Environmental Technology, Vol. 22. pp 1313-1324 © Selper Ltd, 2001 REM NUT ION EXCHANGE PLUS STRUVITE PRECIPITATION PROCESS L. LIBERTI*, D. PETRUZZELLI AND L. DE FLORIO Department of Civil and Environmental Engineering, Polytechnic University of Bari V.le Turismo 8, 74100 Taranto, Italy (Received 15 March 2001; Accepted 4 June 2001) ABSTRACT Nutrients control technologies from wastewater are based on destructive technologies which defer the problem from the diluted liquid-phase (effluent) to a more concentrated waste (sludge) in the case of phosphates, or to nitrogen gas and/or volatile compounds in the case of ammonia. The REM NUT process allows for simultaneous removal of phosphate and ammonium ions by selective ion exchange and recovery by chemical precipitation in the form of struvite (magnesium ammonium phosphate) from the spent exchangers regeneration eluates. In the paper revised versions of the REM NUT process, i.e., P-driven layouts, are presented and cost effectiveness is compared to chemical precipitation based on the use of ferric chloride. Keywords: Wastewater P-removal; P-recovery; magnesium ammonium phosphate; struvite fertiliser manufacture [3]. Conventional Methods for P Removal at Municipal and Industrial WWTP are based on: INTRODUCTION The west European phosphate industry has fixed an objective of using 25% recovered phosphates (probably the only recyclable detergent ingredient) within a decade and has recognised sewage and animal wastes among the major alternative sources of P [1]. Total P content of the above waste streams amounts to approx. 5x105 and 8x105 t y-1 respectively [2]. A stricter regulatory pressure on P discharge to control eutrophication, known limitations of biological P removal and controls on the disposal of related P-laden sludge land are triggering renovated interest toward alternative processes with improved performance allowing for simultaneous removal and recovery of nutrient species. Current practice for industrial recycling of phosphorus from waste water treatment plants (WWTP) is based on phosphate precipitation as either calcium phosphates or struvite (MgNH4PO4 and MgKPO4) pellets. The chemistry of the two compounds is different, but integration of their recovery into sewage treatment is similar. Calcium phosphate may be recycled into industrial processes or processed to local manufacture of fertilisers while struvite can probably be used directly as fertiliser (although a better substantiation of its economic value is needed) or it can be incorporated into Chemical precipitation: FeCl3, Al2(SO4)3 , (AlCl3)n , Ca(OH)2 or their combination is added at various points in WWTP inducing precipitation of insoluble phosphates, removed as waste sludge and usually disposed-of in sanitary landfills. The economic value associated with Pladen slurry is limited while sludge production increases significantly [4,5]. Enhanced Biological Nutrient Removal (EBNR): provision for an anaerobic zone in the activated sludge bioreactor may allow for simultaneous removal of P (beyond the need for biomass synthesis as "luxury uptake") and N (through de/nitrification). P ends up in sewage sludge (it may be incidentally recovered from supernatant liquor after anaerobic digestion of sludge) while N is stripped out to the atmosphere as nitrogen gas [4,6-8]. The European Directive No.271/91 on Urban Wastewater [9], now enforced in all member States [10], sets strict nutrient discharge limits to prevent eutrophication in sensitive areas (1-2 mgP L-1), with a similar approach assessed since the late seventies in the US and Canada Great Lakes area 1313 [11]. In addition to chemical precipitation, largely adopted although relatively expensive, bio-P removal techniques have attracted renewed interest on the international scene recently although generally they are less technically effective to cope with the Directive’s limits [7,12-16]. This is a consequence of the (expected) lower operation costs of EBNR processes and possible P recovery from sludge digestion supernatant. On the other hand, chemical precipitation often yields excessive sludge P content for spreading on agricultural land [17]. BioP removal, on the contrary, invariably induces P release by hydrolysis during sludge digestion and this in turn may lead to uncontrolled phosphate scaling in the form of struvite (more often in anaerobic respect to aerobic sections) and resulting malfunctioning may be so extensive to yield WWTP shut-downs [18] Over the last few years, resurgent interest has been observed in the industrial recovery and recycling of phosphorus. Several water companies have built or tested Precovery systems [13-16] and others are currently doing so on full scale plants [19-24]. Among others the Crystalactor® process, developed by DHV Water BV, The Netherlands [19,20] and the Phosnix® process, developed by Unitika Ltd, Japan [21,23,24], deserve special mention. The REM NUT process presented in this paper, developed at Italy’s National Research Council [25,26], allows for P, NH4 and K removal from dilute streams through selective ion exchange followed by struvite precipitation in proper conditions. The process is suitable for different applications, thus overcoming limitations of biological processes, and may be integrated with (rather than substituted for) other P-recovery technologies, particularly as a mainstream (tertiary) treatment in small-medium size WWTP where bio-P might not be easy to operate. THE REM NUT PROCESS Developed in the mid 1980s for removal and recovery of phosphate, ammonium and potassium ions from wastewater in the form of a premium quality slow-release fertiliser, i.e., ammonium and potassium struvite MgNH4PO4, and MgKPO4 in its basic configuration the REM NUT process relies on two unit operations (Figure 1): selective ion exchange for removal of nutrients (NH4+, K+, HPO4=) from wastewater and their concentration in the ion exchangers’ regeneration eluate chemical precipitation of nutrients from this latter in the form of struvite after addition of Mg2+ at controlled pH, while the supernatant solution is recycled. The Main Features of the Process are: 1314 two ion exchange units, cationic and anionic, based on a natural zeolite (Clinoptilolite, Phillipsite or Chabasite) and a “scavenger” strong base resin respectively, are used for selective removal (>90%) of nutrients from wastewater to the discharge limits imposed by current legislation according to: Figure 1. Conceptual scheme of the REM NUT process. Z-Na + NH4+ (K+) === Z-NH4 (K+) + Na+ (i) Mg2+ + NH4+ (K+)+ HPO4= === MgNH4(K+)PO4 (s) + H+ (iii) 2R-Cl + HPO4= === R2-HPO4 + 2Cl- (ii) (Z = zeolite, R = anion exchanger) regeneration of both ion exchangers is carried-out with neutral 0.6M NaCl brine (i.e., seawater wherever possible) with cyclic regeneration make-up as low as 2BV (ion exchanger Bed Volume) through a “zero discharge” closed loop technique [27] cation and anion exchangers’ regeneration eluates are properly mixed, pH is raised to 9.5 (where incidental presence of heavy metals retained by the zeolite is precipitated) and a soluble Mg salt (e.g., MgCl2) is added to yield a virtually non-toxic sterile struvite-rich precipitate (Table 1) according to: Table 1. Overall effluent quality is improved by additional side benefits including incidental removal of residual suspended solids (90%), biological oxygen demand, chemical oxygen demand, (i.e., bio-persistent refractory organics, phenol derivatives, surfactants, pesticides, endocrine disrupters, oestrogens etc., >65%) and microorganisms (90%). Reduction of these latter (approx. 1 log) in particular will proportionally minimise disinfection demand and related health hazards associated with haloforms formation (THM, AOX) during final chlorination. The process passed extensive laboratory study [28], pilot scale investigation [29] and two demonstration campaigns with a fully automated 240 m3d-1 pilot plant (Figure 2) carried out at West Bari, Italy, WWTP (MayDecember 1983, funded and supervised by Italy’s National Research Council) [30,31] and at South Lyon, MI, USA, WWTP (January-May 1986, funded and supervised by the U.S. Environmental Protection Agency) [32,33]. Typical analysis of struvite-rich precipitate recovered from municipal sewage with REM NUT process. Struvite content : >93% w Organic matter: <7% w MgO:P2O5:N=15:27:5 As<0.3; Cd<0.5; Cr(VI)<0.1; Crtotal<0.35; Cu<0.2; Hg<0.5; Pb<4.5; Se<0.02 Ni<2; Zn<25; Fe<200 (mgkg-1) Microbial charge: almost sterile Radioactive content: nil 1315 Figure 2. Outside view of 240 m3 d-1 REM NUT mobile plant. In spite the of promising results achieved, however, the organic phase (activated sludge) and the effluent supernatant REM NUT process did not reach full scale application yet due is admitted to the P-driven REM NUT scheme. The NH4essentially to: loaded zeolite may be conveyed to bio-regeneration through unbalance between P and N in municipal sewage (P:N nitrification-(de)nitrification and then recycled. 1:10 on molar basis), and hence in the exchanger In all cases approx. 1:1 stoichiometric amounts of P-PO4 regeneration eluates calling for the expensive addition of and N-NH4 will be retained by selective ion exchange and chemicals to yield P:N:Mg = 1:1:1 stoichiometry for precipitated as struvite, after Mg addition to ion exchangers’ struvite precipitation regeneration eluate. As mentioned, the final effluent is still high P-discharge limits enforced in several EU Countries acceptable for eutrophication control with improved quality (e.g., 10 to 20 mg l-1 P in Italy) in terms of COD, suspended solids etc. poor attitude of (waste)water industry toward With respect to the full version, the P-driven REM NUT innovation scheme obviously requires proper design and sizing of ion relative abundance of the natural P deposits exchange sections. Under these conditions cost-effectiveness of process chemistry may largely improve as the external The turn of millennium now offers a different scenario addition of phosphatess to reach Mg:NH4:PO41:1:1 molar for the last three drawbacks and promotes resurgent interest ratio for struvite precipitation, is no longer required and toward the REM NUT process, provided the P/N unbalance chemical consumption is limited to Mg (MgCl2) and alkaline could be addressed as discussed later. buffer (NaOH) for pH control. Additional savings of chemicals (80%) have been estimated with seashore installations where seawater may be P-DRIVEN REM NUT SCHEME used as ion exchangers regenerant and a source of Mg for The REM NUT process was revisited for removing and struvite precipitation as indicated by preliminary tests [35] recovering all phosphate and just an equimolar amount of and confirmed recently in Japan [24]. Through proper design ammonium ion from sewage by selective ion exchange, and arrangement of the basic flow-sheet other revisited REM leaving excess NH4+ to other conventional treatment processes NUT schemes may be assumed. Among others, pre(e.g., bio(de)nitrification). concentration of phosphate ion by selective anion exchange The so-called P-driven REM NUT process may assume followed by recovery as Ca-phosphate or struvite from the ion different layouts as shown in Figure 3. exchanger eluate was successfully tested on a demonstration According to scheme 3a (full REM NUT), applicable scale with animal wastes (pig farm) in Northern Italy [35]. with N:P1:1 molar ratio and nutrient-rich effluents (e.g., A pilot investigation is now planned to assess feasibility animal wastes), the influent stream is processed on both ion of the P-driven REM NUT scheme. exchange units for quantitative recovery of phosphate and ammonium load. Scheme 3b (P-driven REM NUT) is ECONOMIC EVALUATION applicable with an unbalanced N/P ratio as, most commonly, in municipal effluent (N/P 10/1). In this case, while the Three process schemes (Figure 4) have been compared whole stream is processed for PO4-selective ion exchange on under design data and unit costs summarised in Table 2 for a the anionic section, approximately 1/10 of the influent stream typical 11,000 m3d-1 municipal installation discharging into (i.e., a reverse fraction with respect to N/P ratio) undergoes "sensitive areas" (i.e., 1mg l-1 P final concentration). NH4-selective ion exchange on the cationic unit and 9/10 is Scheme A, based on the most common chemical postby-passed to other de-ammoniation treatment. Biological precipitation of phosphorus by direct addition of FeCl3 and nitrification-denitrification (bio N-deN) appears particularly cationic polyelectrolyte to secondary effluent, was assumed as suitable to this aim and offers great synergy. Indeed bio Nreference. Alternatively, the modified REM NUT layout was deN will provide sidestreams or pints in the mainstream with considered under two different schemes (B and C), both relatively high NH4+ content (many bio N-deN works typically including phosphorus pre-concentration by selective “accidentally” achieve also some bio-P removal, but generally ion exchange followed by chemical precipitation. Scheme B not enough to cope with Directive P limits). The combination refers to wastewater containing only phosphate ion (e.g., of bio N-deN (<90%) with P-driven REM NUT treatment will nitrified sewage), to be more efficiently precipitated as ferric offer a key configuration as water companies usually will not phosphate from the P-concentrated anion exchanger wish to address P removal independently from N removal regeneration eluate. Scheme C applies to the wider case of questions. effluents containing both ammonia and phosphates (e.g., non In another REM NUT scheme currently investigated nitrified municipal sewage), to be recovered in a 1:1 molar [34], excess ammonium is absorbed by Na-form zeolite added ratio through selective ion exchange followed by struvite directly into the WWTP activated sludge reactor. The mixed precipitation with the so-called P-driven REM NUT layout. liquor is then submitted to fractional sedimentation to Almost the same amount of ferric phosphate (i.e., separate the mineral phase (ammonia-loaded zeolite) from the 176 t y-1) is recovered directly from diluted secondary effluent 1316 (10 mg l-1 P) in scheme A and from the concentrated Figure 3. ion exchange eluate (450 mg l-1 P) in scheme B. This latter, in Schematic layouts of REM NUT process (Z-Na: sodium-form zeolite; R-Cl chloride-form resin). spite of additional investment and operation, provides two main advantages over scheme A: a smaller precipitation reactor may be used with a more concentrated phosphate solution leakage of phosphate crystal fines in the final effluent 1317 (potentially exceeding P discharge limit) is prevented through the recycling of precipitation supernatant. An additional major advantage associated with scheme C is the recovery of more valuable struvite (285 t y-1) instead of ferric phosphate. The resulting cost summaries for schemes A, B and C are reported in Table 3 and compared in Figure 5. From the above data, the finite convenience of the P-driven REM NUT Figure 4. Flowsheet of P removal processes under comparison (flowrate; 11,000m 3d-1)A: Chemical precipitation. B: Chemical precipitation following ion exchange. C: Chemical precipitation following P-driven REM NUT. (Z-Na; sodium-form zeolite; R-Cl: chloride-form anion resin. 1318 Table 2. Design data for P-removal from municipal sewage (mg l-1) and unit cost of chemicals (¤t-1). Parameter Influent Effluent Chemical Precipitation P-driven REM NUT 1 40-45 10-20 10-15 1 5 10 5-10 Product Cost Revenue Ferric chloride Cationic polyelectrolyte (°) NaCl MgCl2.6H2O Sodium hydroxide Struvite 250 3,370 200 500 650 P-PO4 N-NH3 BOD SS Flow-rate 10 50 25 80 11,000 m3d-1 500 (°) type Nymco Dryfloc 652 process is demonstrated. Relevant to this aim is the economic revenue associated with recovery of struvite. The suggested price of recovered struvite has varied between 500 ¤t-1 USEPA [32,33] and 300 ¤t-1 [23,26] whilst recently the retail price on the small market was set at 1,000 ¤t-1 [24]. Assuming an intermediate figure of 500 ¤t-1, revenues would cover >40% of O&M costs for scheme C (struvite) compared to as low as <3% using Al or Ca precipitating agents. It has been assumed that the market value of Fe-phosphate will at very best cover transport and disposal costs and so it has been assumed to be zero. Although appropriate at this stage, no economic value was associated with improved effluent quality after REM NUT treatment and nutrients discharge control (related to environmental sensitivity of areas of reference), was assumed equivalent for all schemes under comparison. Moreover, difference in transport costs of recovered byproducts was disregarded on the assumption that they could be easily sold to local farmers or markets near WWTP catchement areas (although reuse of Al or Ca phosphate would unrealistically require a fertiliser factory next door). FERTILISER VALUE OF STRUVITE Magnesium ammonium phosphate is a relatively rare mineral with the most important natural source being rotting organic material such as guano (birds excrements) and animal manure [37,38]. In addition to spontaneous precipitation from biological digestion of municipal and animal sludge, it is a common constituent of renal and vesical calculii in humans and animals [39]. Magnesium (and potassium) ammonium phosphates are the most important representatives of a group of compounds with general formula MeNH4(K)PO4 (Me=divalent metal) wherein the elements may be necessary for plant nutrition [37,38,40]. These compounds exhibit slight solubility in water suggesting that they might be suitable as slow release nonburning fertilisers [38,40,41]. The rate of release to plants, however, is often determined by bacterial action rather than solubility, although evidence exists of the strong influence exerted by granule sizes [42]. Laboratory studies on pulverised struvite confirm that release rates are much greater than expected on the basis of its solubility and it was concluded that soil nitrification is the rate controlling factor in nutrient release to plants [41,43]. Accordingly, fertiliser granulation and dose play a relevant role in determining its agronomic properties. Stable forms of magnesium ammonium phosphate are hexahydrate and monohydrate (transition temperature 57°C), this latter being slightly less soluble in water (0.14 vs. 0.18 g l-1 at 25°C) [37,38]. Synthetic magnesium ammonium phosphate was commercialised in the USA on a small scale essentially in the monohydrate form (8%N, 40%P2O5, 25% MgO) and also as a mixture of ammonium and potassium derivative to reach NP-K ratio exceeding 7-40-6 [37,38,44]. Several comparative studies with urea formaldehyde, ammonium nitrate and ammonium sulphate to test nitrogen release were carried out with success on ryegrass, bluegrass, buckwheat, cicer arietinum and others [43]. As for phosphorus response, struvite responded better (even double) than 1319 superphosphates and its effectiveness as a source of magnesium which is completely soluble and ready available to plants for nutrition was also demonstrated [43]. Many applications of struvite in the USA refer to container grown ornamentals (pot flowers) [45], field grown ornamentals [46] and plant nurseries, a market able to afford the somewhat higher price of synthetic magnesium ammonium phosphate thanks to the excellent results achieved so far. Struvite was successfully used to grow chrysanthemums, poinsettias, azaleas and others [47]. Bushes and trees also showed superior height and trunk diameter [37,47,48,49,50]. In minor cases, a number of field crops (beets, winter wheat, potatoes, tobacco) were fertilised with magnesium ammonium phosphate with results comparable or even superior to super-phosphates [47,51]. Tomatoes responded well to struvite application in large field experiments in Florida where it gave greater yields than other conventional fertilisers [37]. Magnesium potassium phosphate was used for limited field crops in different experiments on ryegrass, bushbeans and tomato under non-leaching conditions [49]. It resulted in a good source of P and K, while under leaching conditions potassium struvite showed finite superiority due to its lower solubility with respect to closer equivalents (potassium superphosphate and sulphate) [41,47]. ION EXCHANGE INDUSTRY Ion exchange (IE) is a well established industrial technology. Despite strong competition of membrane technology (reverse osmosis, nanofiltration and electrodialysis), IE continues to play an important role in water treatment with specific reference to the power industry (condensate polishing), the electronic industry (ultrapure water >20 Mcm-1) and water conditioning generally in different industry sectors [52]. More than 50% of world IE application refers to natural water conditioning (i.e., softening, de-alkalization, demineralization, organic matter and colour removal, iron, manganese and nitrate removal as well as specific environmental applications with reference to heavy metals removal). Due to a smaller market demand beyond catalytic and molecular sieve applications, commercial availability of synthetic and natural zeolites is less developed than synthetic resins, limited essentially to specialised applications in the UK and USA. 1320 Figure 5. Overall economic comparison among three schemes proposed for P recovery from municipal sewage. Table 3. Cost summary for a 11,000 m3d-1 P removal and recovery plants based on the three proposed schemes (see Figure 4). Capital cost (¤ x 103) A B C c1 precipitation reactor 175 20 20 c2 ion exchange columns - 90 100 c3 resin inventory (*) - 120 144 c4 pumps 20 13 15 c5 vessels 15 10 17 c6 bag filtration unit 15 10 7 c7 electric plant 8 10 13 c8 piping and valves (10% c1-c7) 22.3 27.5 31.6 c9 installation (5% c1-c8) 12.3 15 17.4 c10 instrumentation (5% c1-c8) 12.3 15 17.4 c11 mounting and fittings (5% c1-c8) 12.3 15 17.4 c12 engineering (10% c1-c11) 28.2 34.5 40 310.0 380 440 (10 y, 5% y) 40 49.2 60 power (0.1 ¤kWh-1) 5.3 17.5 18 labour (1unit x 2shifts) 60 60 60 resin back-up (5% y c3) - 6 7.2 c15 maintenance (5% c1-c11) 14.2 19 20 213 258.7 336.9 Total investment Running cost (¤y-1 x 103) c13 amortisation c14 operation: chemicals (°) Total O&M cost Revenue (¤y-1 x 103) struvite 142.6 Net cost 213 258.7 194.3 Net unit cost (¤m-3) 0.053 0.064 0.048 (*) type Amberlite IRA 458 from Rohm&Haas Co.,USA (schemes B and C) type Zeolyst 13x18x80 from PQ Corporation,USA (scheme C) (°) FeCl3, PE (scheme A); NaCl, FeCl3 (scheme B); NaCl, MgCl2, NaOH (scheme C) Worldwide sales of ion exchange resins exceed 300 M¤ y-1 [52]. With an average unit cost for synthetic resins between 2,000 to 4,000 ¤ t-1 and assuming 10% annum for resins inventory, the associated business may be easily quantified. c) The Main Negative Features of IE Technology are: a) b) Relatively high cost (particularly with chemicals for resins regeneration) hardly acceptable for municipal wastewater treatment environmental impact related to disposal of resin regeneration eluates 1321 easy fouling of ion exchangers. The above limitations may be minimised through a "zero discharge" approach relying on maximum resin regeneration efficiency like the “closed loop” technique developed for the REM NUT process. This latter uses a “scavenger” strong base anion exchanger1, selected after extensive kinetic and thermodynamic investigation of the phosphate/sulphate/chloride multi-anion system extended to over 50 commercial anion exchangers. The updated version of this product is regularly marketed at average price (4,000 ¤ t-1) and exhibits improved kinetic behaviour and enhanced resistance to fouling. A novel ion exchanger with improved P-selectivity has been proposed quite recently [53] and contacts are in progress to evaluate applicability to the REM NUT process. As for the cation exchanger a clinoptilolite equivalent synthetic zeolite2 or a natural Phillipsite with improved selectivity toward NH4 ion have been identified, also exhibiting improved kinetic and thermodynamic performance [34]. These were preferred to the natural Clinoptilolite3 used in previous applications of the REM NUT process that, given the geographic localisation of extraction sites (Eastern Europe, Russia, USA), might be subject to market unavailability. It is hoped that development of the P-driven REM NUT process will potentially shed new business opportunities on the IE market, with reference to either the above mentioned products or to equivalent materials. The corresponding potential business for IE manufacturers in the next decade in the EU has been quantified at about a 10% increase in the world market on an annual basis [54]. In this context, IE manufacturers should welcome the Pdriven REM NUT process and be involved in any financing programme at demonstration and development level. type Amberlite IRA 458 from Rohm&Haas, Philadelphia, USA 2 type Zeolyst Molecular Sieve13x16x40 from PQ Corporation, NJ, USA 3 type 1010AO-2AQ from Anaconda Mines, Co.,CA,USA 1 CONCLUSIONS Deeper understanding and field testing of developing technology confirm that P-removal and recovery from sewage and animal waste may be feasible and cost effective, provided that tailor-made process design as well as plant operation and control are ensured. Legislative pressure on the level of P-removal from wastewater and P content in sludge on one side and economic drivers such as the wastewater industry striving for competition, new business opportunities for ion exchange market and depletion of good quality phosphate rock on the other are likely to increase general appeal of P-recovery schemes. On these premises conventional P recovery methods based on direct (pre-, sim-, post-) precipitation of insoluble phosphates by addition of polyvalent ions (Fe3+, Al3+, Ca2+ or their combination) to P-containing effluents of municipal, zootechnical or industrial origin are now being challenged by more engineered processes with higher efficiency and increased added value of by-products recovered. 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