Carbon-rich and low-ash hydrochar formation from sewage sludge by alkali-thermal hydrolysis coupled with acid-assisted hydrothermal carbonization.

[Display omitted] • Carbon-rich and low-ash hydrochars is prepared innovatively from sewage sludge. • Hydrochar produced from sludge alkaline hydrolysate showed nanoparticle structure. • Multilayer microsphere structure was formed from sludge alkali-thermal hydrolysate. • Hydrochar with carbon content over 70% and ash content less than 5% was realized. • Hydrolysis temperature is an important factor to influence the hydrochar formation. The production of carbon-rich and low-ash hydrochar from sewage sludge is attracting interest due to its great application prospect in high value-added carbon materials fields, but which is impossible through direct hydrothermal carbonization. In this study, alkali-thermal hydrolysis followed by acid-assisted hydrothermal carbonization was thus proposed. Thermal hydrolysis at strong alkaline environment was more effective than acid one to promote the dissolution of organic matters and restrain the release of inorganic matters from sludge, which created a favorable condition for hydrochar formation in a carbon-rich and low-ash way. Alkali-thermal hydrolysis began to show a positive effect on the dissolution of organics in sludge when temperature exceeded the threshold of 90 °C, and an increase of 9.77 % was found at 150 °C when compared to 30 °C. Acid-assisted hydrothermal carbonization of alkali-thermal hydrolysate (ATH) at pH 1.0 strongly promoted condensation polymerization of dissolved organics to form hydrochar and meanwhile inhibited introduction of dissolved inorganics. The nanosized microparticulate hydrochar derived from ATH-30 had a carbon and ash content of 50.98–61.31 % and 10.76–12.09 %, while the micro-sized microspheric hydrochar with multiple deposition layers formed from ATH-150 showed a better performance in carbon-rich and low-ash aspect where a carbon and ash content of 58.24–70.07 % and 0.40–3.24 % was realized, both of which were obviously superior to the direct hydrochar (carbon 34.86 % and ash 46.11 %). The condensation of dissolved organics during alkali-thermal hydrolysis stage is important to the carbonization degree of hydrochar. This study provides a new perspective in sludge disposal and production of advanced carbon materials. [ABSTRACT FROM AUTHOR]