Environmental Technology, Vol. 22. pp 1279-1286 © Selper Ltd, 2001 ASSESING THE POTENTIAL FOR STRUVITE RECOVERY AT SEWAGE TREATMENT WORKS S. A. PARSONS1*, F. WALL1, J. DOYLE1, K. OLDRING2 AND J. CHURCHLEY2 1School of Water Sciences, Cranfield University, Cranfield, Bedfordshire, U.K Trent Water Ltd, Avon House, St Martins Road, Coventry, U.K. 2Severn (Received 12 February 2001; Accepted 30 April 2001) ABSTRACT Struvite in wastewater treatment plants was identified as early as 1939. Problems with struvite formation date back to the 1960s when it was noticed at the Hyperion treatment plant, Los Angeles. Operators at the plant noticed crystalline deposits on the underside of post digestion screens. The digested sludge stream was diluted and it was thought the problem was solved, until five years later when the normal gravity flow of digested sludge had decreased to such a stage that pumping was required. This paper reports the findings of a series of experiments undertaken to identify the potential of recovering struvite from sludge liquors. Seven sludge treatment works (STW) have been investigated including one detail. A number of the works has the potential to form over 100 mg l-1 of struvite. Keywords: Phosphorus removal, phosphorus recovery, struvite, scaling, sludge liquors. INTRODUCTION Since the implementation of the EC Urban Waste Water Treatment Directive, (UWWTD) 97/271/EC (21st May 1991) a number of fundamental changes in wastewater treatment have occurred [1]. Two of the changes directly impact upon water companies’ treatment of sludge produced from wastewater treatment facilities Dumping of sewage sludge at sea is now prohibited. Nitrogen and phosphorus limits have been imposed to reduce the potential of eutrophication of sensitive inland and coastal waters. The removal of compounds containing nitrogen and phosphorus is a key element of the UWWTD and is intended to reduce and prevent eutrophication of sensitive inland and coastal waters. Eutrophication can be defined in two ways: either the result of over fertilisation of aquatic environments, with anthropogenic inputs being the cause [2]; alternatively a natural phenomenon which increases the organic load in a lake due to increased nutrients. With more stringent standards imposed regarding nutrient removal, processes have been developed to remove compounds containing nitrogen and phosphorus. The result of removing greater concentrations of phosphorus from the wastewater is that the wasted sludge has a greater concentration of phosphorus, nitrogen and magnesium (Table 1). This combination of ions found in sludges produced from nutrient removal, specifically biological nutrient removal (BNR) processes, can result in the formation of a mineral called struvite. Struvite is a white crystalline substance consisting of magnesium, ammonium and phosphorus in equal molar concentrations (MgNH4PO4.6H2O). Struvite forms according to the reaction shown below. 2 Mg 3 NH4 PO4 6 H2O MgNH4 PO4 (H2O)6 Struvite has a distinctive orthorhombic crystal structure and can be identified via X-ray diffraction (XRD) by matching the 1279 Table 1. Comparison of BNR and activated sludges. Parameters Units BNR sludge Activated sludge Total-COD Total Solids Total Nitrogen Total Phosphorus Soluble Phosphorus mg l-1 mg l-1 mg l-1 mg l-1 mg l-1 15320 12620 486 335 55 13640 11080 399 143 34 Total Calcium Total Magnesium pH mg l-1 mg l-1 mg l-1 686 108 7.2 247 39 7.4 intensity and position of the peaks produced to a database for the crystal structure. The crystal habit and polarity are discussed in detail elsewhere [3]. Struvite precipitation can be separated into two stages: nucleation and growth. Nucleation occurs when constituent ions combine to form crystal embryos. Crystal growth continues until equilibrium is reached and in systems continuously replenished with struvite constituents; e.g. wastewater treatment plants, crystal growth continues indefinitely. Struvite precipitation is controlled by pH, supersaturation, temperature and the presence of impurities such as calcium [4] and can occur when the concentrations of Mg2+, NH4+ and phosphate ions PO43- exceed the solubility product (Ksp ) for struvite. The Ksp is given by the following expression: Ksp = [Mg 2+] [NH4+] [PO43-] The relationship between Ksp and pH indicates that struvite solubility decreases with increasing pH, which in turn leads to an increase in the struvite precipitation potential (SPP) of a water. The recovery of struvite has recently become an issue at wastewater treatment works. This is because of two reasons (i) it is a possible resource which has potential use as a fertiliser and (ii) recovering struvite can lead to reduced problem with struvite fouling which is a major problem in wastewater treatment plants. Natural sources of struvite include guano deposits and cow manure and it has been shown to be a highly effective source of nitrogen, magnesium and phosphorus for plant foliage and soil applications. Struvite can be recovered from wastewater and sludges etc. if the chemical constituents of the sludge are such that the K sp value is exceeded. A range of processes has been used to recover struvite including fluidised bed reactors and pellet reactors, Table 2. In all of these processes the precipitation is Table 2. Examples of P recovery at bench, pilot and full scale. Reference Scale Source Method P removal [16] [17] Waki et al., 1987 Somiya et al., 1989 bench aeration aeration /pH 88% after 120 mins >90% at pH 9.5 [13] Ohlinger et al., 2000 bench FBR digester liquor synthetic digester liquors digester liquor >80% [18] Kabdasli et al., 2000 bench textile waste aeration + seed crystals aeration [19] Lind et al., 2000 bench human urine [20] [26] Webb and Ho 1992 Munch and Barr, 2001 Matsumiya et al., 2000 Battistoni et al., 1998 bench pilot reactor piggery waste dewatering liquors Pilot scale reactor belt liquors pilot FBR belt press liquors digester liquor aeration 80% NaOH/MgCl2 >90% digester liquor NaOH/MgCl2 aeration ~90% removal at 1.5 Mg:P 61.7–89.6 % removal of PO43>90% [21] [12] [22] [23] Yamamoto et al., pilot reactor 1988 Suigimori et al., 1995 pilot reactor [27] Battistoni et al., 2001 full scale FBR [14] Taruya et al., full scale FBR belt press liquors dewatering liquors [24] Susckha et al., 2000 bench/full scale dewatering liquors 1280 adsorption on to zeolite MgSO4/NaOH aeration /pH/ MgOH2 seawater MgCl2/MgOH2 1-2 Mg:P aeration ~90% removal of NH3 65-80% removal of NH3 94% >70% - [15] Jaffer et al., 2001 bench FBR/full centrifuge liquors achieved by either (i) pH changes or (ii) concentration changes or both. The pH is changed either by dosing base in the form of NaOH or MgOH2 or by aeration of the liquors to degas the solution. The second method to initiate precipitation is to increase the concentration of one of the constituent ions, usually Mg, so that the driving force for precipitation in promoted. Struvite scale problems were first identified in wastewater treatment plants as early as 1939 [5]. Whilst studying digestion Rawn (1939) found crystalline material identified as struvite, in the digested sludge supernatant lines. Problems with struvite formation date back to the 1960s when it was noticed at the Hyperion treatment plant, Los Angeles [6]. Operators at the plant noticed crystalline deposits on the underside of post digestion screens. The digested sludge stream was diluted and it was thought the problem was solved, until five years later when the normal gravity flow of digested sludge had decreased to such a stage that pumping was required. The pipeline had diminished in size from twelve inches in diameter to six [6]. Benisch et al. identified annual costs related to struvite scales typically range between $2,000 and $10,000 per MGD of secondary dry weather capacity for the majority of treatment plants with anaerobic digesters [7]. It is therefore essential to identify sites where scale may become or already is a problem and identify preventative methods. This paper assesses the potential for forming struvite at a number of sewage treatment works and reviews the processes available to recover pure reusable material. MATERIALS AND METHODS Mass Balance Six sewage works in the Severn Trent Water region were selected to assess the impact of sludge treatment, water hardness and treatment process on scale formation. Weekly samples of digester feed sludge, digested sludge and centrate liquors were collected over a six-week period. Computer Simulations A commercially available computer model (Struvite version 3.1) developed by R. E. Loewenthal and I. Morrison of the Department of Civil Engineering, Cape Town, South Africa, was used to predict the SPP based upon the chemistry of the water tested. This model was based upon research incorporating a number of equations involving ionic equilibria and ion activity coefficients. The computer software model was used to assess the formation of struvite at seven sewage works and why these may be particularly prone to struvite precipitation . The computer model required the total NaOH/MgCl2 97% concentrations of magnesium, ammonia species and inorganic phosphorus as well as alkalinity, pH, temperature and partial pressure of carbon dioxide. From these data the SPP was calculated. Formation and Dissolution Experiments A jar tester (Phipps and Bird PB-900) was used in a series of experiments to investigate the formation of struvite in liquors taken from Coleshill sludge distruction plant (SDP). X-ray diffraction (XRD) analysis was used to identify the precipitates formed with inductively coupled plasma (ICP) analysis applied in a series of dissolution experiments to compare and determine the purity of magnesium and phosphorus in the precipitates formed. Again the computer model was applied to predict the SPP based upon the chemistry of the water tested. Impact of Turbulence upon pH in real Liquors. A 1-litre sample of centrate liquor was placed in a jar and mixed at 300 rpm in an attempt to produce turbulent conditions. A pH probe and stopwatch were used to measure the change in pH over time. The pH meter was first calibrated and fixed in the solution to prevent movement and damage. RESULTS AND DISCUSSION Struvite Formation The SPP for each sampling point was calculated using a computer model called Struvite (Version 3.1). This model was developed for the Water Research Commission, South Africa [8]. A series of experiments were undertaken with real sludge liquors to test whether the computer software model could predict struvite formation. The masses of precipitate formed were calculated from the ICP data gained from the remaining magnesium and phosphorus concentrations in the real liquors (Figure 1). The formation of struvite based upon the data input into the computer model initially occurs at a pH of 7.1. In comparison struvite formation was not observed in both real and synthetic liquors until a pH of 7.5 was reached. The mass of precipitates formed appears to display a more linear relationship with respect to pH than the model predicts. The synthetic data generated from the previous jar tests regarding the mass of struvite formed displays a closer relationship to the data generated from the real liquors. The trendline plotted from the synthetic data had an R2 value of 0.93. Trendlines plotted for the masses of struvite formed from real liquors based upon magnesium and phosphorus concentrations remaining in solution produced R2 values of 0.75 and 0.82 respectively. The model whilst useful does tend to under predict the 1281 formation of struvite formation and this must be considered when looking at the potential for recovery. The model was used to assess the potential for formation and hence recovery has been investigated at seven Sewage Works Assessment Figure 1. Comparison of the Struvite model with actual sludge liquors. Severn Trent Water sites. Six sewage treatment works and one sludge destruction plant have been assessed for their potential to form calcite and struvite scales. Three of the works (Coleshill, Wanlip and Mansfield) are known to suffer from scale formation although only, Coleshill had previously been identified as having a struvite scale problem [9]. The chemistry of the sludge liquors is compared in Table 3. The works selected cover a range of pH, hardness and phosphate concentrations. The Struvite model was used to compare the precipitation potential of both calcite and struvite for all seven liquors (Table 4). The impact of chemical phosphorus removal on struvite Table 3. Average levels of selected determinants in settled sludge liquor. Determinant (mg l-1) Barston Coleshill Mansfield Milcote Oswestry Spernal Wanlip pH Total dissolved solids Alkalinity Ammonia Calcium Magnesium Orthophosphate 7.6 1425 2226 523 257 46 2 7.9 1200 3382 888 94 19 96 7.9 902 3700 872 123 52 65 7.5 1360 1883 426 165 34 9 7.2 622 2795 658 185 31 80 7.6 2323 3267 660 321 53 8 7.7 918 3267 957 188 41 99 Table 4. Comparison of average struvite and calcite precipitation potential. Site Barston Coleshill Mansfield Milcote Struvite formation potential (mg l-1) Calcite formation potential (mg l-1) -102 99 64 -56 183 -117 100 79 1282 Oswestry Spernal Wanlip 72 -80 177 formation can be seen by comparing the precipitation potential of Spernal and Barston which have iron dosing and Milcote that has aluminium dosing. Unlike BNR sludges which release phosphorus during digestion in chemical sludge the phosphorus is bound and stays within the sludge. This is clear when comparing the phosphorus levels in the sludge liquors (<10 mg l-1) with that of a BNR sludge, 282 mg l-1 [10]. Therefore for all of these works the potential for forming struvite is significantly reduced and the model predictions were always negative for struvite precipitation. Whilst the chemical phosphorus removal had a significant effect on struvite formation it had little effect on the potential to form calcite. Spernal has the greatest propensity of all works sampled to form calcite, as high as 500 mg l -1, and calcite scale has been identified (by XRD) in the liquor pumps leading to a 20% loss in efficiency. Table 5. Site Barston Coleshill Mansfield Milcote Oswestry Spernal Wanlip Potential value of sludge liquor streams. Struvite formation potential (mg l-1) @ pH 8.5 Value*p/m3 liquor 2 105 237 13 162 16 222 0.14 7 16 0.9 11 0.17 15 28 230 128 Effect of pH pH is the main driving force behind the formation of both calcite and struvite. As the pH is increased then so does the potential to form both minerals (Table 5). The liquor samples collected are only snapshots of what is happening at a sewage treatment works so it is important to consider what happens through the processes. Pumping or aerating sludge liquors has the effect of degassing the solution and removing CO2. This degassing can lead to localised increases in pH by as high as 1 pH unit. Ohlinger et al. showed how increasing turbulence leads to CO2 liberation, an increase in pH and hence an increase in struvite precipitation [11]. The time taken for struvite crystals to nucleate is termed the induction time and this is affected by turbulence where a doubling in mixing speed leads to a halving of the induction time. Samples of liquors from Wanlip and Barston were aerated to show what effect degassing could have on liquor pH. As the liquor is aerated the pH raises from ~ 7.5 to 8.5. Liquors from Coleshill were stirred to degas them. Figure 2 shows the effect of stirring on Coleshill liquors at a range of different alkalinities. This pH change has a significant effect on the potential to form both calcite and struvite scales. For example increasing the pH of Barston liquor to 8.5 raised the precipitation potential to 222 mg l-1 of struvite. The same pH increase for Wanlip led to an increase in the calcite precipitation potential to 616 mg l-1. A number of researchers have used CO2 stripping to preferentially precipitate struvite as a means to recover phosphorus (see Table 2) including Battistoni et al. who aerated BNR centrate liquors, *Value – potential value of struvite £670/tonne 1283 Figure 2. Effect of stirring on the pH of different alkalinity Coleshill centrifuge liquors. Table 6. Comparison of sludge and liquor streams at Slough STW, UK [15]. Stream P-PO4 mg l-1 NH4 mg l-1 Mg mg l-1 Ca Alk pH mg l-1 mg l-1 Temp SPP mg l-1 Thickened SAS Belt Liquor Digested sludge Centrifuge Liquor Centrifuge Cake Crude sewage Settled sewage Effluent C Effluent A 14.2 14.2 389 1.6 482 11 NA 121 50.7 6.9 285.8 7.3 18.3 17.2 -21 -342 154 94.9 1166 615 153 44 NA 56 98.8 2580 7.3 7.6 26.8 24.1 198 140 94.9 5.7 5.7 5.6 0.6 4477 16.1 23.9 0.8 1.4 1049 8.9 8 8.1 6.7 NA 118 111 109 112 482 360 356 199 268 7.0 7.9 7.7 8.2 7.6 NA 14 14 13.4 13 420 -341 -352 -276 -440 precipitating struvite and recovering 80% of phosphorus from the liquor [10,12]. Recovery of Struvite Recovery experiments have typically been undertaken with sludge liquors. Jaffer et al., compared liquid and sludge streams from Slough sludge treatment works (STW), UK [15]. They identified those streams that had the greatest potential for struvite formation (Table 6). Whilst the digested sludge and centrifuge cake had the highest potential they contain mainly solids making recovery very difficult. The digested sludge liquors were chosen to be the best option for recovery. The evaluation of digested sludge liquors from the seven STW reported here showed that 4 out of the seven works consistently had the potential to form over 100 mg l -1 of struvite. A range of processes have been investigated to recovery struvite [10-27], Table 2. Experiments have been undertaken on bench, pilot and full scale and precipitation is usually encouraged by changing the pH by either dosing base in the form of NaOH or MgOH2 or by aeration of the liquors to degas the solution. The second method to initiate precipitation is to increase the concentration of one of the constituent ions, usually Mg, so that the driving force for precipitation in promoted. Some authors have used magnesium hydroxide as a source of magnesium ions and to raise the pH. Salutsky et al., 1284 achieved 90% phosphorus recovery with magnesium hydroxide addition, but at a temperature of 25oC [25]. Munch and Barr also used magnesium hydroxide as a dual function chemical and obtained an average of 94% phosphorus removal as struvite [26]. However, using magnesium hydroxide to serve both functions means that the magnesium dose or the pH can not be optimised independently of each other. The Phosnix process uses magnesium hydroxide, but also has sodium hydroxide addition to control the pH. The sodium hydroxide requirement is less with magnesium hydroxide, than with magnesium chloride [14]. An advantage of using magnesium chloride over magnesium hydroxide is that magnesium chloride disossociates faster than magnesium hydroxide, resulting in shorter reaction times. A shorter reaction time means a smaller full-scale reactor can be constructed as the hydraulic retention time can be reduced. Some authors have managed to crystallise phosphorus from wastewater without the addition of any chemicals. Battistoni et al., (1997) removed 80% of phosphorus from belt press liquors, from a treatment plant that had nitrification, denitrification and anaerobic digestion [10]. The liquors were aged and air stripped to remove carbon dioxide. The pH was raised from 7.9 to 8.3-8.6 and the phosphorus was removed as struvite. The liquor had a very high Mg:P ratio of 3.7 : 1, so did not require magnesium addition. However, when the work was repeated with centrate liquor from a biological nutrient removal plant, phosphorus removal was achieved as a mixture of struvite and hydroxyapatite. The Mg:P ratio had decreased to 0.22:1 and was no longer sufficient to exclusively form struvite [12]. Recently 10% seawater (containing 1250 mg l-1) has been used as the magnesium source at a pilotplant [21]. Typical processes used are fluidised bed reactors (FBR) or pellet reactors, where the material is collected as small solid pellets. There are a number of full scale plants operating across the world, the largest of which are in Japan. The three main plants operating are situated at Shimane Prefecture (500 m3 day-1), Fukuoka Prefecture (170 m3 day-1) and at Osaka South Ace Centre (266 m3 day-1). They each use magnesium addition (magnesium hydroxide or chloride) and pH adjustment (to pH 8.1 – 8.9) to cause struvite precipitation. The fine crystals of struvite formed are grown to 0.5-1 mm granules by air stirring or recirculation stirring over an average 10 day residence time. The extracted granules are separated (fine crystals are returned to the reactor) and either left to stand or air-dried down to 10% water content. The Shimane Prefecture reactor removes 90% of soluble phosphates from the treated liquors. The recovered struvite is sold as a quality fertiliser for 1 – 200,000 Euros tonne-1. In Trevisio, Italy, a full scale FBR is being used to treat dewatering liquor from the belt press treating anaerobic digester sludge from an 85,000 pe sewage works (Figure 3). The plant has recently been commissioned. P removals as high as 86% have been reported using just aeration [27]. It is clear that processes exist to recover struvite from sludge liquors. The assessment of the seven sludge liquors reported here shows that those works without chemical phosphorus removal all have the potential to form struvite in concentrations up to 237 mg l-1. If left untreated this will lead to fouling problems. CONCLUSIONS Many STW in the UK have the potential to form struvite at reasonable concentrations (>100 mg l-1). Digester sludge liquors typically have the highest potential to form struvite although this is usually limited by the magnesium concentration in the liquor. 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