Process development for recovery of vanadium and nickel from an industrial solid waste by a leaching-solvent extraction technique

Valorization of fly ash by nickel ferrite and vanadium oxide recovery through pyro-hydrometallurgical processes: Technical and environmental assessment

The fly ash (FA) from the combustion of heavy oil in power stations is characterized by fine particles containing toxic metals. The sample utilized in this study was gathered from the dust precipitators of seven heavy-oil-consuming Iranian power plants. Substantial quantities of heavy metals, particularly vanadium, iron, and nickel, have been detected in the sample, indicating both its potential utility and hazard to the soil and groundwater. The harmful consequences of FA disposal on the environment have led to the adoption of recycling as a treatment approach in this study. The valorization of FA was investigated by producing nickel ferrite (NiFe2O4) and vanadium pentoxide (V2O5) through a novel approach using a combination of pyro-hydrometallurgical processes, which resulted in proposing a recycling closed-loop flowsheet. Roasting was first practiced to form NiFe2O4 by reacting the nickel and iron content of the FA. The NiFe2O4 showed a low dissolution against inorganic acids (H2SO4, HCl, and HNO3). The vanadium content of the FA showed a remarkable recovery in H2SO4 (91%) and HCl (95.6%), while the dissolution of Ni was limited to 16.85% and 17.5%, respectively. The produced NiFe2O4 acted well in response to the magnetic field, and its purity was further increased to 95-96% through a two-stage process consisting of grinding and magnetic separation. The nano-sized spherical NiFe2O4 with saturation magnetization of 34.66 and 30.82 emu. g-1 was obtained from H2SO4 and HCl residues, respectively. The dissolved vanadium was recovered as V2O5 via oxidation-precipitation in sulfate media and oxidation-ammonium precipitation in chloride solution. The purity of V2O5 in sulfate and chloride media was 93% and 98.5%, respectively. Finally, a life cycle assessment (LCA) study was performed on the suggested methods to track the ecological effects of extracting V and Ni from oil combustion FA. According to the performed LCA, H2SO4 was determined as the proper leaching reagent considering the environmental and technical aspects.

Recovery of vanadium and nickel from heavy oil fly ash (HOFA): a critical review

Heavy oil fly ash "HOFA" is the fly ash generated in power stations using heavy oil as fuel. HOFA is considered a hazardous waste because it contains considerable amounts of heavy metals. However, it contains significant amounts of vanadium "V" and nickel "Ni", which are precious metals for manufacturing processes. This paper presents a critical review of various approaches described in the literature for the recovery of V and Ni from HOFA, including processes of leaching, chemical precipitation, solvent extraction, and ion exchange. The optimum operational parameters and their effects on recovery efficiency are discussed. The digestion mixtures of strong mineral acids used for dissolving all metals present in HOFA are also highlighted. The leaching processes of V and Ni use mainly acidic and alkaline solutions. Bioleaching is a promising environmentally friendly approach for the recovery of V and Ni through using appropriate bacteria and fungi. After leaching, V and Ni compounds are recovered and purified using various techniques, including chemical precipitation, solvent extraction, and ion exchange. In most cases, V and Ni are recovered as thermally decomposable compounds that undergo calcination to produce V₂O₅ and NiO. Eventually, V and Ni are recovered as pure oxides in most approaches, but pure metals are obtained in exceptional procedures.

Adsorption of vanadium (V) ions from the aqueous solutions on different biomass-derived biochars

The paper presents the results of the studies on the vanadium (V) ions removal from the aqueous solutions in the adsorption process on biochars from different biomass types (cow manure BC1, wet distiller grains BC2, spent mushroom substrates BC3). The adsorbents were characterized by means of the SEM-EDS, FTIR, XRD and XPS techniques. The influence of adsorbent type and basic process parameters, such as pH and metal ion concentration in aqueous phase, adsorbent dose and time of contact of phases on the efficiency of V(V) was determined. Based on the obtained results, the mechanism and kinetics of the adsorption processes occurring on the biochar originating from the wet distiller grains as adsorbents with the greatest affinity for the V(V) ions were characterized, using isotherm models of Langmuir, Freundlich, Temkin and Dubinin-Radushkevich and pseudo-first-order, pseudo-second-order as well as intraparticle diffusion kinetic models. Under the constant process conditions (pH = 3.0; m = 0.5 g; c₀ = 50 mg/L) the order of V(V) ions removal from aqueous solutions was as follows: BC2 > BC1 = BC3. The biochar BC2 exhibited the maximum sorption capacity of 1.61 mg V(V)/g. The experimental kinetic data show the adsorption course according to the pseudo-second order model.

On the Potential of a Poly(vinylidenefluoride-co-hexafluoropropylene) Polymer Inclusion Membrane Containing Aliquat® 336 and Dibutyl Phthalate for V(V) Extraction from Sulfate Solutions

A polymer inclusion membrane (PIM) composed of 50 wt% base polymer poly(vinylidenefluoride-co-hexafluoropropylene), 40 wt% extractant Aliquat^® 336, and 10 wt% dibutyl phthalate as plasticizer/modifier provided the efficient extraction of vanadium(V) (initial concentration 50 mg L⁻¹) from 0.1 M sulfate solutions (pH 2.5). The average mass and thickness of the PIMs (diameter 3.5 cm) were 0.057 g and 46 μm, respectively. It was suggested that V(V) was extracted as VO₂SO₄⁻ via an anion exchange mechanism. The maximum PIM capacity was estimated to be ~56 mg of V(V)/g for the PIM. Quantitative back-extraction was achieved with a 50 mL solution of 6 M H₂SO₄/1 v/v% of H₂O₂. It was assumed that the back-extraction process involved the oxidation of VO₂⁺ to VO(O₂)⁺ by H₂O₂. The newly developed PIM, with the optimized composition mentioned above, exhibited an excellent selectivity for V(V) in the presence of metallic species present in digests of spent alumina hydrodesulfurization catalysts. Co-extraction of Mo(VI) with V(V) was eliminated by its selective extraction at pH 1.1. Characterization of the optimized PIM was performed by contact angle measurements, atomic-force microscopy, energy dispersive X-ray spectroscopy, thermogravimetric analysis/derivatives thermogravimetric analysis and stress–strain measurements. Replacement of dibutyl phthalate with 2-nitrophenyloctyl ether improved the stability of the studied PIMs.

Direct recovery of boiler residue by combustion synthesis

Boiler residue (BR) of thermal power plants is one of the important secondary sources for vanadium production. In this research, the aluminothermic self-propagating high-temperature synthesis (SHS) was used for recovering the transition metals of BR for the first time. The effects of extra aluminum as reducing agent and flux to aluminum ratio (CaO/Al) were studied and the efficiency of recovery and presence of impurities were measured. Aluminothermic reduction of vanadium and other metals was carried out successfully by SHS without any foreign heat source. Vanadium, iron, and nickel principally were reduced and gone into metallic master alloy as SHS product. High levels of efficiency (>80%) were achieved and the results showed that SHS has a great potential to be an industrial process for BR recovery. SHS produced two useful products. Metallic master alloy and fused glass slag that is applicable for ceramic industries. SHS can also neutralize the environmental threats of BR by a one step process.

A two-step approach for copper and nickel extracting and recovering by emulsion liquid membrane

The recycling of copper and nickel from metallurgical wastewater using emulsion liquid membrane (ELM) was studied. P507 (2-ethylhexyl phosphonic acid-2-ethylhexyl ester) and TBP (tributyl phosphate) were used as carriers for the extraction of copper and nickel by ELMs, respectively. The influence of four emulsion composition variables, namely, the internal phase volume fraction (ϕ), surfactant concentration (Wsurf), internal phase stripping acid concentration (Cio) and the carrier concentration (Cc), and the process variable treat ratio on the extraction efficiencies of copper or nickel were studied. Under the optimum conditions, 98% copper and nickel were recycled by using ELM. The results indicated that ELM extraction is a promising industrial application technology to retrieve valuable metals in low concentration metallurgical wastewater.

Vanadium removal and recovery from bauxite residue leachates by ion exchange

Bauxite residue is an important by-product of the alumina industry, and current management practices do not allow their full valorisation, especially with regard to the recovery of critical metals. This work aims to test the efficiency of ion exchange resins for vanadium (V) removal and recovery from bauxite residue leachates at alkaline pH (11.5 and 13). As an environmental pollutant, removal of V from leachates may be an obligation of bauxite residue disposal areas (BRDA) long-term management requirements. Vanadium removal from the leachate can be coupled with the recovery, and potentially can be used to offset long-term legacy treatment costs in legacy sites. Kinetics studies were performed to understand the adsorption process. The rate kinetics for the V adsorption was consistent with the pseudo-first-order kinetic model, with a higher adsorption rate for pH 11.5 (1.2 min^-1). Adsorption isotherm data fitted better to Freundlich equations than to the Langmuir model. The maximum adsorption capacity (Langmuir value q _max) was greatest for pH 13 (9.8 mg V g^-1 resin). In column tests, breakthrough was reached at 70 bed volumes with the red mud leachate at pH 13, while no breakthrough was achieved with the effluent at pH 11.5. In regeneration, 42 and 76 % of V were eluted from the resin with 2 M NaOH from the red mud leachate at pH 13 and 11.5, respectively. Further optimization will be needed to upscale the treatment.