Environmental Management of Thermal Power Plant Solid Wastes: Characterization and Sustainable Valorization Strategies

Abstract

Thermal power facilities generate substantial quantities of solid waste during water purification and fuel burning processes, presenting significant challenges for environmental management and resource conservation. This investigation examines and characterizes solid wastes produced by an Egyptian thermal power installation, with focus on water treatment sludge containing aluminum compounds, spent granular activated carbon (GAC), depleted ion-exchange resins (IERs) of various classifications, and combustion residues. Currently, these materials are predominantly sent to landfills without utilization, representing a missed opportunity for resource recovery. This work presents waste generation patterns at an Egyptian thermal power facility and provides comprehensive characterization of these materials. Management approaches were evaluated to improve treatment efficiency, enhance recycling potential, and minimize waste generation, while exploring applications of these materials as suitable starting materials for manufacturing valuable products. The investigation tested environmentally responsible methodologies for waste valorization, including aluminum extraction from treatment sludge and potential reapplication of spent filtration carbon and ion exchange materials. These materials, previously utilized for water purification, have diminished in operational effectiveness over time. However, material analysis confirms retention of favorable porous structure characteristics, indicating potential for reuse. The water treatment operations integral to thermal power generation yield several waste streams with notable potential for CO₂ sequestration applications. Our findings demonstrate that Egyptian heavy fuel oil combustion residues present the highest environmental hazard due to elevated concentrations of potentially toxic metals, while simultaneously offering a unique source of valuable vanadium, nickel, and zinc, suggesting economic viability for metal recovery processes. The proposed resource recovery approaches provide pathways to improve environmental performance and operational efficiency in power generation through effective waste management practices and resource conservation.