Application of Carbon-Based Catalysts Derived from Ship Antifouling Paint Particles in Ultrasound-Fe2+/Peroxydisulfate Advanced Oxidation Process for Activated Sludge Reduction: A Pilot-Scale Study

Activated sludge treatment is plagued by high secondary pollution risks, and ship antifouling paint particles (APPs) as hazardous heavy metal-rich solid wastes generated from hull derusting wastewater, pose severe environmental threats and intractable disposal dilemmas. This study developed a novel pilot-scale activated sludge reduction process coupling APPs-derived carbon-based catalysts with ultrasound-Fe2+/peroxydisulfate (PDS) advanced oxidation. Columnar catalysts were fabricated via direct carbonization-molding using waste APPs from an 82,000 deadweight bulk carrier were used as the sole raw material to prepare columnar catalysts via direct carbonization-molding; single-factor and orthogonal experiments optimized process parameters, Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS) and X-ray Photoelectron Spectroscopy (XPS) characterized catalyst and sludge properties, free radical quenching experiments elucidated reaction mechanisms and a 90-day continuous pilot run assessed catalytic stability. The process achieved a 43.5% sludge removal rate under optimal conditions, accompanied by 100% toluene and 92.3% phenolic compound degradation, as well as efficient total phosphorus (TP) and total nitrogen (TN) removal. Mechanistic studies via characterization and quenching experiments confirmed the catalyst enhanced PDS activation through free/non-free radical synergy and accelerated Fe2+/Fe3+ redox cycling. A 90-day continuous pilot operation demonstrated excellent long-term catalytic stability, with sludge removal rate remaining above 38%. This “waste treating waste” technology realizes high-value APPs resource utilization, provides a low-carbon sludge disposal pathway, and offers a scalable solution for collaborative pollution control in the wastewater treatment and shipping industries.