Search Results (16)

Under conditions of depletion of natural resources and increasing volumes of techno-genic waste from metallurgical and alumina production, the development of technologies for the integrated processing of sludges with the extraction of valuable components becomes highly relevant. This study proposes a method for the combined processing of red mud and dump sludge to obtain pig iron, a rare earth element concentrate, and titanium dioxide. The reduction smelting of a briquetted charge composed of sludge mixtures was carried out in a muffle furnace at 1350–1400 °C with the addition of a reducing agent. Magnetic separation of cast iron slag made it possible to reduce the iron content in the non-magnetic fraction and increase the concentration of REEs. As a result of nitric acid leaching of the non-magnetic slag fraction, followed by neutralization and calcination of the titanium-containing precipitate, a rare earth element concentrate and titanium dioxide containing 96.5% TiO₂ were obtained. The developed method ensures the utilization of technogenic raw materials and contributes to the creation of an additional resource base for the production of strategically important materials. Full article

Due to the large amount of plastic waste that is currently produced, the demand for ecological solutions to this situation has been growing. Many research studies in recent years have focused on polylactic acid (PLA) as a biodegradable material made from renewable resources. The individual components of biodegradable materials should comply with the EN 13432 standard, which defines the properties of a “compostable” material. Careful selection of dyes and pigments is therefore important in terms of maintaining the biodegradability of the finished products. In this article, we focus on evaluating the flow properties of color masterbatches modified with inorganic biodegradable pigments. Two types of PLA were used as polymer pigment carriers, and titanium dioxide, carbon black, and two iron oxides were used as inorganic pigments. We monitored the effect of the type and concentration of pigments on the processability and rheological properties of the prepared color PLA masterbatches. The capillary viscometer and rotary rheoviscometer were used to determine rheological properties. The flow properties of color masterbatches containing 1 and 3 wt.% inorganic pigments with two types of pure polymers, PLA6100 and PLA175, were compared. We found that the color PLA masterbatches had good processability and satisfactory rheological properties, and therefore they are usable for further processing. Full article

This study investigates the industrial potential of red gypsum (RG), a major by-product of titanium dioxide (TiO₂) production, for the development of thermoplastic polypropylene (PP)-based composites via melt extrusion, targeting agricultural applications. Prior to compounding, RG was thermally treated at approximately 200 °C to remove residual moisture and chemically bound water, resulting in its anhydrous form (CaSO₄). PP/RG composites were then formulated with RG loadings up to 20 wt.%, employing stearic acid (SA) as a compatibilizer. The resulting materials were thoroughly characterized and successfully processed through industrial-scale injection molding up to 250 °C. Morphological and FTIR analyses confirmed the role of SA in enhancing both filler dispersion and interfacial adhesion between RG and the PP matrix. SEM images revealed finer and more uniformly distributed RG particles, resulting in a reduced loss of ductility and elongation at break typically associated with filler addition. Specifically, the Young’s Modulus increased from 1.62 GPa (neat PP) up to 3.21 GPa with 20 wt.% RG and 0.6 wt.% SA. The addition of 0.6 wt.% SA also helped limit the reduction in stress at break from 46.68 MPa (neat PP) to 34.05 MPa and similarly mitigated the decrease in Charpy impact energy, which declined slightly from 2.66 kJ/m² (neat PP) to 2.24 kJ/m² for composites containing 20 wt.% RG. Preliminary phytotoxicity was assessed using germination tests on Lepidium sativum L. seeds. Eluates from both untreated and SA-treated RG powders resulted in germination indices below 80%, indicating phytotoxicity likely due to high sulfate ion concentrations. In contrast, eluates from composite pellets exhibited germination indices equal to or exceeding 100%, demonstrating the absence of phytotoxic effects. These results highlight the suitability of the developed composites for applications in floriculture and horticulture. The optimized composite pellets were successfully processed via injection molding to manufacture plant pots, which exhibited a dark brown coloration, confirming the effective pigmenting function of RG. These results demonstrate the potential of red gypsum to serve both as a functional filler and pigment in PP composites, providing a sustainable alternative to iron oxide pigments and promoting the valorization of industrial waste through resource recovery. Full article

The synthesis of oxide nanopowders through ultrasonic spray pyrolysis (USP) represents a sustainable method for producing high-purity, spherical particles tailored for advanced material applications. Recent developments in USP synthesis leverage the continuous transport of aerosols from an ultrasonic generator to a high-temperature furnace, with nanopowders collected efficiently using an electrostatic precipitator. This study explored the use of USP for titanium oxysulfate and aluminum nitrate solutions derived from the aluminum industry, focusing on resource recovery and waste reduction. Titanium oxysulfate was synthesized by leaching slag, generated during the reduction of red mud, with sulfuric acid under oxidizing, high-pressure conditions. After purification, the titanium oxysulfate solution was processed using USP in a hydrogen reduction atmosphere to yield spherical titanium dioxide (TiO₂) nanopowders. The hydrogen atmosphere enabled precise control over the nanoparticles’ morphology and crystallinity, enhancing their suitability for use in applications such as photocatalysis, pigments, and advanced coatings. In parallel, both synthetic and laboratory solutions of aluminum nitrate [Al(NO₃)₃] were prepared. The laboratory solution was prepared by leaching aluminum hydroxide oxide (AlOOH) with hydrochloric acid to form aluminum chloride (AlCl₃), followed by a conversion to aluminum nitrate through the addition of nitric acid. The resulting aluminum nitrate solution was subjected to USP, producing highly uniform, spherical alumina (Al₂O₃) nanopowders with a narrow size distribution. The resulting nanopowders, characterized by their controlled properties and potential applicability, represent an advancement in oxide powder synthesis and resource-efficient manufacturing techniques. Full article

This study presents a comparative analysis of titanium leaching from tionite (a byproduct of the titanium dioxide production process) and carbothermally reduced red mud (derived from aluminum residues). Tionites from the sulfate process and red mud residue are known for their environmental impacts due to their metal content and acidic/basic nature. This study explored leaching as a method to recover titanium and other metals under high-pressure and high-temperature conditions using sulfuric acid. Experiments were conducted in an autoclave with different parameter changes, like varying oxygen pressure, temperature, and reaction time to optimize metal extraction. The leaching efficiency of titanium was found to be higher in the carbothermal-reduced slag compared to tionite due to the altered mineral phases in the reduced material. XRD and SEM-EDS analyses confirmed the differing leaching behaviors, with titanium compounds in tionite showing greater resistance to dissolution. These findings highlight the importance of thermal pre-treatment for optimizing metal recovery from industrial residues. The main aim of this study is to contribute to the development of sustainable waste management solutions for tionites and red mud, emphasizing the potential of hydrometallurgical methods for metal recovery. The results are expected to inform future research and industrial applications, advancing the recovery of valuable metals while reducing the environmental footprint of titanium and aluminum residue disposal. Full article

The production of titanium dioxide in China generates substantial waste acid and ferrous sulfate, which are repurposed into polyferric sulfate for industrial wastewater treatment. However, this water purification agent contains heavy metals like Ti, V, Mn, Cr, Co, Cu, Ni, Zn, Ba, and Pb, posing unrecognized environmental risks. This study identified these risks through pollutant screening and the process analysis of a Jiangsu-based titanium dioxide enterprise, evaluating the potential impacts on water quality and worker health. The results show that concentrations of manganese and titanium in the polyferric sulfate reached up to 163 mg/L and 631 mg/L, respectively. Notably, the non-carcinogenic hazard quotients (HQs) for cobalt, vanadium, and manganese were 307, 5.6, and 2.6, all exceeding the safe limit of 1, with cobalt presenting a particularly significant risk due to its low reference dose (RfD) of 0.0003 mg/kg-d. This study concludes that national standards should be revised to include limits for these pollutants to ensure safer practices in industrial wastewater treatment. Full article

The solid waste and waste acid generated during the production of titanium dioxide contain considerable amount of scandium, which are valuable secondary resources. In this study, the titanium dioxide waste acid was used to leach the scandium-containing solid waste, and the leached solution was pretreated for iron removal by reduction-crystallization process. After that, scandium was recovered from the leached solution by using the P204-TBP co-extraction system. The process parameters were investigated systematically. The results showed that iron powder reduction-crystallization for iron removal at molar ratio of Fe:Fe³⁺ = 0.25 was most suitable for subsequent extraction, and the scandium extraction efficiency could reach 100% using 15% P204-5% TBP at 25 °C with A/O = 8. This study provided a novel process for treating scandium-bearing solid waste with scandium-bearing waste acid, showing great potential for industrial application. Full article

In view of the current situation wherein acid resources and valuable components in titanium dioxide waste acid cannot be effectively extracted and are prone to secondary pollution, our research team proposed a new technique consisting of step extraction and the comprehensive utilization of titanium dioxide waste acid. In this paper, the thermodynamics of selective precipitation and the preparation of doped iron phosphate from waste acid were studied. The thermodynamics results show that the content of Al³⁺, Mn²⁺, Mg²⁺, and Ca²⁺ in the reaction system can be tuned by adjusting the pH during the pre-precipitation process. In the first step, these impurity ions should be settled as much as possible; then, Fe²⁺ should be oxidized to Fe³⁺ so as to obtain iron phosphate with higher purity in the next step of the precipitation process. The effects of the reaction temperature, seed crystals, pH value, and P/M on the precipitation process were investigated in detail. The experimental results show that in the reduced state, the optimal precipitation conditions are a temperature of 75 °C, an initial pH value of 4.5, and an optimal P/M molar ratio of 1.1. In the oxidized state, the optimal precipitation conditions are a temperature of 60 °C, a solution pH = 2.5, and a reaction time of 25 min. After calcination, the precipitate mainly consists of iron phosphate, which basically meets the requirements of an iron phosphate precursor. Full article

In the quest to develop nanometrically defined catalytic systems for applications in the catalytic valorization of agri-food wastes, small Ni-based nanoparticles supported on inorganic solid supports have been prepared by decomposition of organometallic precursors in refluxing ethanol under H₂ atmosphere, in the presence of supports exhibiting insulating or semi-conductor properties, such as MgAl₂O₄ and TiO₂, respectively. The efficiency of the as-prepared Ni-based nanocomposites has been evaluated towards the hydrogenation of unsaturated fatty acids under solvent-free conditions, with high selectivity regarding the hydrogenation of C=C bonds. The influence of the support on the catalytic performance of the prepared Ni-based nanocomposites is particularly highlighted. Full article

Access to fresh water is an increasing concern worldwide. The contamination of this vital liquid is largely caused by discharges of pollutants into rivers and seas from different types of industries. Waste dyes from different industries have been classified as harmful to health. In this study, polymeric nanomaterials based on polylactic acid (PLA) and nanoparticles of titanium dioxide (TiO₂) and zinc oxide (ZnO) modified by ultrasound-assisted extrusion were obtained. These materials were evaluated by FTIR, DRX, TGA, DSC, SEM and methylene blue adsorption. From the results of the physicochemical characterizations, it was possible to observe the presence of TiO₂ and ZnO nanoparticles dispersed in the polymeric matrix, increasing the crystallinity and thermal stability of the polymer. In addition, a good dispersion of the nanoparticles could be seen by means of SEM, due to the extrusion assisted by ultrasound. The methylene blue dye adsorption tests revealed that the best result was 98% dye adsorption in a time of 13 min for the 1.5% PZT sample. Additionally, this material could be used for 3 adsorption cycles without affecting its adsorbent properties. Full article

Scandium metal has generated a lot of interest during the past years. This is due to the various crucial applications it has found ground in and the lack of production in countries outside China and Russia. Apart from rare earth ores, scandium is present in a variety of wastes and by-products originating from metallurgical processes and is not currently being sufficiently valorised. One of these processes is the production of titanium dioxide, which leaves an acidic iron chloride solution with a considerably high concentration of scandium (10–140 ppm) and is currently sold as a by-product. This research aims to recover scandium without affecting the solution greatly so that it can still be resold as a by-product after the treatment. To achieve this, two commercial ion-exchange resins, VP OC 1026 and TP 260, are used in the column setup. Their breakthrough curves are plotted with mathematical modelling and compared. Results indicate that VP OC 1026 resin is the most promising for Sc extraction with a column capacity of 1.46 mg/mL, but Zr, Ti, and V coextract have high capacities, while Fe does not interfere with the adsorption. Full article

This study was focused on the historical evolution of the waste management policy carried out by the Spanish industry devoted to titanium dioxide pigments manufacturing for minimising its environmental impact. This challenge was achieved by modifying the original chemical process and converting the originally dissolved sulphate and sulphuric acid present in the final streams of the factory into sulphate minerals (melanterite FeSO₄·7H₂O, szomolnokite FeSO₄·H₂O, and gypsum CaSO₄·2H₂O). These by-products were physicochemically, mineralogically and radiologically characterised in order to gain basic information for its subsequent commercial use. Some of the uses summarised in this study for both ferrous sulphates are as a supplier of iron to prevent chlorosis, animal food, manufacture of cement (to reduce Cr VI), primary flocculants for ferrous sulphates, magnetite nanoparticle and nano-Fe₂O₃ formation, production of magnetite concentrate, remediation of polluted soils with metals, and treatment of wastewaters. Red gypsum was analysed as a substitute for natural gypsum in the manufacture of cement, construction materials, inhibitor in soil erosion, and the immobilisation of heavy metals in agricultural soils and carbonation processes. Full article

This paper presents a method of utilising ilmenite MUD created during the production of titanium dioxide (TiO₂) according to the sulphate method as an additive for Portland cement composites. After the production process, undissolved MUD was additionally rinsed with water and filtrated in the factory to make it more useful (R-MUD) for implementation and also to turn back some of the by-products of the production of TiO₂. R-MUD is less hazardous waste than MUD. It has a lower concentration of sulphuric acid and some heavy metals. The rinsing process raised the concentration of SiO₂, which is a valuable part of R-MUD because of its potential pozzolanic activity. This means that the R-MUD might be a reactive substitute of part of Portland cement in building composites. The article presents the results of research on the pozzolanic activity of R-MUD and other materials with proved pozzolanic activity, such as silica fume, fly ash and natural pozzolana (trass). Tests were performed using thermal analysis techniques. The tests showed that the pozzolanic activity or R-MUD after three days is at the same level as silica fume and after 28 days it is twice as high as the activity of fly ash. Beyond the 180th day of curing, R-MUD had the same level of activity as fly ash. The summary is supplemented by calorimetric tests, which confirm the high reactivity of R-MUD compared to other commonly used concrete additives, already in the initial hydration period. In summary, heat of hydration after 72 h of Portland cement with R-MUD is at the same level as the heat of hydration of Portland cement with silica fume and also pure Portland cement grout. The results confirm that the process of formation of micro-silica contained in R-MUD react with calcium hydroxide to form the C-S-H phase, which is responsible for the microstructure of cement composites. Full article

In view of the current situation where the acid resources and valuable components in titanium dioxide waste acid cannot be effectively extracted and are prone to secondary pollution, the research team proposed a new technology of step extraction and comprehensive utilization of titanium dioxide waste acid. In this paper, the preparation of doped iron phosphate from waste acid by selective precipitation was studied. The thermodynamics of selective precipitation, the effect of the reaction temperature, the initial pH value, the molar ratio of P/Fe, and the dispersant on the precipitation process were investigated in detail. The thermodynamics results show that iron(II) in titanium dioxide waste acid is oxidized and is preferentially precipitated with phosphoric acid to form iron(III) phosphate, when compared with other impurity ions. The experimental results show that the optimal precipitation condition is a temperature of 60 °C, an initial pH value of 2.5, an optimal P/Fe molar ratio of 1.1, and a dispersant polyethylene glycol at 5 mL (Per 50 mL of waster acid). After calcination, the precipitate mainly consists of iron phosphate and a small amount of aluminum phosphate. Meanwhile, the utilization ratios of iron and phosphorus were 98.81% and 98.39%, respectively. Moreover, the mass percentage of Fe₂O₃ and P₂O₅ and the molar ratio of Fe/P were 99.13% and 1.03, which basically met the requirements of the iron phosphate precursor. Full article

The waste of apatite-nepheline ore processing was chosen as the material of study for the present investigation. The chemical and phase compositions have been analyzed and the route of the new technology has been developed. Treatment of the waste with diluted hydrochloric acid enables to separate apatite, nepheline, titano-magnetite minerals from titanite (CaSiTiO₅). The obtained titanite concentrate contains 30–32% of titanium dioxide. Interaction of titanite with hydrochloric acid under heating and stirring conditions results in calcium leaching. The titanite decomposition is accompanied by titanium and silica oxides precipitation. The resulting solid has been used as a precursor for the synthesis of functional materials. Mechanochemical activation of the precursor provides the structural and morphological disorder of the initial particles. Thermodynamic stability of activated particles is achieved by chemisorption or roasting. Full article