Preparation of α-CaSO4·½H2O with tunable morphology from flue gas desulphurization gypsum using malic acid as modifier: A theoretical and experimental study

Facet-engineering strategy of phosphogypsum for production of mineral slow-release fertilizers with efficient nutrient fixation and delivery

Phosphogypsum (PG) presents considerable potential for agricultural applications as a secondary primary resource. However, it currently lacks environmentally friendly, economically viable, efficient, and sustainable reuse protocols. This study firstly developed a PG-based mineral slow-release fertilizer (MSRFs) by internalization and fixation of urea within the PG lattice via facet-engineering strategy. The molecular dynamics simulations demonstrated that the binding energy of urea to the (041) facet of PG surpassed that of the (021) and (020) facets, with urea's desorption energy on the (041) facet notably higher than on the (021) and (020) facets. Guided by these calculations, we selectively exposed the (041) dominant facet of PG, and then achieving complete urea fixation within the PG lattice to form urea-PG (UPG). UPG exhibited a remarkable 48-fold extension in N release longevity in solution and a 45.77% increase in N use efficiency by plants compared to conventional urea. The facet-engineering of PG enhances the internalization and fixation efficiency of urea for slow N delivery, thereby promoting nutrient uptake for plant growth. Furthermore, we elucidated the intricate interplay between urea and PG at the molecular level, revealing the involvement of hydrogen and ionic bonding. This specific bonding structure imparts exceptional thermal stability and water resistance to the urea within UPG under environmental conditions. This study has the potential to provide insights into the high-value utilization of PG and present innovative ideas for designing efficient MSRFs.

Glucose microenvironment sensitive degradation of arginine modified calcium sulfate reinforced poly(lactide-co-glycolide) composite scaffolds

Poly(lactide-co-glycolide) (PLGA) and calcium sulfate composites are promising biodegradable biomaterials but are still challenging to use in people with high levels of blood glucose or diabetes. To date, the influence of glucose on their degradation has not yet been elucidated and thus calls for more research attention. Herein, a novel calcium sulfate whisker with L-arginine was used to effectively tune its crystal morphology and was employed as a reinforced phase to construct the PLGA-based composite scaffolds (ArgCSH/PLGA) with a sleeve porous structure. ArgCSH/PLGA showed excellent elastic modulus and strength in the compression and bending models. Moreover, an in vitro immersion test showed that ArgCSH/PLGA possessed degradation and redeposition behaviors sensitive to glucose concentration, and the adsorbed Arg played a crucial role in the degradation process. The subsequent cell functional evaluation showed that ArgCSH could effectively protect cells from damage caused by AGEs and promote osteogenic differentiation. The corresponding degradation products of ArgCSH/PLGA displayed the ability to regulate osteoblast bone differentiation and accelerate matrix mineralization. These findings provide new insights into the interaction between biomaterials and the physiological environment, which may be useful in expanding the targeted choice of efficient bone graft biodegradable materials for diabetic osteoporosis.

Revealing maleic acid role in the preparation of α-hemihydrate gypsum from titanium gypsum through experiments and DFT calculations

Titanium gypsum (TG) is rarely used to produce α-hemihydrate gypsum (α-HH) because of its poor crystallinity and high impurity and moisture contents. Here, a method is proposed to prepare α - HH by adjusting the reaction temperature, CaCl2 solution concentration and maleic acid dosage based on acid leaching and heat-treated TG as raw material. The effect of maleic acid and Fe3+ ions on the preparation of α-HH were systematically analyzed using density functional theory (DFT) and typical materials characterization methods, X-ray diffraction (XRD), scanning electron microscope (SEM) and X-ray photoelectron spectroscopy (XPS). Under the optimal conditions (CaCl2 concentration of 23 % and reaction temperature of 95 °C), the maleic acid is chemically adsorbed on the crystal surfaces of α-HH, the strongest adsorption is in the (111) surface. Increasing the maleic acid concentration from 0 to 0.15 % decreased the aspect ratio of the α-HH crystals from 8.26 to 0.96, respectively, where the optimal dosage was 0.1 %. The theoretical results proved that the substitution energy of Fe3+ was greater than that of Ca2+, and Fe3+ ions can spontaneously enter the α-HH lattice to replace Ca2+ ions. Furthermore, the adsorption energy of maleic acid on the (111) surface increased after the substitution of Fe3+ to generate a synergistic effect that hinders α-HH growth along the c-axis, resulting in the preferred morphology. The results of this study provide a new method for using waste TG to produce a high-value-added product.

A Critical Review of the Enhanced Recovery of Rare Earth Elements from Phosphogypsum

The increasing demand for rare earth elements (REEs), especially from new and innovative technology, has strained their supply, which makes the exploration of new REE sources necessary, for example, the recovery of REEs from phsophogypsum (PG). PG is a byproduct during the wet production of phosphoric acid, which is an attractive secondary resource for REEs due to a large amount of REEs locked in them. In most cases, REEs contained in PG are mainly encapsulated in the gypsum crystal, leading to a low leaching efficiency. Therefore, it is particularly important to use various methods to enhance the leaching of REEs from PG. In this review, we summarized and classified various enhanced leaching methods for the recovery of REEs from PG, and the advantages and disadvantages of different methods were compared. A joint method of recrystallization and RIL may be a promising enhanced leaching approach for the recovery of REEs from PG. Recrystallization could achieve both the complete REE release and simultaneous preparation of industrial materials with high value added, such as high-strength α-hemihydrate gypsum by phase transformation of PG, and the RIL technology could adsorb the releasing REEs and realize their efficient extraction. Such a combination appears to show significant advantages because of high REE recovery, as well as high value-added product preparation at low cost.

Novel Synergistic Process of Impurities Extraction and Phophogypsum Crystallization Control in Wet-Process Phosphoric Acid

Phosphogypsum, as a byproduct of wet-process phosphoric acid reaction, has caused many environmental pollution problems. To improve the property and purity of phosphogypsum in the wet-process phosphoric acid process, a liquid-solid-liquid three-phase acid hydrolysis synergistic extraction reaction system was established by adding a certain amount of extractant in the actual production process. In order to study the extraction effect and residue of impurities in the reaction system, the phase, morphology, and impurity occurrences of phosphogypsum were systematically analyzed. The results showed that when the reaction time was 7 h, the reaction temperature was 80 °C, the reaction speed was 200 r/min, the volume ratio of the extractant to diluent (dilution ratio) was 1:4 and the volume ratio of the oil phase/aqueous phase (O/A ratio) was 1:1, P2O5 conversion was the highest in phosphate rock, and the residual P2O5 content in phosphogypsum was as low as 0.36%. The morphology of the phosphogypsum crystal was uniform and coarse long strip. The main forms of residual impurities were silicate, aluminum fluoride with crystal water, aluminate, phosphate, and fluoride. Meanwhile, the residual amount of main impurities in phosphogypsum was significantly reduced. Through this novel method, the property of phosphogypsum can be improved through the generation process and is greatly beneficial for its utilization and the recycling development of the wet-process phosphoric acid industry.

Mussel-inspired dynamic facet-selective capping approach to highly uniform α-calcium sulfate hemihydrate crystals

We report herein a dynamic facet-selective capping (dFSC) strategy for α-calcium sulfate hemihydrate crystal growth from dihydrate gypsum in the presence of a catechol-derived PEI capping agent (DPA-PEI) with inspiration by the biomineralization process of mussel. The crystal shape is controllable and varies from long and pyramid-tipped prisms to thin hexagonal plate. The highly uniform truncated crystals have extremely high compression and bending strengths after hydration molding.

Insights into the Role of Na+ on the Transformation of Gypsum into α-Hemihydrate Whiskers in Alcohol-Water Systems

Alcohol-water solution-mediated transformation of gypsum into α-hemihydrate (α-HH) whiskers provides a green alternative for the high-value-added recycling of flue gas desulfurization (FGD) gypsum. However, the role of non-lattice cations during the transformation is still unclear. We report an evolution from "boosting-retarding" to "boosting-retarding-boosting" and finally to "boosting only" effect of non-lattice Na⁺ functioned by the concentration of ethylene glycol (EG) in water solutions. The driving force increased almost linearly upon the introduction of Na⁺ through the formation of ion pairs, and a higher slope was obtained at a higher EG concentration. Adsorption of Na⁺ ions and solidification of eugsterite on gypsum surfaces blocked the nucleation sites of α-HH. The retarding effect first rapidly increased and gradually approached a limit, following a parabolic trend after Na⁺ ions were introduced. Pentasalt, with a structure similar to that of α-HH, precipitated on the gypsum surface at higher c(Na⁺). The interaction of the driving force and the structural evolution of calcium sulfate ionic clusters accounts for the evolution of transformation kinetics. The retardation zone was compressed with the increase in EG volume ratios, and a monotonic boosting effect upon Na⁺ was observed at a 35.0 vol % of EG. Nucleation kinetics dominates the aspect ratio of α-HH whiskers. This study may provide a significant guidance for the utilization of FGD gypsum.

Experimental Study and Mechanism Analysis of Preparation of α-Calcium Sulfate Hemihydrate from FGD Gypsum with Dynamic Method

Flue-gas desulphurization (FGD) gypsum is a highly prevalent industrial by-product worldwide, which can be an excellent alternative to natural gypsum due to its high content of CaSO₄·2H₂O. The preparation of α-calcium sulfate hemihydrate is a high-value pathway for the efficient use of FGD gypsum. Here, a dynamic method, or an improved autoclaved process, was used to produce α-calcium sulfate hemihydrate from FGD gypsum. In this process, the attachment water of the mixture of FGD gypsum and crystal modifiers was approximately 18%, and the pH value was approximately 6.0. The mixture did not need to be pressed into bricks or made into slurry, and it was directly sent into the autoclave reactor for reaction. It was successfully applied to the practical production and application of FGD gypsum, citric acid gypsum and phosphogypsum. In this work, the compositions and morphology of the product at different stages of the reaction were examined and compared. In particular, single-crystal diffraction was used to produce the crystal structure of CaSO₄·0.5H₂O, and the results were as follows: a = 13.550(3); b = 13.855(3); c = 12.658(3); β = 117.79(3)°; space group C2. The preferential growth along the c-axis and the interaction mechanism between the carboxylate groups and the crystal were discussed throughout the analysis of the crystal structure.

Research hotspots and trends of comprehensive utilization of phosphogypsum: Bibliometric analysis

Phosphogypsum is a by-product of the phosphate fertilizer industry. It is generally treated by stacking, which not only causes environmental pollution, but also wastes resources. Therefore, the harmless, comprehensive, and high-value utilization of phosphogypsum has attracted more and more scholars around the world. From the perspective of bibliometrics, this paper systematically and comprehensively describes the research progress, trends and hot spots of phosphogypsum resource utilization. This article is based on a scientific network database, and a total of 1067 articles from 1985 to 2020 were collected. Then, use VOSViewer software to perform co-occurrence, co-citation analysis and cluster analysis. The visual analysis results demonstrate that the research on the resource utilization of phosphogypsum shows the characteristics of rapid growth. The active countries are mainly China, Brazil, Spain and the United States. Four of the top 10 active organizations are from China. It systematically expounds the changes in research hotspots in this field at different stages and possible future research hotspots. Including the gradual attention to the preparation of phosphogypsum building materials, phosphogypsum adsorption materials, and radioactive elements in phosphogypsum; the extraction of rare earth elements from phosphogypsum; the use of phosphogypsum to prepare fertilizer or soil improvement. Research shows that phosphogypsum can be reasonably designed, transformed, and used in different fields.However, the radioactivity contained in phosphogypsum should be paid attention to because it has an impact on humans and the environment. We believe that this research provides a comprehensive and systematic overview for future research on phosphogypsum resource utilization.

Mechanical activation to enhance the natural floatability of waste printed circuit boards

The metal in the waste printed circuit boards (WPCBs) is an excellent secondary metal resource. WPCBs were ground to dissociate, and impurities in the dissociated product were removed by gradient flotation to recover valuable metals in this study. The effects of crushing methods on size composition and dissociation state of the crushed products were studied. Then the gradient flotation experiment was designed to verify the natural floatability of ground materials. Grinding test shows that impact crushing has greater grinding fineness (-0.074 mm) than shear crushing, which is 42.14% and 26.18% respectively with 5 min grinding. The flotation test results illustrate that the natural floatability of impurities increases with the grinding fineness, that is, the yield of floats increases without flotation reagents. For impact crushing and shear crushing, the floats yields are 38.48% and 31.75% respectively, accompanied by 70.53% and 65.46% impurity removal for ground materials with 5 min grinding. Subsequently, 21.61% and 26.35% of impurities can be further removed with the aid of collector. Finally, the recovery of Cu in concentrate reaches 67.84% and 65.75%, respectively. FT-IR proves that the excellent floatability of particles is caused by the significant hydrophobic group. Mechanical grinding has been proved to have double effects of improving dissociation and natural floatability.

Effects of Impurities on CaSO4 Crystallization in the Ca(H2PO4)2-H2SO4-H3PO4-H2O System

Wet-process phosphoric acid is a fundamental process in the fertilizer industry. The influence of impurities on crystallization kinetics of CaSO₄ was investigated in the Ca(H₂PO₄)₂-H₂SO₄-H₃PO₄-H₂O system using a mixed suspension mixed product removal crystallizer. Effects of Si, Al, Fe, Mg, K, and Na on crystal morphology and structure were examined in the highly acidic system through scanning electron microscopy and high-resolution transmission electron microscopy. Results show that the increase of Mg, K, and Na content facilitates crystal growth. Si, Al, and Fe are beneficial to CaSO₄ crystal growth at a certain concentration range. Impurities also affect the crystal morphology, and the addition of Si, Fe, and Na promotes the formation of needle-like crystals compared with other impurities. X-ray diffraction results show that the preferred crystal growth direction is (020), and the interplanar spacing of the crystals is affected by the element radius of the impurities.

Aspect ratio-controlled preparation of α-CaSO4·0.5H2O from phosphogypsum in potassium tartrate aqueous solution

In this study, a simple and efficient strategy is developed to synthesize rod-shaped α-CaSO4·0.5H2O crystals with tunable aspect ratio from industrial phosphogypsum only in potassium tartrate aqueous solution at a low temperature. Industrial phosphogypsum can be effectively converted into rod-shaped α-CaSO4·0.5H2O crystals with the assistance of potassium tartrate, and the aspect ratio of α-CaSO4·0.5H2O crystals gradually decreases from 52 : 1 to 1 : 1 with increasing the concentration of potassium tartrate. The formation process of the rod-shaped α-CaSO4·0.5H2O crystals in this system involves the dissolution of CaSO4·2H2O and nucleation of α-CaSO4·0.5H2O crystals. The tartrate ions from potassium tartrate in this system preferentially bind to (001) and (002) facets of α-CaSO4·0.5H2O crystals, inhibiting the growth of α-CaSO4·0.5H2O crystals along the c-axis and controlling its morphology and aspect ratio.

Reverse Flotation Separation of Fluorite from Calcite: A Novel Reagent Scheme

Fluorite (CaF2), as an important strategic mineral source, is usually separated from calcite by the common froth flotation method, but this separation is still not selective enough. The development of a selective collector and/or depressant is the key to achieving high selective separation. 1-Hydroxyethylidene-1,1-diphosphonic acid (HEDP or H4L) is widely used as an environmentally friendly water treatment reagent due to its low cost and excellent anti-scaling performance in an aqueous solution. In this study, a novel reagent scheme was developed using HEDP as a fluorite depressant and sodium oleate (NaOL) as a calcite collector for the first time. When 3 × 10−5 mol/L of HEDP and 6 × 10−5 mol/L of NaOL were used at pH 6, the optimal selective separation for single minerals and mixed binary minerals was obtained. Zeta potential measurements indicated that HEDP possessed a stronger adsorption on fluorite than calcite, while NaOL did the opposite. This novel reagent scheme is of low cost, uses a small dosage, and is friendly to the environment, which makes it a promising reagent scheme for fluorite flotation in industrial application.

Selective Flotation of Cassiterite from Calcite with Salicylhydroxamic Acid Collector and Carboxymethyl Cellulose Depressant

Cassiterite is the most common and important tin-bearing mineral, and calcite, a primary gangue mineral is generally found in tin deposit. The flotation separation of cassiterite from calcite remains a challenge due to their similar response to traditional reagents. In cassiterite flotation, sodium oleate (NaOL) and sodium silicate (SS) have been widely used as a collector and a depressant, respectively. However, the low selectivity of NaOL and the large amount of SS required (which leads to serious problems in wastewater treatment) remain a difficult issue. In this study, a novel reagent scheme using lead nitrate as the activator, salicylhydroxamic acid (SHA) as the collector and carboxymethyl cellulose as the depressant was employed to improve the separation selectivity of cassiterite from calcite. Results of the flotation experiment using this new reagent scheme showed that compared with the previously reported scheme using benzohydroxamic acid (BHA) as the collector, the separation of cassiterite from calcite exhibited a higher selectivity and selectivity index (SI). The mechanism of the selective separation was investigated by zeta potential measurements, Fourier transform infrared and X-ray photoelectron spectroscopy analysis.