Techno-economic assessment of a novel algal-membrane system versus conventional wastewater treatment and advanced potable reuse processes: Part II.

This study developed a comprehensive techno-economic assessment (TEA) framework to evaluate an innovative algae resource recovery and near zero-liquid discharge potable reuse system (i.e., the main system) in comparison with a conventional potable water reuse system (i.e., the benchmark system). The TEA study aims to estimate the levelized costs of water of individual units and integrated processes including secondary wastewater treatment, advanced water purification for potable reuse, and sludge treatment. This would provide decision-makers valuable information regarding the capital and operational costs of the innovative main system versus a typical potable water reuse treatment train, along with possible routes of cost optimization and improvements for the design of full-scale facilities. The main system consists of (i) a novel algal-based wastewater treatment coupled with a dual forward osmosis and seawater reverse osmosis (Algal FO-SWRO) membranes system for potable water reuse and hydrothermal liquefaction (HTL) to produce bioenergy and subsequent nutrients extraction from the harvested algal biomass. The benchmark system includes (ii) an advanced water purification facility (AWPF) that consists of a conventional activated sludge biological treatment (CAS), microfiltration (MF), brackish water reverse osmosis (BWRO), ultraviolet/advanced oxidation process (UV-AOP), and granular activated carbon (GAC), with anaerobic digestion for sludge treatment. Capital expenditures (CAPEX) and operational expenditures (OPEX) were calculated for each unit of both systems (i.e., sub-systems). Based on a 76% overall water recovery designed for the benchmark system, the water cost was estimated at $2.03/m3. The highest costs in the benchmark system were found on the CAS and the anaerobic digester, with the UV-AOP combined with GAC for hydrogen peroxide (H2O2) quenching as the driving factor in the increased costs of the system. The cost of the main system, based on an overall 88% water recovery, was estimated to be $1.97/m3, with costs mostly driven by the FO and SWRO membranes. With further cost reduction and optimization for FO membranes such as membrane cost, water recovery, and flux, the main system can provide a much more economically viable alternative in its application than a typical benchmark system.

Life cycle energy use and greenhouse gas emissions for a novel algal-osmosis membrane system versus conventional advanced potable water reuse processes: Part I.

This study applied a life cycle assessment (LCA) methodology for a comparative environmental analysis between an innovative algae resource recovery and near zero-liquid discharge potable reuse system (i.e., the main system) versus a conventional potable reuse system (i.e., the benchmark system) through energy use and greenhouse gas (GHG) emissions. The objective of this study is to demonstrate that pilot-scale data coupled with LCA would provide valuable information for system optimization, integration, and improvements for the design of environmentally sustainable full-scale systems. This study also provides decision-makers valuable information regarding the energy demand and environmental impact of this innovative main system compared to a typical tried-and-true system for potable water reuse. The main system consists of a novel algal-based wastewater treatment coupled with a dual forward osmosis and seawater reverse osmosis (Algal FO-SWRO) membranes system for potable water recovery and hydrothermal liquefaction (HTL) to recover biofuels and valuable nutrients from the harvested algal biomass. The benchmark system refers to the current industry standard technologies for potable water reuse and waste management including a secondary biological treatment, microfiltration (MF), brackish water reverse osmosis (BWRO), ultraviolet/advanced oxidation process (UV-AOP), and granular activated carbon (GAC), as well as anaerobic digestion for sludge treatment. Respective energy and GHG emissions of both systems were normalized and compared considering 1 m3 of water recovered. Based on an overall water recovery of 76% designed for the benchmark system, the energy consumption totaled 4.83 kWh/m3, and the system was estimated to generate 2.42 kg of CO2 equivalent/m3 with most of the emissions coming from the biological treatment. The main system, based on an overall water recovery of 88%, was estimated to consume 4.76 kWh/m3 and emit 1.49 kg of CO2 eq/m3. The main system has high environmental resilience and can recover bioenergy and nutrients from wastewater with zero waste disposal. With the application of energy recovery devices for the HTL and the SWRO, increase in water recovery of the FO membrane, and replacement of the SWRO membrane with BWRO, the main system provides an energy-competitive and environmentally positive alternative with an energy demand of 2.57 kWh/m3 and low GHG emissions of 0.94 kg CO2 eq/m3.

Techno-economic optimization of phosphorous recovery in an algal-based sewage treatment system.

Previous reports have documented the technical viability of an algal pathway for treating primary effluent and recovering its phosphorus-content (P) via hydrothermal liquefaction (HTL) of the resulting biomass. In this pathway, leaching P from HTL-derived biochar was found as the critical step impacting the economics of P-recovery. As such, a process model was developed in the current study to optimize P leaching from biochar as a function of five parameters. Model predictions under various conditions agreed well with measured data (r2 = 0.93; n = 184). The validated process model was then integrated with a cost model to establish the following conditions as optimal for leaching P from biochar: batch leaching time of 72 h; eluent NaOH concentration of 0.5 M; eluent-to-biochar ratio of 20; temperature of 60 °C; and provision of mixing. Under these conditions, 73.5% of P from biochar could be recovered at $5.98/kg P.

Biofertilizer recovery from organic solid wastes via hydrothermal liquefaction.

Hydrothermal liquefaction (HTL) has emerged as a viable pathway for processing wet organic solid wastes (OSW) to yield biocrude oil which could be upgraded to transportation fuels and specialty chemicals. The HTL process results in two byproducts laden with high levels of carbon, nitrogen, and phosphorous. Recovery of phosphates in the byproducts as struvite and ammoniacal-nitrogen (NH4-N) as ammonium sulfate is proposed here as a promising pathway to utilize the HTL byproducts. A case study of this pathway using algal biomass as a model OSW yielded 8.2 g struvite/100 g OSW and 10.7 g ammonium sulfate/100 g OSW. Heavy metal levels in both struvite and ammonium sulfate crystals were below EPA regulations for land application. This biofertilizer recovery pathway could render OSW processing by HTL a greener alternative to anaerobic digestion, offering feedstock versatility, substantially smaller footprint, and a higher degree of OSW valorization.

Removal and recovery of nutrients from municipal sewage: Algal vs. conventional approaches.

This paper presents a pilot scale study of an algal-based sewage treatment and resource recovery (STaRR) system capable of treating municipal sewage and recovering its nitrogen- and phosphorous-content as fertilizer. Core components of the STaRR system include i) mixotrophic cultivation of algal biomass in settled sewage; ii) hydrothermal liquefaction (HTL) of the resulting algal biomass, and iii) processing of the products of HTL to recover energy in the form of biocrude and nutrients in the form of struvite. Performance of a pilot-scale STaRR system in recovering nitrogen (N) and phosphorus (P) from settled sewage as struvite is documented and compared with that of existing and emerging technologies. Nutrient removal per unit energy input in the STaRR system is estimated as 257.1 g N/kWh and 36.6 g P/kWh while that in eight full-scale sewage treatment plants (STPs) averaged 74.3 g N/kWh and 135.1 g P/kWh. Energy required to treat primary effluent in the STaRR system (531.5 kWh/MG) is estimated to be lower than the average in the 8 STPs (1,037.9 ± 503.3 kWh/MG). While existing technologies had been originally designed for removal of nutrients rather than any recovery, a review of the literature revealed 12 emerging technologies for nutrient recovery. Nutrient recovery performance of the STaRR system (5.9% N and 71.6% P) is shown to be superior to that of those 12 emerging technologies. Recoveries recorded in the STaRR system translate to a yield of 2.4 kg struvite per 100 m3 of primary effluent. Results of this study imply that the STaRR system deserves due consideration as a greener and sustainable pathway for nutrient removal and recovery from sewage.