The sewage sludges are the byproducts of the wastewater treatment. The new perspective of the wastewater value chain points to a sustainable circular economy approach, where the residual solid material produced by sewage sludge treatments is a resource rather than a waste. A sewage sludge treatment system consists of five main phases; each of them can be performed by different alternative processes. Each process is characterized by its capability to recover energy and/or matter. In this paper, a state of the art of the sludge-to-energy and sludge-to-matter treatments is provided. Then, a scenario analysis is developed to identify suitable sewage sludge treatments plants that best fit the quality and flowrate of sewage sludge to be processed while meeting technological and economic constraints. Based on the scientific literature findings and experts’ opinions, the authors identify a set of reference initial scenarios and the corresponding best treatments’ selection for configuring sewage sludge treatment plants. The scenario analysis reveals a useful reference technical framework when circular economy goals are pursued. The results achieved in all scenarios ensure the potential recovery of matter and/or energy from sewage sludges processes.

Wastewater treatment (WWT) is a foremost challenge for maintaining the health of ecosystems and human beings; the waste products of the water-treatment process can be a problem or an opportunity. The sewage sludge (SS) produced during sewage treatment can be considered a waste to be disposed of in a landfill or as a source for obtaining raw material to be used as a fertilizer, building material, or alternative fuel source suitable for co-incineration in a high-temperature furnace. To this concern, this study’s purpose consisted of developing a decision model, supported by an Artificial Neural Network (ANN model), allowing us to identify the most effective sludge management strategy in economic terms. Consistent with the aim of the work, the suitable SS treatment was identified, selecting for each phase of the SS treatment, an alternative available on the market ensuring energy and/or matter recovery, in line with the circular water value chain. Results show that the ANN model identifies the suitable SS treatments on multiple factors, thus supporting the decision-making and identifying the solution as per user requirements.

The steelmaking processes are considered extremely energy-intensive and carbon-dependent processes. In 2018, it was estimated that the emissions from global steel production represented 7–9% of direct emissions generated by fossil fuels. It was estimated that a specific emissions value of 1.8 tCO₂ per ton of steel was produced due to the carbon-dependent nature of the traditional blast furnace and basic oxygen furnace (BF-BOF) route. Therefore, it is necessary to find an alternative solution to the BF-BOF route for steel production to counteract this negative trend, resulting in being sustainable from an environmental and economic point of view. To this concern, the objective of this work consists of developing a total cost function to assess the economic convenience of steelmaking processes considering the variability of specific market conditions (i.e., iron ore price, scraps price, energy cost, etc.). To this purpose, a direct reduction (DR) process fueled with natural gas (NG) to feed an electric arc furnace (EAF) using recycled steel scrap was considered. The approach introduced is totally new; it enables practitioners, managers, and experts to conduct a preliminary economic assessment of innovative steelmaking solutions under market uncertainty. A numerical simulation has been conducted to evaluate the profitability of the investment considering the economic and environmental costs. It emerged that the investment is profitable in any case from an economic perspective. On the contrary, considering the environmental costs, the profitability of the investment is not guaranteed under certain circumstances.

The need to significantly reduce emissions from the steelmaking sector requires effective and ready-to-use technical solutions. With this aim, different decarbonization strategies have been investigated by both researchers and practitioners. To this concern, the most promising pathway is represented by the replacement of natural gas with pure hydrogen in the direct reduced iron (DRI) production process to feed an electric arc furnace (EAF). This solution allows to significantly reduce direct emissions of carbon dioxide from the DRI process but requires a significant amount of electricity to power electrolyzers adopted to produce hydrogen. The adoption of renewable electricity sources (green hydrogen) would reduce emissions by 95–100% compared to the blast furnace–basic oxygen furnace (BF–BOF) route. In this work, an analytical model for the identification of the minimum emission configuration of a green energy–steel system consisting of a secondary route supported by a DRI production process and a renewable energy conversion system is proposed. In the model, both technological features of the hydrogen steel plant and renewable energy production potential of the site where it is to be located are considered. Compared to previous studies, the novelty of this work consists of the joint modeling of a renewable energy system and a steel plant. This allows to optimize the overall system from an environmental point of view, considering the availability of green hydrogen as an inherent part of the model. Numerical experiments proved the effectiveness of the model proposed in evaluating the suitability of using green hydrogen in the steelmaking process. Depending on the characteristics of the site and the renewable energy conversion system adopted, decreases in emissions ranging from 60% to 91%, compared to the BF–BOF route, were observed for the green energy–steel system considered It was found that the environmental benefit of using hydrogen in the secondary route is strictly related to the national energy mix and to the electrolyzers’ technology. Depending on the reference context, it was found that there exists a maximum value of the emission factor from the national electricity grid below which is environmentally convenient to produce DRI by using only hydrogen. It was moreover found that the lower the electricity consumption of the electrolyzer, the higher the value assumed by the emission factor from the electricity grid, which makes the use of hydrogen convenient.