Slow pyrolysis is a promising technology to convert sewage sludge into char: a stable solid product with high carbon and phosphorus content. However, due to its heavy metals content, char use in agriculture is avoided in many European Union (EU) countries. This study aimed to test a solution, based on integrating slow pyrolysis and chemical leaching, to separate phosphorus and other inorganics from char, obtaining an inorganic P-rich fertiliser and a C-rich solid usable for industrial purposes. The sludge was first characterized and then processed in a 3 kg/h slow pyrolysis reactor at 450 °C for 30 min. The resulting char was processed by chemical leaching with acid (HCl, HNO₃) and alkali (KOH) reagents to extract inorganic compounds. To optimize the inorganic extraction, three case studies have been considered. The char obtained from sewage sludge pyrolysis contained around 78% d.b. (dry basis) of inorganics, 14% d.b. of C, 14% d.b. of Al, and almost 5% d.b. of P. The leaching tests enabled to extract 100% of P, Mg, and Ca from the char. The remaining char contained mainly carbon (27%) and silica (42%), with a surface area of up to 70 m²/g, usable as adsorbent or precursor of sustainable materials.

The cost and environmental impact of sludge disposal methods highlight the necessity of new solutions for resource recovery. This study aims at concurrently producing activated carbon while recovering phosphorous by applying an integrated thermo-chemical treatment to a sludge of industrial origin. The sludge was first subjected to slow pyrolysis on a laboratory scale at different temperatures, and the produced chars were processed by leaching to obtain biocoal. Leaching tests enabled us to define the optimal slow pyrolysis temperatures to maximize leaching performances. Then, sludge was processed in a slow pyrolysis pilot-scale plant, and the produced char was subjected to acid leaching and finally to physical activation. Chemical precipitation was then applied to the liquid leachate to recover phosphorous as a salt. Laboratory-scale slow pyrolysis and leaching tests showed that a higher pyrolysis temperature leads to a lower degree of demineralization by leaching. Leaching enabled us to reduce the char ash content by almost 88%, extracting 100% P, Mg, Ca, and Fe and almost 90% Al. Physical activation of biocoal with CO₂ at 700 and 800 °C produced materials with a surface area of 353 and 417 m² g⁻¹, respectively, that make them potentially applicable as adsorbents in wastewater treatment or in industrial emissions processes. Moreover, the activated carbons showed the atomic H/C and O/C ratios of anthracite, which opens a wide range of alternative market applications to fossil coal, such as metallurgy and the advanced material sector. In addition, the high P and K concentrations in the salt obtained by precipitation make it a promising fertilizing product in line with the current regulations.