase ammonia concentrations in sludge
digesters. Recovery processes require high concentrations of ammonia to be
effective (up to several thousand mg/l) (Shi, 2011) and are therefore suitable for the
treatment of digestates or concentrated dewatering liquors. Ammonia stripping for
N recovery is already employed at full-scale to sludge dewatering liquors following
AD (Dichtl et al., 2007); steam stripping, distillation and reversible chemosorption
have also been proposed, although these require high energy comsumption (Shi,
2011). Removal by sidestream treatment using a biogas stripping technique is also
suggested as a feasible method to control ammonia concentrations in food waste
AD processes (Walker et al., 2011; Serna-Maza et al., 2014) and may also be
potentially applicable to sludge AD for ammonia control and N recovery.
Biofertilisers
Amino acid chelated trace elements (AACTE) is an effective fertiliser product that is
currently manufactured and marketed in China, but production is limited by the
availability of protein sources. Liu et al. (2009) describe a novel technique for the
preparation of AACTE from aerobic biological wastewater treatment sludge. The
technology involved several stages of extensive chemical processing of the sludge,
including protein extraction and hydrolysis to produce amino acids, amino acid
purification and chelation with trace elements, and drying. However, an economic
assessment showed that the treatment costs were favourable compared to the
market value of the fertiliser product. The residual sludge generated by the process
(representing approximately 50% of the input DS) was transformed by sintering with
coal fly ash and iron tailings to produce a bioceramic material, which was effective
at ammonium and phosphate sorption from wastewater, and was also
economically viable.
Specialist Chemicals
Biopolymers
Settled
Raw WW sewage Effluent
Primary Activated Secondary
sedimentation sludge process sedimentation
Waste
*Pretreatment activated
sludge
Second stage
PHA-
enriched
biomass
Biogas Biosolids
Figure 10: Proposed integrated wastewater treatment scheme for production of PHAs
from activated sludge (adapted from Chua et al., 2003 and Coats et al., 2007); *If
activated sludge is optionally used to supply VFAs, the efficiency of fermentation is
increased by applying a pre-treatment process
Using AS as the mixed microbial culture and substrate source for PHA production has
many advantages, however, further optimisation is necessary to increase process
efficacy, organic loading rate, and biomass PHA enrichment, as well as to reduce
the energy consumption involved in downstream processing (Gurieff and Lant, 2007;
Serafim et al., 2008; Tyagi and Lo et al., 2013). Further work is also necessary on the
associated residuals management and nutrient resource recovery after PHA
extraction, and to develop simple polymer recovery processes and applications for
PHA where purity of the polymer is less critical (Serafim et al., 2008). Nevertheless,
predictions are optimistic about the potential of PHA production from AS (Chua et
al., 2003; Coats et al., 2007; Gurieff and Lant, 2007) and it is plausible that this
technology will become part of a more integrated strategy to maximise the
resource efficiency potential of AS.
Biopesticides
The value of the biopesticide market in Europe in 2011 was 325 M and microbial
biopesticides represented almost 14% of total sales (AGROW, 2013). The demand for
biopesticides has increased significantly since 2000 with an annual growth rate
equivalent to approximately 17% due to better scientific support and user
confidence, and pressure to adopt more sustainable agricultural practices. Overall,
biopesticides account for approximately 5% of the European agrochemical market
(AGROW, 2013). The UK retail price of commercial insecticides formulated with
Bacillus thuringiensis is approximately 75/kg.
Activated sludge contains a source of organic carbon and other essential nutrients
suitable for supporting microbial growth as a substrate and culture media for various
biological processes. An example of this is the culturing and growth of B. thuringiensis
(Bt), a naturally occurring and effective biopesticide agent that produces various
crystal proteins that have highly specific insecticidal activity (Andrews et al., 1987;
Shieh, 1988; Bravo et., 2011). The use of AS as a production system for B. thuringiensis
and the effects of process conditions on the stability and entomotoxicity have been
investigated by several authors (for example, Sachdeva et al., 2000; Vidyarthi et al.,
2002; Brar et al., 2004).
Bacillus thuringiensis is cultured in sterile liquid sludge (in some cases hydrolysed) to
produce a stable aqueous suspension with similar or better insecticidal properties
compared to standard commercial formulations (Sachdeva et al., 2000; Brar et al.,
2004). Furthermore, Sachdeva et al. (2000) estimated the costs of using sludge to
produce B thuringiensis were approximately 40% smaller compared to a standard
synthetic medium. Pre-treatment is simpler compared to using other organic
substrates and sludge provides a complete nutrient source without further
supplementation. The overall best performance and product efficacy was
obtained at a sludge solids concentration of 2.5% (Vidyarthi et al., 2002).
Using sludge directly as a feed for animals, poultry and fish has been proposed, but
the small content of digestible nutrients and metabolisable energy render the
material unsuitable as a constituent of high energy diets, and sludge may also
interfere with animal health and nutrition, and food quality for human consumption
(Webber, 1991). An alternative approach is to recover components of nutritional
value from sludge. For example, AS can contain more than 60% (DS) of microbial
proteins (Table 1) and reported recovery efficiencies for extracting intracellular
proteins from WAS are in the range 80 - 90% (Chishti et al., 1992; Hwang et al., 2008).
However, use in animal feeds is unlikely to be an acceptable or viable approach to
AS resource utilisation due to concerns about dietary impacts and also because
economical nutrient supplements are available that avoid potential dietary
contamination issues (Tyagi and Lo, 2013).
However, extracting enzymes from AS for use as industrial chemicals has significantly
more potential and also because they can be used to increase hydrolysis rates and
biogas production in AD processes (Nabarlatz et al., 2008). The global market for
industrial enzymes was estimated at 2 billion in 2010 and is expected to increase to
2.6 billion by 2015 (BCC Research, 2011). Protease and lipase represent two of the
main intracellular enzymes detected in AS and have been successfully extracted by
a combination of non-ionic detergent and/or cation exchange resin treatments and
agitation (Gessesse et al., 2003; Nabarlatz et al., 2008) and these enzymes are
amongst the most widely used by industry (Haki and Rakshit, 2003). Indeed,
proteases constitute more than 65% of the global industrial enzyme market and are
extensively used in the food, pharmaceutical, leather, textile and detergent
industries. Lipases are the most versatile enzymes and are applied in a range of
bioconversion reactions and they are extensively used in the dairy, oleochemical
(eg biodiesel), detergent, pulp, pharmaceutical, cosmetic and leather industries
(Hou, 2002). Culture media represent up to 40% of the production costs of industrial
enzymes, therefore, using AS for this purpose could represent a significant potential
beneficial saving (Tyagi and Lo, 2013).
Heavy metals
The extraction of heavy metals directly from sludge or incinerator ash has been
recognised as a technically feasible recovery option since the early 1980s (Webber,
1991) and was reviewed most recently by Tyagi and Lo (2013). For example,
recoveries of individual elements of >97% by ultrasonication assisted acid leaching
have been achieved at both laboratory and pilot scale with high metal industrial
sludges. Tyagi and Lo (2013) describe a commercial plant in China which has
applied this technology to recover metals from sludge produced by printed circuit
board factories. Industrial sludges from electronics and metal based industries
potentially contain large metal concentrations and consequently represent a
potential environmental hazard. Therefore, metal extraction has both a financial
and environmental benefit by recovering a valuable resource and also reducing the
potential hazardous nature of the sludge for disposal. Neither of these conditions
usually apply to AS from municipal WWTP, however, since the metal content is below
critical environmental thresholds; therefore recovery is less economical compared to
high-metal contaminated industrial sludges and the material can be recycled
directly for beneficial uses following appropriate controls and procedures. Metal
concentrations increase in the residual ash following sludge incineration,
nevertheless, although a technically feasible option, no examples of the recovery of
metals from sludge or incinerator ash could be found.
Nanochemicals
The feedstock material for nanochemical production represents a major cost in the
manufacturing process and large volumes of inexpensive precursors are required
(Yuvakkumara et al., 2014). Recent research has therefore focussed on the recovery
of high-value, specialised nano-chemicals, for example, high purity nano-SiO2, from
waste organic and mineral residues (Kim et al., 2010; Yuvakkumara et al., 2014). Zou
et al. (2012; 2013) recently demonstrated the potential synthesis of high purity nano-
SiO2 and nano-Al(OH)3 from carbonised AS by a chemical extraction procedure. The
efficiency of the recovery process depends on the total concentrations of the main
elements present in the sludge but, unfortunately, no data were provided on the
sludge chemical properties. By way of reference, Eriksson (2001) reported the mean
total concentrations of Si and Al in Swedish sewage sludges were 4.5 and 4.0% (DS),
respectively. Treatment and/or disposal of process effluents are not reconciled by
Zou et al. (2012; 2013) or Yuvakkumara et al. (2014) and the nano-chemical
recovery procedures from organic residues require significant energy inputs for high
temperature treatments. Nevertheless, they are considered to be more economical
and resource efficient compared to conventional production routes.
Fibre products
Novel Microorganisms
The unique microbiological characteristics of AS sludge are a major reason for the
effectiveness of the process in wastewater treatment. The microbial biodiversity of
AS and in anaerobic sludge treatment is highly dynamic and provides a significant
resource capable of performing important biotransformation and bioaccumulation
activities, including P and PHA accumulation, for instance, and fermentation and
methanogenic reactions. Many studies demonstrate this diversity and the adaption
of AS bacteria to biodegradation of anthropogenic organic chemicals, for
example, pyrethroid pesticides; herbicides; industrial solvents, chemicals and
precursors, and endocrine disruptors (Chong and Chen, 2007; Porter and Hay, 2007;
Guo et al., 2009; Jeong et al., 2008; Wang et al., 2009).
Activated sludge bacteria are also a source of virus-binding proteins (VBPs) which
can be applied in new technologies for the potential control of environmental
sources of infectious viral diseases (Sano et al., 2004). The predatory activity of
bacteriophagous protozoa in the AS process is also an important mechanism for
eliminating pathogenic bacteria (Figure 11), as shown in the classical experiments of
Curds and Fey (1969). Although not a complete barrier to transmission, these
biological properties and mechanisms, coupled with secondary sludge
sedimentation, which also physically removes larger (oo)cysts and eggs of parasitic
protozoa and helminths (Feachem et al., 1983), explain why AS has reduced the risk
to human health from infectious microorganisms potentially present in urban
wastewater.
Construction Materials
Using sewage sludge directly or the ash from sludge incineration as a substitute for
standard minerals in construction materials has been a long-established alternative
approach to the main sludge management routes (Webber, 1991). Whilst extensive
research has been completed to develop and improve production technologies
(Donatello and Cheeseman, 2013), their industrial uptake remains extremely limited.
This is because most of the technologies are uneconomic compared to readily
available standard aggregate and other feedstock minerals (Tyagi and Lo, 2013).
Sludge incineration ash is used to manufacture bricks at modest industrial scale in
Japan (Tyagi and Lo, 2013) and there was some commercial interest shown in the
UK (Anderson et al., 1996). A novel construction product developed by Forth et al.
(2006) is the Bitublock, which is produced by combining a blend of different waste
materials, including sewage sludge incineration ash, recycled glass and steel slag
with a bitumen binder. However, due to the porosity of the ash, the proportion of
bitumen binder required increased from 5% without ash inclusion to 16% at an
incorporation rate equivalent to 37.5%; this may therefore constrain the maximum
amount of ash that may be potentially used. Nevertheless, Forth et al. (2006)
projected that, assuming a filler blending rate of 10%, all of the ash produced from
sludge incineration could be utilised in block manufacture to meet the demand for
house construction in the UK.
The use of AS specifically and sewage sludge in general, as adsorbents for municipal
and industrial wastewater filtration is another alternative application avenue that
has been extensively research (for a comprehensive review, see Smith et al., 2009).
Activated sludge has a high propensity for metal adsorption and this characteristic
has advantages for the treatment of industrial, metal laden wastewaters (Dobson
and Burgess, 2007; Hammaini et al., 2007). This characteristic is associated mainly
with the capacity of AS for biosorption of metals, which is a physico-chemical
process based on ion exchange, complexation and surface microprecipitation
reactions involving a large variety of binding sites of extracellular polymeric
substances (EPS) and bacterial cell surfaces (Pagnanelli et al., 2009). Biosorption
mechanisms are very effective at removing heavy metals from wastewater and can
achieve removal efficiencies of 75100% (Dobson and Burgess, 2007). Metal
precipitation reactions with AS are also potentially important and control the
solubility of other elements, such as Pb (Pagnanelli et al., 2009).
Dried waste treatment sludges and AS, and sludge carbonised and chemically
activated by acid treatment have been examined in various water filtration
applications as low-cost adsorbents for metals, organic and other industrial
chemical contaminants (Gupta and Suhas, 2009; Smith et al., 2009; Bhatnagar and
Sillanp, 2010). Activated carbons represent the most sophisticated filtration
materials produced from sludge involving high temperature (500 1000 oC) pyrolytic
carbonisation and chemical activation steps (Smith et al., 2009). The energy
demand for the process can also be met through the combustion of generated
syngas. Reducing the inorganic content of carbonised char by acid washing with
HCl significantly improves performance and also enables the potential recovery of
other valuable resources including phosphate minerals. Chemical activation utilising
alkali metal hydroxides (KOH) is considered the most effective method for producing
high surface area adsorbents from sludge (Smith et al., 2009). This technology
represents another example of the opportunities available for exploiting wastewater
treatment sludge as a resource, and where scale-up to industrial application has yet
to occur.
The energy balance of the AS process can be improved in the short term through
better process operation, in the medium term by expanding the current interest
in recovering energy from the residual sludge and in the longer-term by the
recovery of other valuable industrial chemicals from AS.
Energy recovery from AS by AD will increase and maximum biogas yields will be
achieved through the improved understanding and management of the
digestion process and by applying biomass disruption techniques. A life cycle
assessment is necessary to determine the most efficient techniques that maximise
the energy yield with the least resource expenditure. A combination of efficiency
improvements in the AS process with measures to maximise energy recovery by
sludge AD can bring the overall wastewater treatment process close to energy
self-sufficiency.
Recycling sludge in agriculture and for other land application purposes is already
a well established practice for the beneficial recovery of major plant nutrients (N,
P and S) and using sludge as an agricultural fertiliser is widely regarded as the
best practicable environmental option for sludge management. The AS process
is potentially very efficient at capturing P and maximising P recovery by this route
is necessary to assist in establishing a circular economy for this critical and finite
nutrient resource to ensure long-term food security. The displacement of high-
energy mineral fertilisers by nutrients supplied in sludge also provides a positive
contribution to the energy and GHG balance of wastewater and sludge
treatment.
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