Grantee Research Project Results

Final Report: Sustainable PFAS Removal from Biosolids A Multifaceted, Biochar-Based Approach

EPA Contract Number: 68HERC25C0012
Title: Sustainable PFAS Removal from Biosolids A Multifaceted, Biochar-Based Approach
Investigators: Shubert, Jason R
Small Business: Talon LPE, Ltd.
EPA Contact: Richards, April
Phase: I
Project Period: December 16, 2024 through June 15, 2025
Project Amount: $100,000
RFA: Small Business Innovation Research (SBIR) - Phase I (2025) RFA Text |  Recipients Lists
Research Category: Small Business Innovation Research (SBIR)

Description:

This Phase I SBIR project investigated and evaluated biochar-based approaches for removing PFAS from wastewater biosolids through laboratory-scale experiments. Over six months, our research team conducted comprehensive experiments to evaluate the technical feasibility and commercial viability of using biochar derived from beef cattle manure (BCM) to treat PFAS contamination in biosolids. 

Our research investigated three distinct biochar-based treatment pathways. The first pathway involves directly blending biochar into biosolids, leveraging biochar's adsorptive properties to capture and sequester PFAS compounds within the solid matrix while requiring minimal changes to existing biosolids management practices. The second pathway utilizes a leaching process to mobilize PFAS from biosolids into a liquid phase, followed by biochar adsorption column treatment to remove dissolved PFAS compounds. The third pathway employs pyrolysis of the biosolids themselves to produce biochar while simultaneously destroying PFAS compounds through high-temperature thermal treatment. 

A key innovation lies in the strategic use of beef cattle manure as the biochar feedstock. BCM represents an abundant waste stream in the Texas Panhandle region that typically requires costly disposal, while our process converts this liability into a valuable treatment medium, creating both reliable feedstock availability and strong economic incentives for adoption. 

Summary/Accomplishments (Outputs/Outcomes):

Our Phase I research achieved several breakthrough technical milestones demonstrating the viability of biochar-based PFAS remediation. We successfully established scalable biochar production processes from cattle manure with yields consistently achieving 40-45% even at higher temperatures, indicating excellent feedstock efficiency for commercial-scale production. 

Through systematic evaluation of biochar modification techniques, we discovered that chemical activation significantly enhances PFAS removal performance. Acid activation using hydrochloric acidoutperforms base activation, with our optimized HCl-activated biochar achieving significant improvements in PFAS removal efficiency compared to unmodified biochar. Our optimized BCM biochar produced at 600°C with HCl activation achieved 64% removal of total PFAS compounds with an adsorbed phase concentration of 16.9 mg/g. 

Laboratory studies of treatment approaches yielded encouraging results, though many PFAS measurements relied on method detection limits rather than actual quantification, indicating that further analytical work with lower detection limits would strengthen these conclusions. Leaching column experiments indicated low PFAS mobility (0.03-1.55% per compound), though experimental limitations prevented definitive conclusions about biochar effectiveness in reducing leaching. It is likely that our experiment needs to be redesigned. 

The most promising breakthrough came through our biosolids pyrolysis pathway, which achieved exceptional PFAS destruction rates of .::99% across all tested temperatures (500-700°C). At the highest temperature, we observed greater than 99.99% removal of target PFAS compounds from the solid phase, though the fate of the removed PFAS requires further investigation. 

Our research demonstrated biochar production and activation processes using standard laboratory equipment, providing a foundation for potential future scale-up studies. 

Commercial Progress

Over the past several months, significant progress has been made toward the commercialization of our PFAS remediation technology. We initiated contact with the Amarillo wastewater treatment plant  (WWTP) to obtain biosolids for testing and explore a potential commercial partnership. We also began outreach to WWTPs known to exceed PFAS limits, compiled a list of key decision-makers. To deepen our understanding of the regulatory and market landscape, we met with Earl Lott of Lott Environmental Consulting regarding TCEQ and EPA requirements and partnered with Foresight/TABA for market research. We participated in the City of Austin's Circular Business Accelerator and attended the City's Circular Showcase and the TCEQ trades how in San Antonio to build relationships and explore integration into municipal infrastructure. We continued our dialogue with the City of Austin on PFAS testing protocols and met with experts at the University of Texas to evaluate hydrothermal liquefaction versus pyrolysis for PFAS remediation. 

echnological development efforts included discussions with Advanced Renewable Technology Inc. 
(ARTi) about recalibrating reactors for PFAS destruction and integrating an activation system into a modular biochar production unit. We engaged with PYREG and GECA Environmental to explore pyrolysis of biosolids and reviewed existing literature on biochar's interaction with PFAS. We also connected with United Rentals to better understand WWTP design. Our partnership with Mc6 Cattle Feeders was further formalized for future manure-based biochar initiatives, and we initiated grant funding discussions through the City of Amarillo. Internally, we conducted a two-hour commercialization planning session and completed a full review of the TABA report, focusing particularly on strategies for safely disposing of used biochar while ensuring PFAS containment. Finally, we secured four letters of intent from commercial partners, affirming their interest in expanding collaboration contingent on a Phase 2 award. These combined efforts have positioned us strongly for launching a pilot project and building a comprehensive commercialization strategy.

The market opportunity is substantial and growing rapidly. Wastewater treatment plants nationwide face increasing regulatory pressure to address PFAS contamination in biosolids, with current disposal methods becoming increasingly costly and restricted. Our technology offers compelling value propositions including cost-effective treatment, operational simplicity requiring minimal infrastructure modifications, and multiple revenue streams through treatment services and potential biochar sales. 

Strategic partnerships established during Phase I provide clear pathways for scaling and deployment. Relationships with equipment suppliers like PYREG and ARTi offer access to proven biochar production platforms, while partnerships with cattle operations ensure reliable, low-cost feedstock supplies. 

Conclusions:

Our Phase I achievements establish a strong foundation for Phase II development and commercialization. We have demonstrated clear technical feasibility across all proposed treatment pathways, with biosolids pyrolysis emerging as the most promising approach for complete PFAS destruction. Industry interest is evidenced by secured letters of intent from multiple partners, established pilot site relationships, and stakeholder engagement supporting Phase II development. 

The comprehensive data generated during Phase I supports both continued technology development and regulatory approval processes. Our characterization of biochar properties, PFAS removal mechanisms, and process scalability provides the technical foundation necessary for engineering design and commercial implementation. Phase I identified several areas requiring further development, including optimization of experimental methods for leaching studies, investigation of PFAS fate during pyrolysis, and economic feasibility analysis for commercial deployment. 

Phase II efforts will focus on scaling the most promising treatment approaches while developing comprehensive business networks for widespread implementation. The combination of proven technical performance, established commercial partnerships, and validated market demand positions our technology for successful commercialization and meaningful impact on PFAS contamination in biosolids.