Sludge-derived hierarchically porous carbon electrode prepared via CaCO3-assisted dual crosslinking for enhanced phosphate electrosorption

[Display omitted] •ALE-based electrode for P removal was prepared by dual crosslinking and calcination.•ALE provided porous carbon network and CaCO3 regulated the hierarchical structure.•High P electrosorption capacity and low energy consumption were achieved at 1.2 V.•ZHPC-1-Ca had high stability in a wide pH range of 4–10 and 20 cyclic tests. Electrosorption is considered a promising technology to remove charged pollutants in an efficient and green way, wherein the electrode materials are crucial for achieving its high performance. In this study, a Zr-containing hierarchically porous carbon electrode (ZHPC-1-Ca) tailored for phosphate removal was synthesized based on alginate-like exopolysaccharides (ALE), a biomass extract of excess sludge. The gel-forming ability of ALE provided a basis for obtaining a conductive carbon matrix with well-dispersed metal active sites, and the pore structure of ALE-derived electrodes was simply regulated via a dual-crosslinking strategy. In the synthesis, CaCO3 acted as both the hard template and the crosslinker, while Zr facilitated pore formation during the secondary crosslinking process. ZHPC-1-Ca exhibited a maximum electrosorption capacity of 12.40 mg g−1 at 1.2 V, with a low energy consumption of 3.166 kWh kg−1-P. The electrosorption behavior was well fitted with the pseudo-first-order kinetics and the Langmuir isotherm model. Moreover, ZHPC-1-Ca maintained stable electrosorption performance under pH 4–10 and during twenty capture-release cycles (85.2%). The electrosorption mechanisms were primarily elucidated as electrostatic attraction, ligand exchange, and Lewis acid-base interaction, contributing to the enhanced and selective phosphate removal. This study achieves a simple and controllable synthesis of hierarchically porous carbon electrodes using sludge biopolymers, which extends the application of sludge-derived carbon in phosphate electrosorption.