Search Results (12)

This study outlines findings from an investigation into the development of a hydrometallurgical process for manufacturing various forms of zinc perrhenate, entirely from waste from recycling and from the Zn–Pb industry. Scraps of Re-bearing Ni-based superalloys and acidic waste, circulating zinc solutions generated during the production of Zn by the electrolytic method and which contain >45 g/dm³ of Zn, Na, Mn, and Mg, were used in the research. In the publication, the conditions for the production of three types of zinc perrhenate, i.e., Zn(ReO₄)₂·4H₂O, Zn(ReO₄)_2, and Zn(ReO₄)₂·2H₂O, are presented. As a result of the analysis of the obtained results, it was concluded that to obtain the above-mentioned forms of zinc perrhenate, zinc carbonate can be used, precipitated from acidic, waste, and multi-component solutions after their prior neutralization to pH 4.0 and partial purification from Mn, Mg, and Na using metallurgical zinc oxide. Zinc carbonate should be precipitated using Na₂CO₃ at pH 6.3 and subsequently purified from other impurities, i.e., Mg, Na, and Mn, using aqueous ammonia solutions. As a result, zinc carbonate was obtained, which was used in a reaction with an aqueous solution of HReO₄ to produce zinc perrhenate. The precipitated forms of Zn(ReO₄)₂ were obtained by appropriately drying the crude and hydrated Zn(ReO₄)₂ to obtain its tetrahydrate, dihydrate, and anhydrous forms, respectively, using drying temperatures of 55, 135, and 185 °C. The developed technology has been submitted for a patent and is an example of a technology founded on the principles of sustainable development, with a particular emphasis on the minimalization of loss of rhenium and zinc at all stages of its realization. Full article

Nickel–iron-layered double hydroxide (NiFeLDH) is one of the promising catalysts for the oxygen evolution reaction (OER) in alkaline electrolytes, but its conductivity limits its large-scale application. The focus of current work is to explore low-cost, conductive substrates for large-scale production and combine them with NiFeLDH to improve its conductivity. In this work, purified and activated pyrolytic carbon black (CBp) is combined with NiFeLDH to form an NiFeLDH/A–CBp catalyst for OER. CBp not only improves the conductivity of the catalyst but also greatly reduces the size of NiFeLDH nanosheets to increase the activated surface area. In addition, ascorbic acid (AA) is introduced to enhance the coupling between NiFeLDH and A–CBp, which can be evidenced by the increase of Fe-O-Ni peak intensity in FTIR measurement. Thus, a lower overvoltage of 227 mV and larger active surface area of 43.26 mF·cm⁻² are achieved in 1 M KOH solution for NiFeLDH/A–CBp. In addition, NiFeLDH/A–CBp shows good catalytic performance and stability as the anode catalyst for water splitting and Zn electrowinning in alkaline electrolytes. In Zn electrowinning with NiFeLDH/A–CBp, the low cell voltage of 2.08 V at 1000 A·m⁻² results in lower energy consumption of 1.78 kW h/Kg_Zn, which is nearly half of the 3.40 kW h/Kg_Zn of industrial electrowinning. This work demonstrates the new application of high-value-added CBp in hydrogen production from electrolytic water and zinc hydrometallurgy to realize the recycling of waste carbon resources and reduce the consumption of fossil resources. Full article

Autoclave leaching of zinc concentrate (Sphalerite) is an environmentally friendly process compared to roasting, which discharges pollutants into the atmosphere. Due to the amount of iron in the final product, a study is proposed to evaluate different reagents for eliminating iron from the autoclave outcome, minimizing Zn losses. The colloid formation, zinc losses, iron removal, phase separation stage characteristics (sedimentation and filtering), and reagent costs were used to evaluate six-iron precipitating reagents: CaO, Na₂CO₃, CaCO₃, NaOH, MgO, and Ca(OH)₂. CaO shows 99.5% iron removal and 87% zinc recovery. Although CaO was one of the reagents with significant zinc recovery, it presented operational difficulties in the filtration stage due to the high viscosity of the mixtures. Finally, Ca(OH)₂ is the reagent recommended due to its ease of use, zinc yield recovery, electrowinning efficiency, and iron precipitate filtration rate. Zinc recovery was above 80%, while the iron concentration in the solution was below 50 ppm. Full article

The current study presents an effort to develop a sustainable hydrometallurgical process for the recovery of copper from waste printed circuit boards (PCBs) to be applied at local small to medium industrial units. The process aims to separate and recover copper from filter dust produced during the crushing of PCBs using a hammer mill in a recycling facility. Due to the high plastic content in the dust (approximately 30% w/w), the metal fraction was separated gravimetrically, and the material originated consisted mainly of Cu (23.8%), Fe (17.8%), Sn (12.7%), Pb (6.3%), Zn (3.4%), Al (3.3%), Mn (1.6%), and Ni (1.5%). Prior to copper recovery, the dust was leached with HCl as a pretreatment step. During this step, more than 80% of iron, zinc, and tin were leached out. The resulting solid consisted mainly of Cu (37.6%) and Fe (10.7%), leading to a copper enrichment of around 60% in the powder. The leaching of copper was conducted in a two-step process using H₂SO₄ as a leaching agent with the addition of H₂O₂ as an oxidizing agent. The experimental conditions had low energy requirements (no heating or agitation needed). The leaching of Cu reached 98%. Despite the pretreatment step, the concentration of other metals (Fe, Zn, Ni) in the pregnant solution was too high to proceed to electrowining. Therefore, the organic solvent ACORGA M5640 was selected for the extraction of copper from the pregnant solution. The extraction was conducted in two stages at pH equilibrium 1.5, and the loaded organic phase was stripped with HCl in two steps. The strip liquor was suitable for electrowinning. Full article

Zinc electrowinning is an energy-intensive step of hydrometallurgical zinc production in which ohmic drop contributes the second highest overpotential in the process. As the ohmic drop is a result of electrolyte conductivity, three conductivity models (Aalto-I, Aalto-II and Aalto-III) were formulated in this study based on the synthetic industrial electrolyte conditions of Zn (50–70 g/dm³), H₂SO₄ (150–200 g/dm³), Mn (0–8 g/dm³), Mg (0–4 g/dm³), and temperature, T (30–40 °C). These studies indicate that electrolyte conductivity increases with temperature and H₂SO₄ concentration, whereas metal ions have negative effects on conductivity. In addition, the interaction effects of temperature and the concentrations of metal ions on solution conductivity were tested by comparing the performance of the linear model (Aalto-I) and interrelated models (Aalto-II and Aalto-III) to determine their significance in the electrowinning process. Statistical analysis shows that Aalto-I has the highest accuracy of all the models developed and investigated in this study. From the industrial validation, Aalto-I also demonstrates a high level of correlation in comparison to the other models presented in this study. Further comparison of model Aalto-I with the existing published models from previous studies shows that model Aalto-I substantially improves the accuracy of the zinc conductivity empirical model. Full article

Zinc recovery from spent pickling acids (SPAs) can play an important role in achieving a circular economy in the galvanizing industry. This work evaluates the scale-up of membrane-based solvent extraction technology aimed at the selective separation of zinc from industrial SPAs as a purification step prior to zinc electrowinning (EW). The experiments were carried out at a pilot scale treating SPAs batches of 57 to 91 L in a non-dispersive solvent extraction (NDSX) configuration that simultaneously performed the extraction and backextraction steps. The pilot plant was equipped with four hollow fiber contactors and 80 m² of total membrane area, which was approximately 30 times higher than previous bench-scale studies. Tributylphosphate diluted in Shellsol D70 and tap water were used as organic and stripping agents, respectively. Starting with SPAs with high Zn (71.7 ± 4.3 g·L⁻¹) and Fe (82.9 ± 5.0 g·L⁻¹) content, the NDSX process achieved a stripping phase with 55.7 g Zn·L⁻¹ and only 3.2 g Fe·L⁻¹. Other minor metals were not transferred, providing the purified zinc stripping with better quality for the next EW step. A series of five consecutive pilot-scale experiments showed the reproducibility of results, which is an indicator of the stability of the organic extractant and its adequate regeneration in the NDSX operation. Zinc mass transfer fluxes were successfully correlated to zinc concentration in the feed SPA phase, together with data extracted from previous laboratory-scale experiments, allowing us to obtain the design parameter that will enable the leap to the industrial scale. Therefore, the results herein presented demonstrate the NDSX technology in an industrially relevant environment equivalent to TRL 6, which is an essential progress to increase zinc metal resources in the galvanizing sector. Full article

The electrolytic production of metallic zinc from processing zinc sulfide concentrates generates a residue containing cadmium, copper, and cobalt that need to be removed from the electrolytic zinc solution because they are harmful to the zinc electro-winning process. This residue is commonly sent to other parties that partly recover the contained elements. These elements can generate revenues if recovered at the zinc plant site. A series of laboratory tests were conducted to evaluate a method to process a zinc plant residue with the objective of recovering cobalt into a salable product. The proposed process comprises washing, selective leaching, purifying and precipitation of cobalt following its oxidation. The process allows the production of a cobalt rich hydroxide precipitate assaying 45 ± 4% Co, 0.8 ± 0.2% Zn, 4.4 ± 0.7% Cu, and 0.120 ± 0.004% Cd at a 61 ± 14% Co recovery. Replicating the whole process with different feed samples allowed the identification of the critical steps in the production of the cobalt product; one of these critical steps being the control of the oxidation conditions for the selective precipitation step. Full article

Electrowinning is a technique that can be used to obtain high-purity elements through electrolysis. The degradation of accelerated life testing for Pd-based electrodes is discussed in this study. The lifetime of the electrodes was examined by multiplying the acceleration rate with the current to measure the voltage of the electrodes. The acceleration rate was set to 10, 20, and 30 times. Four components were deposited on the TiO₂ plate. The ratio of Ir to Sn was fixed at 1:1, while Ta was deposited at 10 wt.%. Pd was deposited at 2, 4, 8 and 10 wt.% to create Pd-Ir/Sn-Ta. The initial voltage decreased as the Pd deposition amount increased irrespective of the acceleration rate. The lower the acceleration rate, the lower the voltage. An increase in the Pd content caused the initial voltage to be low. The multiple of the acceleration rate slightly increased for all cases of life testing for one year. When the test was conducted by increasing the current density by 20 times, the increase in voltage was proportional to the Pd deposition amount. However, for the 30 times acceleration rate, the lifetime of the electrodes was shortened as the Pd content increased. It can be inferred that the content of Pd and the ratio of Ir to Sn can influence the lifetime of the electrodes. According to these results, if the multiple of the acceleration rate is too extreme, the lifetime of the electrodes cannot be evaluated because they are damaged in an extreme situation. Full article

In this work, oxidizing roasting was combined with leaching to separate copper, lead, and zinc from a concentrate obtained by bulk flotation of a low-grade ore sourced from the Jiama mining area of Tibet. The flotation concentrate contained 7.79% Cu, 22.00% Pb, 4.81% Zn, 8.24% S, and 12.15% CaO; copper sulfide accounted for 76.97% of the copper, lead sulfide for 25.55% of the lead, and zinc sulfide for 67.66% of the zinc. After oxidizing roasting of the flotation concentrate, the S content in the roasting slag decreased to 0.22%, indicating that most sulfide in the concentrate was transformed to oxide, which was beneficial to leaching. The calcine was subjected to sulfuric acid leaching for separation of copper, lead, and zinc; i.e., copper and zinc were leached, and lead was retained in the residue. The optimum parameters of the leaching process were: a leaching temperature of 55 °C; sulfuric acid added at 828 kg/t calcine; a liquid:solid ratio of 3:1; and a leaching time of 1.5 h. Under these conditions, the extents of leaching of copper and zinc were 87.43% and 64.38%, respectively. Copper and zinc in the leaching solution could be further separated by electrowinning. The effects of leaching parameters on the extents of leaching of copper and zinc were further revealed by X-ray diffraction and scanning electron microscopy analysis. Full article

The influence of adsorbate (D2EPHA and kerosene) on the process of zinc electrowinning from sulfuric acid electrolytes was analyzed. The main objective was to critically compare three factors: (1) Three types of activated carbon (AC); (2) adsorption temperatures and contact time; and (3) zinc recovery efficiency. The results showed that organic components reduced the efficiency of zinc recovery. Moreover, wood-based ACs had a higher adsorption capacity than coal- and coconut-based ACs. To maintain a removal efficiency of 99% or more, wood-based ACs should constitute at least 60% of the adsorbate. The temperature of adsorption did not affect the removal efficiency. Additionally, the feeding rate of adsorbate in the solvent was inversely proportional to the removal efficiency. A feeding rate of the liquid pump of over 3 mL/min rapidly increased the delta pressure. For the same contact time, 99% of adsorbate removal occurred at 1 mL/min compared to approximately 97% at 0.5 mL/min. In the presence of 100 mg/L zinc, with increasing adsorbate from 0–5%, the recovery efficiency of zinc decreased from 100% to 0% and the energy consumption increased from 0.0017–0.003 kwh/kg zinc. Considering the energy consumption and zinc deposit mass, 0.1% of the adsorbate is recommended for zinc electrowinning. Full article

Double leached Waelz oxide (DLWO), with 76% zinc, is a secondary zinc containing raw materials obtained by the treatment of electric arc furnace dust. The content of fluoride in DLWO is still too high for direct leaching, as fluoride has a detrimental effect on electrowinning for zinc production. Knowledge of the characteristics of DLWO, and especially on how a fluoride mineral might exist, can contribute to further improvement of the selective leaching for the removal of fluoride. In this study, DLWO was characterized using analytical techniques, such as inductively coupled plasma-optical emission spectroscopy (ICP-OES), ¹⁹F liquid-state nuclear magnetic resonance (¹⁹F LS NMR), X-ray powder diffraction analysis (XRD), scanning electron microscopy coupled with energy dispersive spectroscopy (SEM-EDS) and ¹⁹F solid-state nuclear magnetic resonance (¹⁹F SS NMR). This study showed that DLWO mainly consisted of zincite (ZnO), cerussite (PbCO₃) and a spinel containing zinc, iron and manganese. The fluoride mineral identified was calcium fluoride (CaF₂). In SEM analysis, fluorine was found in larger grains together with calcium and oxygen, which was possibly calcium carbonate. Full article

In this research, some experimental steps were investigated to recover zinc contained in crude zinc oxide (C.Z.O.). In the first stage, the C.Z.O. was treated in NH₃–NH₄Cl–H₂O solution to dissolve the metals. The optimized leaching conditions in batch experiments were obtained: agitation speed 250 rpm, concentration of ammonia and ammonium chloride 2.5 mol/L and 5 mol/L, respectively, time 30min, temperature 40 °C, and L/S = 6 mL/g. The extraction percentage of zinc was over 81% under the optimized leaching conditions. The kinetic study indicates that zinc extraction from the C.Z.O particles was very rapid. In the second stage, the solution from the leaching process was purified by adding zinc dust to the solution. The Cu, Cd, Pb, Sb, and As could be reduced to levels of 0.03, 0.09, 0.87, 0.22, and 0.12 mg/L after the purification process. Finally, the electrowinning process was used to recover dissolved Zn from the final solution. The zinc content in the electrowon zinc was more than 99.99%. Full article