Atomized sludges via spray-drying at low temperatures: an alternative to conventional wastewater treatment plants.

Removal of sludges from Wastewater Treatment Plants (WWTP) represents a serious worldwide environmental problem for which alternatives other than their simple incineration are investigated. In this work the treatment of raw sludge from urban WWTP by means of a minimization process through spray-drying is analyzed as well as some proposals for revaluating the resulting dry product. Analysis is supported by some experimental results obtained with a laboratory spray dryer. The experimental procedure at laboratory scale is extrapolated to an industrial plant scale. An economic analysis of the proposal in relation to other possible sludge treatments is presented, taking into account in this case the comparison between the costs of the processes of sludge thickening, stabilization and dehydratation and the costs of spray-drying (especially power consumption), minimization of the final waste and reuse options. Finally, an environmental balance of the process is presented. In contrast with the classical treatment line, this alternative allows transforming sludges, i.e., a waste, into a valuable product with several applications.

Environmental effects of using clay bricks produced with sewage sludge: leachability and toxicity studies.

Use of sewage sludge from wastewater treatment plants as a raw material for making clay bricks has been analyzed to be an option to dumping sludges into landfills. This alternative has been shown feasible and interesting due to the high rate of use of ceramic materials in the building sector. However, it meets with some environmental issues and some prejudices on the part of users. This work shows some leachability and toxicity tests (outgassing and offgassing) which demonstrate the environmental compatibility of these ceramic products to be used as building materials and even in deconstruction of the building once its useful life is ended.

Valorization of pellets from municipal WWTP sludge in lightweight clay ceramics.

A direct result of the growing number of municipal wastewater-treatment plants (WWTPs) has been an increase in the generation of large amounts of sewage sludge that requires environmentally acceptable final destination. To decrease the volume of sludge, a common technique is drying the sludge at a low temperature in rotary kilns. The result of this process is a granulated material consisting of dehydrated sludge pellets. After this treatment, this pelletized material becomes easier to manipulate, but it also becomes a more toxic waste, containing dangerous substances, mostly of the lipid type. At its final stage, this material is usually incinerated, used as a comburent material, used as an agricultural fertilizer, or used in the cement industry. Each application has its own problems and requires remediation measures from the safety and environmental viewpoints. In this study, we looked beyond these possible applications and analyzed the transformation of sewage sludge through a ceramization process into a material similar to expanded clays; we subsequently explored its uses in the building industry or in the agriculture industry, among others. Both the properties of the product material and the production method were characterized, and an environmental analysis was conducted. The new, lightweight material had a microstructure with open porosity and low thermal conductivity. Environmental characterization such as the leaching test revealed that undetectable amounts of hazardous metals from the sludge were present in the leachate after the sludge went through a thermal treatment, despite their initial presence (with the exception of vanadium, which could pose some restrictions on some of the proposed uses for the final product). Toxicity tests also showed negative results. The study of gaseous emissions during production revealed emissions factors similar to those during the production of conventional clay ceramics, although with higher organic emissions. As for conventional clay ceramics, industrial production would require the implementation of some type of air-depuration system. The results showed that the ceramization of sludge pellets is a promising valorization technique worth considering from both the economic and technological perspectives.