Phosphorus recovery from waste activated sludge by sponge iron seeded crystallization of vivianite and process optimization with response surface methodology

As a novel phosphorus recovery product, vivianite (Fe3(PO4)2·8H2O) has attracted much attention due to its enormous recycling potential and foreseeable economic value. Taking sponge iron as seed material, the effect of different reaction conditions on the recovery of phosphorus in waste activated sludge by vivianite crystallization was studied. Through single factor tests, the optimal conditions for vivianite formation were in the pH range of 5.5–6.0 with Fe/P molar ratio of 1.5. Scanning electron microscopy (SEM), powder X-ray diffraction (XRD), and energy dispersive spectroscopy (EDS) were used to analyze the components of the crystals. The results showed that the vivianite produced by sponge iron as the seed crystal were larger and thicker (300–700 μm) than other seed (200–300 μm) and without seed (50–100 μm). Moreover, vivianite, which was synthesized with sponge iron as seed, was obviously magnetic and could be separated from the sludge by rubidium magnet. The Box-Behnken design of the response surface methodology was used to optimize the phosphorus-recovery process with sponge iron (maximum phosphorus recovery rate was 83.17%), and the interaction effect of parameters was also examined, pH had a significant effect on the formation of vivianite. In summary, this research verifies the feasibility of using sponge iron as the seed crystal to recover phosphorus in the form of vivianite from waste activated sludge, which is conducive to the subsequent separation and utilization of vivianite.