Innovative Wastewater Treatment Using 3D-Printed Clay Bricks Enhanced with Oyster Shell Powder: A Life Cycle Assessment

With growing global concerns over sustainable wastewater treatment, there is a pressing need for low-cost, eco-friendly filtration solutions. This study conducted a life cycle assessment (LCA) to evaluate the potential of improving slow sand filtration efficiency by integrating alternative materials like clay and oyster shell powder (OSP), while minimizing the environmental footprint. Additionally, the adaptability of three-dimensional (3D) printing was explored to incorporate these materials into innovative filter designs, assessing scalability for broader wastewater applications. Ten filter configurations, including a slow sand filter (SSF) enhanced with OSP (90:10) and 3D-printed clay–OSP bricks (ratios of 90:10, 85:15, 80:20), were assessed across three sourcing distances: local (in situ), regional (161 km), and distant (1609 km). The results showed that SSFs with OSP consistently delivered lower environmental impacts, reducing freshwater ecotoxicity, eutrophication, and human toxicity by up to 4% compared to conventional SSFs, particularly when transport was minimized. Among brick-based systems, single-brick columns offered the best balance of performance and impact, while three-brick columns had the highest environmental burden, largely due to the increased electricity use. Economic analysis reinforced the environmental findings: SSFs with OSP were the most cost-effective option, followed closely by SSFs, while brick-based systems were slightly more expensive, with costs rising sharply when sourcing distances exceeded 161 km. Overall, integrating OSP into SSFs offers an optimal balance of sustainability and affordability, while single-brick columns (90:10) present a promising alternative. Future research should further optimize material blends and design configurations to align with long-term environmental and economic goals.