Retrofitting Municipal Wastewater Treatment Facilities toward a Greener and Circular Economy by Virtue of Resource Recovery: Techno-Economic Analysis and Life Cycle Assessment

A promising route to transition wastewater treatment facilities (WWTFs) from energy-consuming to net energy-positive is to retrofit existing facilities with process modifications, residual biosolid upcycling, and effluent thermal energy recovery. This study assesses the economics and life cycle environmental impacts of three proposed retrofits of WWTFs that consider thermochemical conversion technologies, namely, hydrothermal liquefaction, slow pyrolysis, and fast pyrolysis, along with advanced bioreactors. The results are in turn compared to the reference design, showing the retrofitting design with hydrothermal liquefaction, and an up-flow anaerobic sludge blanket has the highest net present value (NPV) of $177.36MM over a 20-year plant lifetime despite 15% higher annual production costs than the reference design. According to the ReCiPe method, chlorination is identified as the major contributor for most impact categories in all cases. There are several uncertainties embedded in the techno-economic analysis and life cycle assessment, including the discount rate, capital investment, sewer rate, and prices of main products; among which, the price of biochar presents the widest variation from $50 to $1900/t. Sensitivity analyses reveal that the variation of discount rates causes the most significant changes in NPVs. The impact of the biochar price is more pronounced in the slow pyrolysis-based pathway compared to the fast pyrolysis since biochar is the main product of slow pyrolysis.