Wastewater Treatment and Deinking Sludge Utilization Possibilities for Energy and Material Recovery in the Leningrad Region

Operation of pulp and paper mills generates waste including wastewater treatment sludge and deinking sludge. Both sludge types are generated in large amounts and are mainly disposed of in landfills in the Leningrad Region resulting in environmental degradation. The thesis was aimed at seeking new sustainable ways of sludge utilization. Two paper mills operating in the Leningrad Region and landfilling their sludge were identified: “SCA Hygiene Products Russia” and “Knauf”. The former generates 150 t/day of deinking sludge, the latter – 145 t/day of secondary sludge. Chemical analyses of deinking sludge were performed to assess applicability of sludge in construction materials production processes. Higher heating value on dry basis of both sludge types was determined to evaluate energy potential of sludge generated in the Leningrad Region. Total energy output from sludge incineration was calculated. Deinking sludge could be utilized in the production process of “LSR-Cement” or “Slantsy Cement Plant Cesla” factories, and “Pobeda” and “Nikolsky” brick mills without exceeding current sludge management costs.

Deinking sludge utilization possibilities: technical, economic, and environmental assessments

This report introduces the ENPI project called “EMIR - Exploitation of Municipal and Industrial Residues” which was executed in a co-operation between Lappeenranta University of Technology (LUT), Saint Petersburg State University of Economics (SPbSUE), Saint Petersburg State Technical University of Plant Polymers (SPbSTUPP) and industrial partners from both Leningrad Region (LR), Russia and Finland. The main targets of the research were to identify the possibilities for deinking sludge management scenarios in co-operation with partner companies, to compare the sustainability of the alternatives, and to provide recommendations for the companies in the Leningrad Region on how to best manage deinking sludge. During the literature review, 24 deinking sludge utilization possibilities were identified, the majority falling under material recovery. Furthermore, 11 potential utilizers of deinking sludge were found within the search area determined by the transportation cost. Each potential utilizer was directly contacted in order to establish cooperation for deinking sludge utilization. Finally, four companies, namely, “Finnsementti” – a cement plant in Finland (S1), “St.Gobian Weber” – a light-weight aggregate plant in Finland (S2), “LSR-Cement” – a cement plant in LR (S3), and “Rockwool” – a stone wool plant in LR (S4) were seen as the most promising partners and were included in the economic and environmental assessments. Economic assessment using cost-benefit analysis (CBA) indicated that substitution of heavy fuel oil with dry deinking sludge in S2 was the most feasible option with a benefit/cost ratio (BCR) of 3.6 when all the sludge was utilized. At the same time, the use of 15% of the total sludge amount (the amount that could potentially be treated in the scenario) resulted in a BCR of only 0.16. The use of dry deinking sludge in the production of cement (S3) is a slightly more feasible option with a BCR of 1.1. The use of sludge in stone wool production is feasible only when all the deinking sludge is used and burned in an existing incineration plant. The least economically feasible utilization possibility is the use of sludge in cement production in Finland (S1) due to the high gate fee charged. Environmental assessment was performed applying internationally recognized life cycle assessment (LCA) methodologies: ISO 14040 and ISO 14044. The results of a consequential LCA stated that only S1 and S2 lead to a reduction of all environmental impacts within the impact categories chosen compared to the baseline scenario where deinking sludge is landfilled. Considering S1, the largest reduction of 13% was achieved for the global warming potential (GWP), whereas for S2, the largest decrease of abiotic depletion potential (ADP) was by 1.7%, the eutrophication potential (EP) by 1.8%, and a GWP of 2.1% was documented. In S3, the most notable increase of ADP and acidification potential (AP) by 2.6 and 1.5% was indicated, while the GWP was reduced by 12%, the largest out of all the impact categories. In S4, ADP and AP increased by 2.3 and 2.1% respectively, whereas ODP was reduced by 25%. During LCA, it was noticed that substitution of fuels causes a greater reduction of environmental impact (S1 and S2) than substitution of raw materials (S3 and S4). Despite a number of economically and environmentally acceptable deinking sludge utilization methods being assessed in the research, evaluation of bottlenecks and communications with companies’ representatives uncovered the fact that the availability of the raw materials consumed, and the risks associated with technological problems resulting from the sludge utilization, limited the willingness of industrial partners to start deinking sludge utilization. The research results are of high value for decision-makers at already existing paper mills since the result provide insights regarding alternatives to the deinking sludge utilization possibilities already applied. Thus, the research results support the maximum economic and environmental value recovery from waste paper utilization.

Potencial de producción de biochar en España a partir de residuos de la industria papelera, de lodos de E.D.A.R., de residuos sólidos urbanos y de residuos ganaderos: Estudio de la fijación de carbono

El biochar es un material rico en carbono que se obtiene tras la pirólisis de la biomasa. Este material ha despertado en los últimos años un gran interés en la comunidad científica principalmente por su capacidad para mejorar la productividad de los suelos, influenciando las propiedades fisicoquímicas de los mismos y como medio de fijación de carbono, reduciendo, por tanto, las emisiones de CO2 a la atmósfera. Sin embargo, lo cierto es que hasta la fecha, no existen conclusiones claras o avances definitivos que permitan crear una estandarización para la comercialización del biochar, debido a la variabilidad de sus propiedades (considerando la materia prima de origen y las condiciones de reacción en la pirólisis). En este estudio, partiendo de un análisis exhaustivo de las distintas publicaciones existentes sobre la materia, se trata de dar respuesta a la pregunta sobre cuál sería el verdadero potencial de producción de biochar en España, al tiempo que se trata de cuantificar cuál sería la reducción de las emisiones de CO2 a la atmósfera que conllevaría gestionar los residuos (industria papelera, lodos de EDAR, RSU y residuos ganaderos) a través de la pirólisis. En particular, se ha cuantificado la reducción de las emisiones de CO2 a la atmósfera y se ha evaluado cuánto biochar se debería producir a partir de residuos papeleros, lodos de EDAR o residuos ganaderos para aumentar en un 1% la cantidad de materia orgánica en un suelo y para llevar el contenido en materia orgánica de los suelos agrícolas españoles a un 3,5%. En primer lugar, sobre la cuantificación de la reducción de las emisiones, cabe concluir que, en todos los residuos estudiados, y bajo todas las condiciones de reacción consideradas, la reducción de las emisiones de CO2 a la atmósfera sería realmente notable, oscilando entre un 22,53% y un 96,12 %. En segundo lugar, para aumentar en un 1% el contenido medio en materia orgánica de la superficie agrícola española, sería necesario un aporte de 2,03816*108 t de materia orgánica, que supondría una demanda mínima de biochar de 255.408.361 t en el caso de la aplicación de biochar de estiércol de vacuno a Por otro lado, para llevar la materia orgánica de los suelos agrícolas a un 3,5%, la demanda de biochar variaría entre un mínimo de 158.937 t en el (Comunidad Autónoma con menor necesidad de aporte de materia orgánica) illa la Mancha (Comunidad Autónoma que, por el contrario, necesitaría mayor aporte). ABSTRACT Biochar is a carbon-rich material obtained after a biomass pyrolysis procedure. This material has aroused in recent years a great interest in the scientific community, mainly for its ability to improve the productivity of soils, influencing the physico-chemical properties of soils and as means of carbon storage, reducing emissions of CO2 into the atmosphere). Despite the interest that may raise this matter, the fact is that to date, no clear conclusions or definitive progress have been done to create a standardization for the commercialization of biochar, due to the variability of its properties (considering the raw material and the reaction conditions in the pyrolysis). This study, based on a thorough analysis of the various existing literature on the subject and, leaving other approaches that could have been taken of the interest of the subject in question, attempts to provide answers to the question about what would be the true potential production of biochar in Spain and what would be the reduction of CO2 emissions into the atmosphere, which would entail waste management through pyrolysis. In particular, this study has identified the reduction of CO2 emissions into the atmosphere and has analyzed whether the production of biochar could increase the organic matter content of Spanish agricultural soils. Firstly, regarding the quantification of emissions reductions, by referring to the values contained in the work, it can be concluded that the reduction of CO2 emissions to the atmosphere would be really remarkable, ranging from 22.53% to 96.12%. Secondly, to increase by 1% the average content of organic matter in the spanish agricultural area would require a contribution of 2.03816*108 t of organic matter, which would demand a minimum of 255.408.361 t of cattle manure biochar and a maximum demand of 1.746.494.190 t of deinking sludge pyrolyzed at 500C. On the other hand, to reach a 3.5%, the demand for biochar would vary from a minimum of 158.937 t, in case of cattle manure biochar at C applied to the Canary Islands (Autonomous Community with less need for input of organic matter), and a maximum of 694.695.081 in case of applying deinking sludge biochar at C to Castilla la Mancha (Autonomous Region, which needs the highest contribution).

Anaerobic treatment of deinking pulp plant effluents

Anaerobic treatment as a first biological stage in wastewater treatment is nowadays a well-established technology in recycled paper processing mills using closed water circuits. Today further developed high-rate processes and especially high-tower reactors are also able to handle lower organic loads and become therefore feasible for deinking pulp plant effluents. The interest in the anaerobic method is based on a positive energy balance in form of biogas production and low biomass yield from the process. The anaerobic treatment method was researched and its suitability for the deinking pulp plant effluents was tested experimentally at Stora Enso Maxau mill. In the theory, the deinking pulp process is introduced and the effluents from the deinking process are characterized. The anaerobic treatment is brought up in depth in terms of its use for the deinking effluents, and different kind of reactor types are presented. In addition, other wastewater treatment methods are shortly introduced with the focus on tertiary treatment. Static biodegradability tests were carried out for the wastewaters both anaerobically and aerobically. Based on the results, the deinking effluents can be degraded anaerobically, and inhibition to the methanogenic bacteria was not noticed. In the aerobic static test a good performance of the existing wastewater treatment plant at Maxau mill was proved. Later on pilot trials with sequential anaerobic-aerobic treatment were carried out for the deinking effluents. The anaerobic reactor used was a so called internal circulation reactor. The results confirmed that the combination of the anaerobic treatment and the aerobic activated sludge process is a suitable method for deinking wastewaters with a COD reduction as good as with a two stage aerobic method. When combined with the outstanding quality of the produced biogas and the cost savings acquired from the lower sludge production, the anaerobic treatment was found to be an especially favorable treatment method.

Fractionation of Zn, Cd and Pb in a Tropical Soil After Nine-Year Sewage Sludge Applications

A long-term field experiment was carried out in the experiment farm of the Sao Paulo State University, Brazil, to evaluate the phytoavailability of Zn, Cd and Pb in a Typic Eutrorthox soil treated with sewage sludge for nine consecutive years, using the sequential extraction and organic matter fractionation methods. During 2005-2006, maize (Zea mays L.) was used as test plants and the experimental design was in randomized complete blocks with four treatments and five replicates. The treatments consisted of four sewage sludge rates (in a dry basis): 0.0 (control, with mineral fertilization), 45.0, 90.0 and 127.5 t ha(-1), annually for nine years. Before maize sowing, the sewage sludge was manually applied to the soil and incorporated at 10 cm depth. Soil samples (0-20 cm layer) for Zn, Cd and Pb analysis were collected 60 days after sowing. The successive applications of sewage sludge to the soil did not affect heavy metal (Cd and Pb) fractions in the soil, with exception of Zn fractions. The Zn, Cd and Pb distributions in the soil were strongly associated with humin and residual fractions, which are characterized by stable chemical bonds. Zinc, Cd and Pb in the soil showed low phytoavailability after nine-year successive applications of sewage sludge to the soil.

Barium uptake by maize plants as affected by sewage sludge in a long-term field study

Along-term experiment was carried out under field conditions in Jaboticabal, SP, Brazil, with the objective of evaluating the concentration of Ba in soil and in maize plants grown in a soil treated with sewage sludge for nine consecutive years. During 2005/2006, maize was used as test plants and the experimental design was in randomized complete blocks with four treatments and five replicates. Treatments consisted of: 0.0, 45.0, 90.0 and 127.5 t ha(-1) sewage sludge (dry basis). Sewage sludge application increased soil Ba concentration. Barium accumulated in the parts of maize plants were generally affected by the successive applications of sewage sludge to the soil. However, the concentration of Ba in maize grain did not exceed the critical levels of Ba for human consumption. Sewage sludge applied to soil for a long time did not affect dry matter and grain production, nevertheless had the similar effect of mineral fertilization. Published by Elsevier B.V.

Concretes and mortars recycled with water treatment sludge and construction and demolition rubble

There are about 7500 water treatment plants in Brazil. The wastes these plants generate in their decantation tanks and filters are discharged directly into the same brooks and rivers that supply water for treatment. Another serious environmental problem is the unregulated disposal of construction and demolition rubble, which increases the expenditure of public resources by degrading the urban environment and contributing to aggravate flooding and the proliferation of vectors harmful to public health. In this study, an evaluation was made of the possibility of recycling water treatment sludge in construction and demolition waste recycling plants. The axial compressive strength and water absorption of concretes and mortars produced with the exclusive and joint addition of these two types of waste was also determined. The ecoefficiency of this recycling was evaluated by determining the concentration of aluminum in the leached extract resulting from the solubilization of the recycled products. The production of concretes and mortars with the joint addition of water treatment sludge and recycled concrete rubble aggregates proved to be a viable recycling alternative from the standpoint of axial compression strength, modulus of elasticity, water absorption and tensile strength by the Brazilian test method. (C) 2008 Elsevier Ltd. All rights reserved.

Mechanical properties of concrete produced with a composite of water treatment sludge and sawdust

In developing countries such as Brazil, the wastes generated in the decanters and filters of water treatment plants are discharged directly into the same rivers and streams that supply water for treatment. Another environmental problem is the unregulated discard of wood wastes. The lumber and wood products industry generates large quantities of this waste, from logging to the manufacture of the end product. Brazil has few biomass plants and therefore only a minor part of these wastes are reused. This paper presents the results of the first study involving a novel scientific and technological approach to evaluate the possibility of combining these two types of wastes in the production of a light-weight composite for concrete. The concrete produced with cement:sand:composite:water mass ratios of 1:2.5:0.67:0.6 displayed an axial compressive strength of 11.1 MPa, a compressive and diametral tensile strength of 1.2 MPa, water absorption of 8.8%, and a specific mass of 1.847 kg/m(3). The mechanical properties obtained with this concrete render it suitable for application in non-structural elements. (C) 2010 Elsevier Ltd. All rights reserved.

Lightweight composite concrete produced with water treatment sludge and sawdust: Thermal properties and potential application

The main objective of this study was to evaluate the potential application of a lightweight concrete produced with lightweight coarse aggregate made of the water treatment sludge and sawdust (lightweight composite), by determining the thermal properties and possible environmental impact of future residue of this concrete. Two types of concrete were prepared: concrete produced with the lightweight composite dosed with cement/sand/composite/water in a mass ratio of 1:2.5:0.67:0.6 and conventional concrete dosed with cement/sand/crushed stone/water in a mass ratio of 1:4.8:5.8:0.8. The thermal properties were determined by the hot wire parallel technique. The possible environmental impact was measured using the procedures and guidelines of the Brazilian Association of Technical Standards - ABNT. The concrete produced with the lightweight composite presented a 23% lower thermal conductivity than the conventional concrete. The concrete produced with the lightweight composite presented a set of thermal properties suitable for the application of this concrete in non-structural sealing elements. The concentration of aluminum in the solubilized extract of the concrete produced with the lightweight composite was much lower than the concentration of aluminum in the water treatment sludge, confirming the possible reduction of environmental impact of this composite for use in concrete. (C) 2010 Elsevier Ltd. All rights reserved.

Long-term stability of hydrogen and organic acids production in an anaerobic fluidized-bed reactor using heat treated anaerobic sludge inoculum

This study evaluates the stability of hydrogen and organic acids production in an anaerobic fluidized-bed reactor (AFBR) that contains expanded clay (2.8-3.35 mm in diameter) as a support medium and is operated on a long-term basis. The reactor was inoculated with thermally pre-treated anaerobic sludge and operated with decreasing hydraulic retention time (HRT), from 8 h to 1 h, at a controlled temperature of 30 degrees C and a pH of about 3.8. Glucose (2000 mg L(-1)) was used as the substrate, generating conversion rates of 92-98%. Decreasing the HRT from 8 h to 1 h led to an increase in average hydrogen-production rates, with a maximum value of 1.28 L h(-1) L(-1) for an HRT of 1 h. In general, hydrogen yield production increased as HRT decreased, reaching 2.29 mol of H(2)/mol glucose at an HRT of 2 h and yielding a maximum hydrogen content of 37% in the biogas. No methane was detected in the biogas throughout the period of operation. The main soluble metabolites (SMP) were acetic acid (46.94-53.84% of SMP) and butyric acid (34.51-42.16% of SMP), with less than 15.49% ethanol. The steady performance of the AFBR may be attributed to adequate thermal treatment of the inoculum, the selection of a suitable support medium for microbial adhesion, and the choice of satisfactory environmental conditions imposed on the system. The results show that stable hydrogen production and organic acids production were maintained in the AFBR over a period of 178 days. (C) 2009 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.

Water Treatment Plant Sludge Discharge to Wastewater Treatment Works: Effects on the Operation of Upflow Anaerobic Sludge Blanket Reactor and Activated Sludge Systems

This experiment examined the effects of the discharge of water treatment plant (WTP) sludge into the following three types of wastewater treatment systems: a pilot-scale upflow anaerobic sludge blanket (UASB) reactor, a pilot-scale activated sludge system, and a full-scale activated sludge sequencing batch reactor (SBR). The UASB reactor received 50 mg of suspended solids ( SS) of WTP sludge per liter of wastewater in the first phase, and, in the second phase, it received 75 mg SS/L. The pilot-scale activated sludge system received 25 and 50 mg SS/L in the first and second phases, respectively. The full-scale WWTP ( SBR) received approximately 74 mg SS/L. The results of the experiments showed that, despite some negative effects on nitrification, there were positive effects on phosphorus removal, and, furthermore, there was the addition of solids in all systems. Water Environ. Res., 82, 392 ( 2010).

CALCINED SLUDGE SINTERING EVALUATION BY HEATING MICROSCOPY THERMAL ANALYSIS

Aiming the use of the sewage sludge produced in one of the largest Brazilian wastewater treatment stations as a raw material for the ceramic industry, the sintering process of the ashes produced from its calcination was evaluated by heating microscopy thermal analysis (HMTA). From the microprocessed images, a method was developed to obtain HMTA dimensional change curves as a function of temperature, equivalent to those usually obtained from dilatometers or by thermomechanical analysis (TMA). The final product after sintering at 1050 degrees C, characterized by X-ray fluorescence spectrometry, scanning electron microscopy and X-ray dispersive energy, indicates the presence of a vitreous phase containing phosphorus, which explains the good sintering properties of the studied calcined sludge, as shown from its HMTA dimensional change curve.

Effects of sewage sludge amendment on the properties of two Brazilian oxisols and their humic acids

The effect of sewage sludge (SS) amendment on the general properties of the top layers of a sandy and a clayey oxisols and on the nature of their humic acid (HA) fractions was evaluated by chemical and physico-chemical techniques. The amended soils, especially the sandy soil, benefited of SS amendment by increasing their pH to above neutrality and enhancing the contents of C, N, P, and Ca and cation exchange capacity. The SS-HA-like sample showed larger H and N contents and a greater aliphatic character and humification degree than the HAs isolated from non-amerided soils. The composition and structure of amended soil HAs were affected by SS application as a function of soil type and layer. In particular, N-containing groups and aliphatic structures of SS-HA-like sample appears to be partially incorporated in the amended soil HAs, and these effects were more evident in the HAs from the sandy oxisol. (C) 2007 Elsevier Ltd. All rights reserved.

Native tree seedling growth when fertilized with different amounts of dry sewage sludge and mineral fertilizer

The increasing volume of urban sewage nowadays generates considerable amount of sludge to be disposed of. One environmentally adequate destination could be the application of treated and stabilized sludge (biosolids) to forest plantations as fertilizer and soil conditioner. The purpose of this study was to analyze the feasibility of applying sewage sludge, evaluating its effects on native tree seedlings. The species evaluated were aroeira-pimenteira (Schinus terebinthifolia Raddi), cabreuva-vermelha (Myroxy-Ion peruiferum L. f.), pau-de-viola (Cytarexyllum myrianthum Cham), unha-de-vaca (Bauhinia forficata Link), which are usually planted in forest restoration. Seedlings were cultivated in pots, containing a volume of 4 dm(3) of soil, within a greenhouse. The study was developed in the proximity of Campinas, SP, Brazil, and installed in November, 2003. The design was entirely randomized including seven treatments: control; mineral fertilization; and different doses of sewage sludge (biosolids) complemented with potassium, due to the low concentration of this element in the sludge produced by the wastewater treatment plant of Barueri (Metropolitan region of Sao Paulo city). The results showed that the application of different dosages of biosolids promoted different responses in stem height and biomass production. The treatment with 20 g/dm(3) of dry sewage sludge promoted both the highest growth and the highest seedling biomass production, compared to the control treatment. All native tree species treated with the highest dosage of sewage sludge showed a growth similar to that of mineral fertilization. The seedlings of aroeira-pimenteira, pau-de-viola, and unha-de-vaca, all typical species of the initial succession in natural forest ecosystems, grew and produced more biomass than cabreuva-vermelha, a typical species of the final forest succession.

Ammonia volatilization in soil treated with tannery sludge

The utilization of tannery sludge in agricultural areas can be an alternative for its disposal and recycling. Despite this procedure may cause the loss of nitrogen by ammonia volatilization, there is no information about this process in tropical soils. For two years a field experiment was carried out in Rolandia (Parana State, Brazil), to evaluate the amount of NH(3) volatilization due to tannery sludge application on agricultural soil. The doses of total N applied varied from zero to 1200 kg ha(-1), maintained at the surface for 89 days, as usual in this region. The alkalinity of the tannery sludge used was equivalent to between 262 and 361 g CaCO(3) per kg. Michaelis-Menten equation was adequate to estimate NH(3)-N volatilization kinetics. The relation between total nitrogen applied as tannery sludge and the potentially volatilized NH(3)-N, calculated by the chemical-kinetics equation resulted in an average determination coefficient of 0.87 (P > 0.01). In this period, the amount of volatilized NH(3) was more intense during the first 30 days; the time to reach half of the maximum NH(3) volatilization (K(m)) was 13 an 9 days for the first and second experiments, respectively. The total loss as ammonia in the whole period corresponded in average to 17.5% of the total N applied and to 35% of the NH(4)(+)-N present in the sludge. If tannery sludge is to be surface applied to supply N for crops, the amounts lost as NH(3) must be taken into consideration. (C) 2010 Elsevier Ltd. All rights reserved.