Method of recovering iron and/or phosphorus from sludge of waste water treatment plants

Abstract

Method of recovering iron and/or phosphorus from sludge of waste water treatment plants, said sludge being obtained after precipitation by iron salts, wherein said method comprises separating sludge from waste water and submitting said sludge to a lactic fermentation to release a liquid phase where iron and phosphorus are dissolved. Lactic fermentation is performed with addition of a co-substrate rich in carbon, preferably rich in carbohydrate, in one single step of biological acidification or a sequencing biological acidification in two steps by first releasing phosphorus from the PAO contained in the sludge. Iron can then be recovered by means of a cationic exchange resin. Phosphorus can be recovered as struvite or calcium phosphate from the remaining solution substantially free from iron ions, after a precipitation step in presence of a magnesium or calcium source and a pH above 7.

Claims

1. Method of recovering iron, phosphorus, or both from sludge of waste water treatment plants, said sludge previously obtained by precipitation by iron salts, said method comprising the steps of: separating sludge from waste water; and submitting said sludge to a lactic fermentation to release a liquid phase, where iron and phosphorus are dissolved.

2. Method according to claim 1, wherein the step of dissolving of iron and phosphorus into said liquid phase comprises submitting said sludge to lactic fermentation with substrates that contain biodegradable carbon.

3. Method according to claim 2, wherein said substrates include carbohydrates, leading, during lactic fermentation, to organic acids production and acidification of the medium to a pH value equal or below 5.

4. Method according to claim 3, wherein said substrates containing carbohydrates are chosen among saccharose, glucose, agricultural industrial or urban organic wastes, crops and crop residues or parts or extracts thereof.

5. Method according to claim 2, wherein said lactic fermentation step is an anaerobic or anoxic fermentation step, carried on at a temperature comprised between 20 C. and 60 C.

6. Method according to claim 2, wherein said substrates are introduced in the lactic fermentation step at a concentration above 0.2 g COD/g VSS.

7. Method according to claim 2, wherein the lactic fermentation step is followed by a liquid/solid separation step, the liquid fraction recovered after said separation step being put into contact with a material able to fix or to separate iron ions from phosphate ions.

8. Method according to claim 7, wherein the cationic exchange resin or the adsorbing material is regenerated by an eluent solution, eluting the iron ions in a form that can be reused in the waste water treatment plant.

9. Method according to claim 8, wherein the cationic exchange resin or the adsorbing material is regenerated by an hydrochloric acid solution, eluting the iron ions in the form of a ferric chloride solution.

10. Method according to claim 9, wherein said method includes recycling iron in the form of ferric salts in waste water treatment plants.

11. Method according to claim 9 being used in waste water treatment plants which include a flocculation step, a dephosphatation step, or both, by ferric chloride.

12. Method according to claim 7, for recovering phosphorus, wherein the lactic fermentation process is performed in the following sequential steps: i) a pre-fermentation step where sludge is pre-fermented with said substrates at a low COD charge, leading to organic acids production and a pH about 6, to release phosphorus from the sludge, ii) a lactic fermentation segment where said pre-fermented sludge is further fermented with said substrates at a higher COD charge, leading to more organic acids production and to a pH about 4, obtaining phosphorus dissolution in the liquid phase, and said fermentation process is followed by: iii) said liquid/solid separation step for obtaining a liquid fraction, named first liquid solution iv) an iron fixation step where said first liquid solution is contacted with a cationic exchange resin or with an adsorbent material, obtaining a second liquid solution substantially free from iron ions, v) and a precipitation step by providing a magnesium source or a calcium source and increasing pH above 7 to precipitate phosphorus from said second liquid solution.

13. Method according to claim 7, for recovering phosphorus, wherein the lactic fermentation process is performed: a) under a single lactic fermentation phase where said sludge is fermented with substrates at a COD charge equal or above 0.3 g COD/g VSS, leading to organic acids production and to a pH decrease to a pH value equal or below 5, obtaining iron and phosphorus dissolved in the liquid phase, and said lactic fermentation process is followed by: b) said liquid/solid separation step for obtaining a liquid fraction, named first liquid solution, c) an iron fixation step where said first solution is contacted with a cationic exchange resin or with an adsorbent material, obtaining a second liquid solution, substantially free from iron ions, d) and a precipitation step by providing a magnesium source or a calcium source and increasing pH above 7 to precipitate phosphorus from said second liquid solution.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will be further described in the below examples given with reference to the accompanying drawing, in which:

(2) FIG. 1 is a schematic diagram of the various treatment steps performed in a waste water treatment plant including the method of the present invention (dotted arrows represent the sludge circuit);

(3) FIG. 2 is a scheme showing the quality of the dissolved iron after one-step biological acidification according to the method of the present invention with sludges issued of different waste water treatment plants (in reference to the treatment steps: EBP refers to biological dephosphatationFeCl.sub.3=dephosphatation by ferric chloride);

(4) FIG. 3 represents the remaining ions concentration in the liquid fraction (which has been separated from the one-step biologically acidified sludge) after fixation on various amounts of a cationic exchange resin;

(5) FIG. 4 is a schematic diagram of the two embodiments of the invention for phosphorus recovery, presenting the sequencing acidification strategy;

(6) FIG. 5 shows the pH evolution by the two-step sequencing acidification without or with addition of various carbon-rich co-substrates;

(7) FIG. 6 shows the phosphate evolution by the two-step sequencing acidification without or with addition of various carbon-rich co-substrates;

(8) FIG. 7 shows the iron evolution by the two-step sequencing acidification without or with addition of various carbon-rich co-substrates.

DETAILED DESCRIPTION OF INVENTIONEXAMPLES

(9) Sludge Samples:

(10) For example 1: the sludge samples were obtained from five different waste water treatment plants. Plant S1 includes a controlled biological dephosphation step, plant S2 and row 1 of plant S4 (S4-1) include nitrogen and carbon treatment steps that induce development of dephosphating bacteria. Plant S3 and row 2 of plant S4 (S4-2) have essentially dephosphatation by addition of ferric chloride. The molar ratios total Fe/total P in the sludge are comprised between 0.4 and 1.2.

(11) The sludge sample used for the tests of example 2 was obtained from a waste water treatment plant (WWTP) treating 360000 population equivalent. It was sampled after thickening by a belt press. Secondary treatment in the WWTP consists of oxidation ditches designed to achieve Enhanced Biological Phosphorus Removal (EBPR). FeCl.sub.3 is applied as complementary P treatment to ensure the legislation limits. Said sludge composition for example 2 (after storage at 4 C.) is presented in table 1 below:

(12) TABLE-US-00001 TABLE 1 total solids TS (g .Math. kg.sup.1) 27 total volatile solids TVS (g .Math. kg.sup.1) 19 total suspended Solids TSS (g .Math. kg.sup.1) 25 volatile suspended solids VSS (g .Math. kg.sup.1) 18 total fixed solids TFS (g .Math. kg.sup.1) 8.1 pH 6.8 total phosphorus TP (g .Math. kg.sup.1) 0.8 NNH.sub.4.sup.+ (mg .Math. L.sup.1) ND Ca.sup.2+ (mg .Math. L.sup.1) 32 Mg.sup.2+ (mg .Math. L.sup.1) 11 K.sup.+ (mg .Math. L.sup.1) 35 NNO.sub.2 (mg .Math. L.sup.1) 0.6 NNO.sub.3.sup. (mg .Math. L.sup.1) 0.1 PPO.sub.4.sup.3 (mg .Math. L.sup.1) 12

(13) Preliminary tests have shown that a storage time between 24 and 240 hours does not impair the dissolution mechanisms.

(14) Analysis:

(15) Total solids (TS), volatile solids (VS), total Kjeldahl nitrogen (TKN) and chemical oxygen demand (COD), were measured with standard methods [21]. After an acidic mineralization (110 C., 1 bar, 60 min), total phosphorus (TP) was analyzed by the ascorbic acid method using an automate spectrophotometry (Gallery, Thermo Scientific, method 984366).

(16) The ionic composition of the supernatants after centrifugation (4 C., 20 000 g) and filtration on a 0.45 m polypropylene membrane was measured with both anion (Cl.sup., NO.sub.2.sup., NO.sub.3.sup., PO.sub.4.sup.3, SO.sub.4.sup.2) and cation (Na.sup.+, NH.sub.4.sup.+, Mg.sup.2+, Ca.sup.2+, K.sup.+) chromatography. A Metrohm 940 Professional Vario IC was equipped with a Metrosep A sup 5 anionic column and a Metrosep C4-250/4,0 column for cations.

(17) Total Phosphorus and iron forms have been determined from ashes obtained after calcination at 550 C. during 4 hours, followed by dissolution in a mixture of sulfuric and nitric acids (75/25) at 120 C. and 1 bar during 1 h.

(18) Total dissolved iron (Fe.sup.2+ and Fe.sup.3+) was then measured by an automate spectrophotometry (Gallery, Thermo Scientific, method 984326).

(19) Co-Substrates

(20) For example 1: the co-substrate rich in assimilable carbon is saccharose.

(21) For example 2: the co-substrates selected from milk serum, WWTP grease, urban organic waste and collective restaurant waste were individually used as co-substrates. Urban organic waste, collective restaurant waste, milk serum and WWTP grease were stored at 20 C. The solid co-substrates were cryogenized and triturated to form a homogeneous mixture. The co-substrates were characterized in total COD (TCOD), TP, carbohydrate, lipid and protein contents. The co-substrates compositions are presented in Table 2 below.

(22) TABLE-US-00002 TABLE 2 Urban Milk WWTP Collective organic White serum grease restaurant waste sugar TCOD (g .Math. kg.sup.1) 64 123 315 336 1170 TP (g .Math. kg.sup.1) 0.6 0.2 0.4 1.4 NP TKN (g .Math. kg.sup.1) 1.4 1.0 3.1 8.5 NP NNH.sub.4.sup.+ (g .Math. kg.sup.1) 0.0 0.2 0.2 0.4 NP Proteins content* 19.2% 5.8% 8.2% 21.5% NP Lipids content* 2.9% 48.8% 31.6% 47.4% NP carbohydrates content* 77.8% 45.4% 60.2% 31.1% NP NP: not performed. *expressed in COD/TCOD.

As Comparative Example: Chemical Acidification

(23) Chemical acidification tests by hydrochloric acid (12 M) were run to estimate the fraction of P released by chemical mechanism during biological acidification. Dilutions caused by the acid dosage were negligible. pH was maintained stable for 15 min at each pH value under continuous stirring (250 RPM) and then lowered from 1 unit till reaching pH 2. Acidified waste activated sludge was sampled at every pH unit. Soluble P (PPO.sub.4.sup.3) and total dissolved iron (Fe.sup.2++Fe.sup.3+) concentrations were determined in the supernatant. PPO.sub.4.sup.3 dissolution was found to be a polynomial function, which was used to estimate the contribution of chemical dissolution during the biological process. The iron dissolution curve was also a polynomial function.

(24) Biological Acidification Tests:

(25) The reactors used on sludge fermentation tests were Erlenmeyer flasks with a total volume of 1280 mL, filled with 640 mL during tests. The reactors were placed on heating plates with magnetic stirring. The reaction temperature was set to 35 C., which corresponds to a mesophilic condition, such as most of the anaerobic digesters in France. A thermally insulated box was used as a cover to promote a homogeneous temperature.

(26) The reactors were closed with a rubber septum, which allowed the insertion of needles for pressure measurement, gas collection or injection, as well as reagents dosage. In every experience start or flask opening, the atmosphere was inerted with nitrogen gas for at least 20 minutes (1 mm.Math.min.sup.1). Glass taps were adapted to the reactor's bottom for sampling without opening the reactors. The internal pressure generated by the gas production during fermentation ensured that no oxygen was reintroduced during sampling. Overpressure was daily removed with a needle through the rubber septum to avoid vial burst. Repeatability was assessed prior to the operation of these experiments by triplicates with sugar at loads of 2-5 gCOD.Math.gVS.sup.1 and provided more than 95% repeatability on pH and soluble P.

Example 1: One-Step Acidification

(27) A co-substrate rich in easily degradable carbon (saccharose) at a ratio of 0.5 gCOD.Math.gVS.sup.1 was added to sludge in the above described reactors under nitrogen, at 35 C. under weak agitation during 48H.

(28) FIG. 2 presents the results on the five sludge samples. The fraction of iron dissolved by biological acidification varies from 33% for a plant with dephosphatation with only ferric chloride up to 92% on the sludge from plant S1 having a controlled biological dephosphatation.

(29) Compared to chemical acidification tests at lower pH on sludge issued from plant S1 which have not managed to dissolve more than 20% of iron from the sludge, biological acidification shows interesting improvement.

(30) Separation of the acidified sludges from its liquid phase in which have been dissolved iron and phosphorus is performed by centrifugation. Fixing iron ions on a cationic exchange resin on the liquid fraction obtained after centrifugation of the acidified sludge from plant S4-1. Resin is a DOWEX type Marathon C. Initial pH of the liquid fraction was 4.81. Increased amounts of resin (5, 20 and 50 g.Math.L.sup.1 respectively) were added, and the mixtures were put under agitation at ambient temperature (20 C.) during 1 h. A reference without resin is added to the list. It is noted that an amount of 5 to 20 g of resin per liter of the liquid fraction issued from the biological acidification allows fixing most of the iron. Results are presented on FIG. 3. It should be observed that the concentration of the dissolved P is not modified.

(31) Regeneration of the resin is performed with an eluent comprising a 4% HCL solution. Iron is then eluted in the form of ferric chloride, that may be recycled into the waste water treatment plant.

Example 2: Sequencing Acidification

(32) The principle of the sequencing acidification is presented in FIG. 4. The first step, in which P-release takes place, was performed in reactors as described above. In this phase, organic acids are produced to enhance intracellular P-release by polyphosphate-accumulating organisms (PAO). However, the co-substrate charge must be limited to avoid an excessive pH reduction and the consequent decrease in the efficiency of PAO's metabolism. The ratio of 0.2 gCOD.Math.gVS.sup.1 brings enough carbon for P release, keeping the pH slightly below 6. A control test without co-substrate was performed in the same conditions. After 48 h, a second P dissolution step was performed, where pH was lowered to dissolve the released P which could be precipitated with cations and other previous non-soluble forms. Acidification was performed biologically by the addition of sucrose (white sugar) as a carbohydrate-rich co-substrate model (0.5 gCOD.Math.gVS.sup.1 during 48 h) or by chemical dosage (HCl 12M). Two strategies of chemical acidification were evaluated only in the control test: sample acidification to pH 4 (R2) and reactor acidification to pH 4 with reaction continuation (R1).

(33) Excluding iron phosphates, pH 4 is sufficient to prevent readily precipitation of released P with amorphous calcium phosphate and/or struvite, the most common forms. Stronger acidifications could induce operational problems such as subsequent excessive chemical needs on pH increase to allow struvite crystallization, methanogenesis inhibition and inefficiency on dewatering processes.

(34) The above experiment plan is summarized in Table 3.

(35) TABLE-US-00003 TABLE 3 Load +48 h Total Co- gCOD/ Acidified Reactor P substrate gVS) sample Reactor intervention R1 782 Control 0 to pH 4; Continuing at pH 4 (HCl addition) R2 782 Control 0 white sugar addition, 0.5 gTCOD/gTVS load R3 786 Collective 0.2 to pH 4 white sugar restaurant addition, 0.5 gTCOD/gTVS load R4 796 Urban 0.2 to pH 4 white sugar organic addition, 0.5 waste gTCOD/gTVS load R5 833 Milk 0.2 to pH 4 white sugar serum addition, 0.5 gTCOD/gTVS load R6 765 WWTP 0.2 to pH 4 white sugar grease addition, 0.5 gTCOD/gTVS load

(36) After 48 h of P-release step, it was observed a slightly lower pH with lactoserum as co-substrate (5.6) and similar values in the other tests: 6.1 to control and WWTP grease and 5.9 to the restaurant and urban organic wastes (FIG. 5).

(37) A greater difference is observed on soluble P, which represents 19% of the total P for the control test and about 30% with organic co-substrates application (FIG. 5). The higher total P value due to the higher P supply caused by lactoserum application (Table 2) may partially explain the greater soluble P amount in this test, but not the difference between the other tests and the control.

(38) After white sugar addition, a quick pH drop was observed from about 6.0 to 4.7 in all tests, but the goal of biological acidification was also pH 4. After that, it remained approximately stable until 96 h of reaction (FIG. 5). Following the acidification, soluble P concentrations (PPO.sub.4.sup.3) increased and reached about 40% of the total P after 96 h in all tests. A maximum of 52% soluble P was obtained in the control test with a retention time of 72 h (FIG. 6).

(39) After P-release step, 24 h of biological acidification (total retention time of 72 h) contributed with more 6-10% (actual waste) and 33% (both control tests) of soluble P, but there was no significant extra P solubilisation with 48 h of biological acidification (total of 96 h). Biological acidification reached pH 4.7 and chemical acidification was performed to achieve pH 4. This pH difference may explain different soluble P concentrations since it opposes precipitation of P with available cations.

(40) Regardless of the applied method, soluble P did not exceed 55%, what is significantly lower than the 75% value previously obtained by directly adding white sugar on 0.5 gCOD.Math.gVS.sup.1 organic charge at the beginning of the pre-fermentation with sludge from the same waste water treatment plant.

(41) Dissolved iron concentrations (Fe.sup.2+ and Fe.sup.3+) after chemical acidification of pre-fermented sludge were between 400 and 500 mg.Math.L.sup.1 (FIG. 7). These values are greater than those obtained with biological sequencing acidification which does not exceed 280 mg.Math.L.sup.1 at pH 4.7.

(42) Soluble iron concentrations were much greater with the application of sequencing acidification than with chemical acidification of sludge without pre-fermentation: 102, 66 and 35 mg.Math.L.sup.1 at pH 2, 3 and 5 respectively. This result confirms the role of pre-fermentation metabolism that would turn iron into more sensible to acidification forms.

(43) Recovery of iron and phosphorus can then be performed according to example 1.

IN CONCLUSION

(44) Strong acidification, induced by a large amount of easily biodegradable organic matter in a single lactic fermentation step of sludge may reduce biological P-release by PAO.

(45) Therefore, dissociating P-release and P-dissolution by applying a two-step sequencing acidification strategy brings the main conclusions below: Sequencing acidification with chemical dosage is more effective (about 50% of soluble P at pH 4) than biological sequencing acidification (about 40% at pH 4.7) but both presented better results than chemical-only acidification (maximum of 11% at pH 3.4). Biological acidification with the applied organic charge did not reach pH 4 probably due to a great amount of ammonium mineralized during the first 48 hours of P-release step which may have increased the buffering capacity. Sequencing acidification strategy showed to be less effective than the input of a larger amount of easily biodegradable COD at the beginning of the tests.