Sustainable treatment of sewage sludge via plasma-electrolytic liquefaction for bio-friendly production of polyurethane foam

Safe and green disposal or utilization of sewage sludge (SS) has attracted significant attention as SS is increasingly produced worldwide and emerges as an environmental burden if without proper treatment. In this study, efficient and sustainable treatment of SS was achieved using plasma-electrolytic liquefaction (PEL) with alkaline catalysts including sodium hydroxide (NaOH), sodium carbonate (Na₂CO₃), and sodium acetate (NaAc) and renewable solvents including polyethylene glycol (PEG) 200 and glycerol. Furthermore, the obtained bio-oil with abundant hydroxyl groups could partially replace polyols derived from fossil energy to synthesize bio-based polyurethane foams (BPUFs) for oil adsorption. The results showed that the Na2CO3 catalyst exhibited better performance and yielded bio-oil with a higher heating value (HHV) of 26.26 MJ/kg, very low nitrogen content (0.14%) and metal ions, and a nearly neutral pH of 7.41, under the optimized conditions. Compared with conventional oil bath liquefaction, PEL can significantly improve the liquefaction efficiency, promote the transfer of metal ions in SS to the solid residue (SR), and facilitate the transfer of nitrogen to the gas phase and SR, thereby upgrading the bio-oil to a certain extent. The BPUFs showed excellent oil adsorption capacity, reusability, and desorption and can play an important role in combating oil spills. The PEL method may provide a green avenue for SS valorization and the comprehensive utilization of the obtained products.