Shane Donatello

Recycling and recovery routes for incinerated sewage sludge ash (ISSA): A review

The drivers for increasing incineration of sewage sludge and the characteristics of the resulting incinerated sewage sludge ash (ISSA) are reviewed. It is estimated that approximately 1.7 milliontonnes of ISSA are produced annually world-wide and is likely to increase in the future. Although most ISSA is currently landfilled, various options have been investigated that allow recycling and beneficial resource recovery. These include the use of ISSA as a substitute for clay in sintered bricks, tiles and pavers, and as a raw material for the manufacture of lightweight aggregate. ISSA has also been used to form high density glass-ceramics. Significant research has investigated the potential use of ISSA in blended cements for use in mortars and concrete, and as a raw material for the production of Portland cement. However, all these applications represent a loss of the valuable phosphate content in ISSA, which is typically comparable to that of a low grade phosphate ore. ISSA has significant potential to be used as a secondary source of phosphate for the production of fertilisers and phosphoric acid. Resource efficient approaches to recycling will increasingly require phosphate recovery from ISSA, with the remaining residual fraction also considered a useful material, and therefore further research is required in this area.

Production of technical grade phosphoric acid from incinerator sewage sludge ash (ISSA)

The recovery of phosphorus from sewage sludge ash samples obtained from 7 operating sludge incinerators in the UK using a sulfuric acid washing procedure to produce a technical grade phosphoric acid product has been investigated. The influences of reaction time, sulfuric acid concentration, liquid to solid ratio and source of ISSA on P recovery have been examined. The optimised conditions were the minimum stoichiometric acid requirement, a reaction time of 120 min and a liquid to solid ratio of 20. Under these conditions, average recoveries of between 72% and 91% of total phosphorus were obtained. Product filtrate was purified by passing through a cation exchange column, concentrated to 80% H(3)PO(4) and compared with technical grade H(3)PO(4) specifications. The economics of phosphate recovery by this method are briefly discussed.

EU landfill waste acceptance criteria and EU Hazardous Waste Directive compliance testing of incinerated sewage sludge ash

A hazardous waste assessment has been completed on ash samples obtained from seven sewage sludge incinerators operating in the UK, using the methods recommended in the EU Hazardous Waste Directive. Using these methods, the assumed speciation of zinc (Zn) ultimately determines if the samples are hazardous due to ecotoxicity hazard. Leaching test results showed that two of the seven sewage sludge ash samples would require disposal in a hazardous waste landfill because they exceed EU landfill waste acceptance criteria for stabilised non-reactive hazardous waste cells for soluble selenium (Se). Because Zn cannot be proven to exist predominantly as a phosphate or oxide in the ashes, it is recommended they be considered as non-hazardous waste. However leaching test results demonstrate that these ashes cannot be considered as inert waste, and this has significant implications for the management, disposal and re-use of sewage sludge ash.

Hydration of Hybrid Alkaline Cement Containing a Very Large Proportion of Fly Ash: A Descriptive Model

In hybrid alkaline fly ash cements, a new generation of binders, hydration, is characterized by features found in both ordinary portland cement (OPC) hydration and the alkali activation of fly ash (AAFA). Hybrid alkaline fly ash cements typically have a high fly ash (70 wt % to 80 wt %) and low clinker (20 wt % to 30 wt %) content. The clinker component favors curing at ambient temperature. A hydration mechanism is proposed based on the authors’ research on these hybrid binders over the last five years. The mechanisms for OPC hydration and FA alkaline activation are summarized by way of reference. In hybrid systems, fly ash activity is visible at very early ages, when two types of gel are formed: C–S–H from the OPC and N–A–S–H from the fly ash. In their mutual presence, these gels tend to evolve, respectively, into C–A–S–H and (N,C)–A–S–H. The use of activators with different degrees of alkalinity has a direct impact on reaction kinetics but does not modify the main final products, a mixture of C–A–S–H and (N,C)–A–S–H gels. The proportion of each gel in the mix does, however, depend on the alkalinity generated in the medium.

An assessment of Mercury immobilisation in alkali activated fly ash (AAFA) cements.

This paper presents total and soluble Mercury contents for three coal fly ashes and alkali-activated fly ash (AAFA) cements consisting of 100% fly ash as starting material. To evaluate the potential of the AAFA cement matrix to immobilise Hg from an external source, another batch of cements, doped with 5000 mg/kg Hg as highly soluble HgCl(2), was prepared. The ashes and control AAFA cements complied with Mercury leaching criteria for non-hazardous wastes according to both TCLP and EN 12457 tests. Fly ash activated cements doped with 5000 mg/kg Hg and aged for 2 days immobilised 98.8-99.6% and 97.3-98.8% of Hg according to TCLP and EN 12457 tests respectively. Evidence from SEM-EDX suggests that Hg was immobilised by precipitation as highly insoluble HgS or Hg(2)S, although partial precipitation as less insoluble HgO or Hg silicates could not be entirely ruled out based on data presented. The results for Hg-doped cements contribute to the growing body of evidence that shows AAFA cement as a useful material for immobilizing elevated concentrations of toxic and hazardous elements.

Change in re-use value of incinerated sewage sludge ash due to chemical extraction of phosphorus

The potential of six different extractants to recover phosphorus (P) from incinerated sewage sludge ash (ISSA) was evaluated. Secondary effects such as the co-dissolution of Zn and Cu were also considered. The residual ISSA from each study was assessed in particular detail, focusing on the leachability of remaining Zn and Cu, major element composition, crystalline phases and overall degree of crystallinity and particle size distribution. The residual ISSA was also evaluated as a pozzolanic material using a Strength Activity Index (SAI) test with mortars containing Portland cement with a 20% substitution by ISSA. All results were compared to tests with untreated ISSA. Overall, the use of 3 of the 6 extractants could be ruled out due to poor P recovery potential and/or a serious compromise of the potential reuse of residual ISSA in Portland cement-based materials. The results highlight the added value of considering the potential reuse of residual ISSA when trying to optimize P recovery from ISSA by wet methods.