Transport and transformation of mercury during wet flue gas cleaning process of nonferrous metal smelting

Removing and recycling mercury from scrubbing solution produced in wet nonferrous metal smelting flue gas purification process

Wet purification technology for nonferrous metal smelting flue gas is important for mercury removal; however, this technology produces a large amounts of spent scrubbing solution that contain mercury. The mercury in these scrubbing solutions pose a great threat to the environment. Therefore, this research provides a novel strategy for removing and recycling mercury from the scrubbing solution, which is significant for decreasing mercury pollution while also allowing for the safe disposal of wastewater and a stable supply of mercury resources. Some critical parameters for the electrochemical reduction of mercury were studied in detail. Additionally, the electrodeposition dynamics and electroreduction mechanism for mercury were evaluated. Results suggested that over 92.4% of mercury could be removed from the scrubbing solution in the form of a Hg-Cu alloy under optimal conditions within 150 min and with a current efficiency of approximately 75%. Additionally, mercury electrodeposition was a quasi-reversible process, and the controlled step was the mass transport of the reactant. A pre-conversion step from Hg(Tu)₄²⁺ to Hg(Tu)₃²⁺ before mercury electroreduction was necessary. Then, the formed Hg(Tu)₃²⁺ on the cathode surface gained electrons step by step. After electrodeposition, the mercury in the spent cathode could be recycled by thermal desorption. The results of the electrochemical reduction of mercury and subsequent recycling provides a practical and easy-to-adopt alternative for recycling mercury resources and decreasing mercury contamination.

Production of H2S with a Novel Short-Process for the Removal of Heavy Metals in Acidic Effluents from Smelting Flue-Gas Scrubbing Systems

Direct sulfidation using a high concentration of H₂S (HC-H₂S) has shown potential for heavy metals removal in various acidic effluents. However, the lack of a smooth method for producing HC-H₂S is a critical challenge. Herein, a novel short-process hydrolysis method was developed for the on-site production of HC-H₂S. Near-perfect 100% efficiency and selectivity were obtained via CS₂ hydrolysis over the ZrO₂-based catalyst. Meanwhile, no apparent residual sulfur/sulfate poisoning was detected, which guaranteed long-term operation. The coexistence of CO₂ in the products had a negligible effect on the complete hydrolysis of CS₂. H₂S production followed a sequential hydrolysis pathway, with the reactions for CS₂ adsorption and dissociation being the rate-determining steps. The energy balance indicated that HC-H₂S production was a mildly exothermic reaction, and the heat energy could be maintained at self-balance with approximately 80% heat recovery. The batch sulfidation efficiencies for As(III), Hg(II), Pb(II), and Cd(II) removal were over 99.9%, following the solubilities (K_sp) of the corresponding metal sulfides. CO₂ in the mixed gas produced by CS₂ hydrolysis did not affect heavy metals sulfidation due to the presence of abundant H⁺. Finally, a pilot-scale experiment successfully demonstrated the practical effects. Therefore, this novel on-site HC-H₂S production method adequately achieved heavy metals removal requirements in acidic effluents.

Enhancement of biofuel production by microalgae using cement flue gas as substrate

The cement industry generates a substantial amount of gaseous pollutants that cannot be treated efficiently and economically using standard techniques. Microalgae, a promising bioremediation and biodegradation agent used as feedstock for biofuel production, can be used for the biotreatment of cement flue gas. In specific, components of cement flue gas such as carbon dioxide, nitrogen, and sulfur oxides are shown to serve as nutrients for microalgae. Microalgae also have the capacity to sequestrate heavy metals present in cement kiln dust, adding further benefits. This work provides an extensive overview of multiple approaches taken in the inclusion of microalgae biofuel production in the cement sector. In addition, factors influencing the production of microalgal biomass are also described in such an integrated plant. In addition, process limitations such as the adverse impact of flue gas on medium pH, exhaust gas toxicity, and efficient delivery of carbon dioxide to media are also discussed. Finally, the article concludes by proposing the future potential for incorporating the microalgae biofuel plant into the cement sector.

Development of Recyclable Iron Sulfide/Selenide Microparticles with High Performance for Elemental Mercury Capture from Smelting Flue Gas over a Wide Temperature Range

Fast and effective removal of elemental mercury in a wide temperature range is critical for the smelting industry. In this work, a recyclable magnetic iron sulfide/selenide sorbent is developed to capture and recover Hg⁰ from smelting flue gas. Benefiting from Se doping, the Hg⁰ capture performance of prepared FeS_xSe_y is significantly enhanced compared with traditional iron sulfide, especially at high temperatures. Considering the recyclability and working temperature, FeS_1.32Se_0.11 exhibits the best Hg⁰ capture performance. The average capture rate of FeS_1.32Se_0.11 is 3.661 μg/g/min at 80 °C and its saturation adsorption capacity is 20.216 mg/g. The flue gas compositions have almost no effect on Hg⁰ capture. X-ray photoelectron spectroscopy and mercury thermal programmed desorption suggest that the stable active Se-S_n^2- adsorption site can combine with Hg⁰ to form HgSe, consequently improving Hg⁰ capture performance at high temperatures. After Hg⁰ capture, the spent FeS_xSe_y can be collected by magnetic separation and regenerated through selective extraction, which facilitates harmless treatment and resource reuse of mercury. With the advantages of excellent Hg⁰ capture performance, wide operating temperature range, and remarkable recycling property, FeS_xSe_y microparticles may be a promising sorbent for Hg⁰ capture in industrial applications, while opening a new avenue to realize the resource utilization toward toxic elements.

Design and analysis of a novel furnace throat for removing dust particles in flue gas emitted from copper smelting furnace by a computational method

A novel furnace throat structure was designed to reduce dust particle concentration in the flue gas emitted from the copper smelting industry. A two-stage turbulence model of the furnace throat based on the RNG k-ε model combined with the stochastic trajectory model was developed to analyze the gas flow and particle trajectories in this furnace throat structure. The resulting turbulent flow fields and particle trajectories under different operating conditions were shown and discussed. It indicates that the furnace throat plays an important role in separating the dust particles from the flue gas by applying centrifugal force and subsequent resistance force. Moreover, the effects of the radius of the inner flue, the number of the spiral plate, and the number of the spiral plate turns on the particle collection efficiency were analyzed to optimize the throat structure. The simulation results show that the furnace throat with inner flue radius of 0.05 m, two spiral plates, and two spiral plate turns has the highest particle collection efficiency. Furthermore, a series of experimental tests were conducted to validate the accuracy of the simulation results, and the measured experimental data show a good correlation with the numerical results.

Hierarchical Ag-SiO2@Fe3O4 magnetic composites for elemental mercury removal from non-ferrous metal smelting flue gas

Hierarchical Ag-SiO₂@Fe₃O₄ magnetic composites were selected for elemental mercury (Hg⁰) removal from non-ferrous metal smelting flue gas in this study. Results showed that the hierarchical Ag-SiO₂@Fe₃O₄ magnetic composites had favorable Hg⁰ removal ability at low temperature. Moreover, the adsorption capacity of hierarchical magnetic composite is much larger than that of pure Fe₃O₄ and SiO₂@Fe₃O₄. The Hg⁰ removal efficiency reached the highest value as approximately 92% under the reaction temperature of 150°C, while the removal efficiency sharply reduced in the absence of O₂. The characterization results indicated that Ag nanoparticles grew on the surface of SiO₂@Fe₃O₄ support. The large surface area of SiO₂ supplied efficient reaction room for Hg and Ag atoms. Ag-Hg amalgam is generated on the surface of the composites. In addition, this magnetic material could be easily separated from fly ashes when adopted for treating real flue gas, and the spent materials could be regenerated using a simple thermal-desorption method.

High-efficient adsorption and removal of elemental mercury from smelting flue gas by cobalt sulfide

Nonferrous metal smelting produces a large amount of Hg⁰ in flue gas, which has caused serious damage to the environment and human health. In this work, amorphous cobalt sulfide was synthesized by a liquid-phase precipitation method and was used for capturing gaseous Hg⁰ from simulated smelting flue gas at low temperatures (50~150 °C). In the adsorption process, Hg⁰ can be transformed into the stable mercury compound, which is confirmed to be HgS by X-ray photoelectron spectroscopy (XPS) and temperature programmed desorption of Hg (Hg-TPD) analysis. Meanwhile, XPS results also demonstrate that S₂^2- species on the surface of cobalt sulfide play an important role in Hg⁰ transformation. At the temperature of 50 °C (inlet Hg⁰ concentration of 214 μg·m^-3), the Hg⁰ adsorption capacity of cobalt sulfide (penetration rate of 25%) is as high as 2.07 mg·g^-1, which is much higher than that of popular adsorbents such as activated carbons and metal oxides. In addition, it was found that the Hg⁰ removal efficiency by cobalt sulfide in the flue gas with high concentration of SO₂ (5%) remained more than 94%. The good adsorption and Hg⁰ removal performance guarantee cobalt sulfide the great superiority and application potential in the treatment of Hg⁰ in smelting flue gas with high concentration of SO₂.

Selective recovery of mercury from high mercury-containing smelting wastes using an iodide solution system

The mercury resources recovery and safe disposal of mercury-containing waste is an urgent problem. In this study, a new method using an iodide solution system was proposed to selectively recover mercury from high mercury-containing smelting wastes. The mercury leaching efficiency, yields, leaching kinetics and thermodynamics were researched. The major factors which affect mercury leaching efficiency including iodide concentration, oxidant, pH and temperature were evaluated. Over 97% and 93% of mercury can be efficiently leached from wastewater treatment sludge (W-S) and acid sludge (A-S). After leaching, the mercury concentration during leaching toxicity test is under the limits set for hazardous waste. Additionally, the electrolytic technology can efficiently recover mercury from leachate in the form of elemental mercury, and the leachate after electrolytic can be reused for mercury leaching. The mercury leaching kinetics follows the shrinking core diffusion model and is controlled by solid product diffusion. The mechanism research shows the leaching efficiency was strongly dependent on the distribution of mercury species in smelting waste. The consequence on mercury leaching and recovery could provide nonferrous smelters with a practical and yet easy-to-adopt perspective to reduce the risk of mercury contamination and selectively recover mercury resources from mercury-containing smelting wastes.

Experimental Studies on Chemical Activation of Cementitious Materials from Smelting Slag of Copper and Nickel Mine

Gellable composite materials (GCM) were prepared from a smelting slag of copper and nickel deposits and cement, and activated using gypsum and chemical activators. The effects of material ratio, dosage of chemical activators, and gypsum on the mechanical properties of GCM were studied. Our results showed that the chemical activators of Na₂SO₄, Na₂SiO₃, NaOH, and Na₂CO₃ could improve the compressive strength of the GCM. Considering the market cost and ease operation, the compressive strength of the GCM could be significantly improved with 2% Na₂SO₄. The experiment results also showed that the compound chemical activator could improve the compressive strength of gelled material. The strength of GCM reaches 41.6 MPa when 2% gypsum and 80% of smelting slags of copper and nickel deposits were used, which met the national standards requirements of GCM. As such, it is expected that a large amount of copper and nickel mining smelting slag could be utilized for the production of cementitious materials.

Solid-liquid separation: an emerging issue in heavy metal wastewater treatment

Solid-liquid separation (SLS) plays a dominant role in various chemical industries. Nowadays, low efficiency of SLS also become a significant problem in heavy metal (HM) wastewater treatment, affecting the effluent quality (HM concentration and turbidity) and overall process economy. In this context, we summarize here the occurrence of solids in HM wastewater, as well as typical SLS operations used in HM wastewater treatment, including sedimentation, flotation, and centrifugation. More important, this article reviews the improvement of the SLS operations by some technologies, including coagulation, flocculation, ballasted method, seeding method, granular sludge strategy, and external field enhancement. It is noted that abiological granular sludge strategy and magnetic field enhancement often possess higher SLS efficiency (faster settling velocity or shorter separation time) than other methods. Hence, the two strategies stand out as promising tools for improving SLS in HM wastewater treatment, but further research is required regarding scalability, economy, and reliability.