Preparation and Characterization of Polyferric Sulfate Derived from Iron Sludge in De-Ironing Water Plants and Its Utilization in Water Treatment

Resource utilization of water treatment residuals (WTRs) has emerged as a significant focus in environmental engineering research. In this study, waste iron sludge from a groundwater de-ironing plant was used as the raw material. Ferric salts were recovered via sulfuric acid leaching and subsequently polymerized into polyferric sulfate (PFS) with varying basicity (B = 0.1–0.4) using the alkalization–aging method. The optimal leaching conditions were determined as a liquid–solid ratio of 10:1, a sulfuric acid concentration of 3 mol·L−1, a reaction temperature of 70 °C, and a reaction time of 30 min, yielding a ferric leaching amount of 0.45 g Fe/g dry sludge. Characterization results revealed that the synthesized PFS exhibited similar ferric polymer species, functional group structures, and polymeric crystal structures to those of commercial PFS (CPFS). Coagulation performance tests demonstrated that at a dosage of 30 mg Fe/L, the prepared PFS achieved turbidity and UV254 removal efficiencies of 96.88% and 81.87%, respectively, outperforming CPFS. In domestic wastewater treatment, combining the synthesized PFS with magnetic nanoparticles Fe3O4@C yielded a magnetic coagulant that further enhanced the removal of turbidity, chemical oxygen demand (COD), and total phosphorus (TP) to maximum efficiencies of 94.66%, 81.97%, and 98.08%, respectively. This study confirms the technical feasibility and environmental–economic benefits of preparing magnetic PFS coagulants from waste iron sludge for wastewater treatment.