Use of water treatment plant sludge in high-rate activated sludge systems: A techno-economic investigation

Coagulants such as aluminum sulfate (Al2(SO4)3 (alum)) and ferric chloride (FeCl3) used in water treatment plants (WTPs) led to the generation of sludge that is usually disposed to landfills. However, the utilization of WTP sludge is being encouraged by authorities to achieve sustainable development. This study aims to investigate WTP sludge utilization in a pilot-scale high-rate activated sludge (HRAS) system as a substitute for conventional coagulants. Based on jar tests, the iron sludge was selected for pilot-scale testing due to its superior ability to enhance the treatment efficiency of the HRAS process compared to alum sludge. Iron sludge addition (20.1 ± 1.6 mg dry sludge/L wastewater) slightly improved the removal efficiency of particulate chemical oxygen demand (pCOD) from 74 % to 81 % (p-value: 0.014). Iron sludge addition had a distinct effect on the sludge characteristics of the HRAS process. The average median particle size (d50) increased from 96 ± 3 to 163 ± 14 μm (p-value<0.00) with the addition of iron sludge, which improved the settleability of the HRAS process sludge. However, the biochemical methane potential (BMP) of the HRAS process sludge decreased by 8.9 % (p-value<0.00) after iron sludge addition. In a scenario analysis of WTP sludge use in a hypothetical HRAS plant, the effluent quality index (EQI), an indicator of environmental impact, was calculated and the cost related to the operation (the transfer and landfill disposal of WTP and HRAS process sludge, energy and chemical consumption of the HRAS plant) was estimated. As a result, using WTP sludge in the HRAS plant did not significantly affect the EQI of the plant but decreased overall cost by 11 %. The results showed that the use of WTP sludge as a coagulant in wastewater treatment could achieve mutual benefits for WTPs and WWTPs and have the potential to realize the circular economy model.