Aluminum recovery as a product with high added value using aluminum hazardous waste

Joint utilization and harmless elimination of aluminum dross and refined magnesium slag to simultaneously recover metallic aluminum and fusing agent

Refined magnesium slag and aluminum dross are two typical hazardous solid wastes that contain significant amounts of leachable fusing agent and aluminum droplets encapsulated by dense oxidized films, respectively. This study creatively proposes a safe and green method for the joint utilization of these two wastes. The interfacial reaction behavior revealed that the dense oxidized films of the aluminum droplets were significantly broken by the erosive action of the fusing agent, providing the necessary conditions for the movement of aluminum droplets. Consequently, the aluminum droplets successfully broke free from the oxidized films and separated together with the fusing agent from the dross under the force of supergravity. The recovery ratios of metallic aluminum and fusing agent reached 98.95 % and 98.13 %, while the aluminum and fusing agent contents in the tailings were reduced to 0.82 wt% and 3.71 wt%. The study also discusses the leaching characteristic of the tailings and the scalability for industrial applications of this method in detail. This study not only achieves valuable resource recovery but also reduces the leaching risk and alleviates the land occupation and ecosystem pressure caused by industrial wastes. The tailings can be harmlessly utilized in related fields through subsequent scientific treatment.

Aluminum Biorecovery from Wastewaters

Aluminum biorecovery is still at an early stage. However, a significant number of studies showing promising results already exist, although they have revealed problems that need to be solved so aluminum biorecovery can have a wider application and industrial upscaling. In this chapter, we revise the existing knowledge on the biorecovery of aluminum from different sources. We discuss the design, overall performance, advantages, technical problems, limitations, and possible future directions of the different biotechnological methods that have been reported so far. Aluminum biorecovery from different sources has been studied (i.e., solid wastes and primary sources of variable origin, wastewater with low concentrations of dissolved aluminum at pH-neutral or weakly acidic conditions, and acidic mine waters with high concentrations of dissolved aluminum and other metal(loid)s) and has shown that the process efficiency strongly depends on factors such as (1) the physicochemical properties of the source materials, (2) the physiological features of the used (micro)organisms, or (3) the biochemical process used. Bioleaching of aluminum from low-grade bauxite or red mud can much be achieved by a diverse range of organisms (e.g., fungi, bacteria) with different metabolic rates. Biorecovery of aluminum from wastewaters, e.g., domestic wastewater, acidic mine water, has also been accomplished by the use of microalgae, cyanobacteria (for domestic wastewater) or by sulfate-reducing bacteria (acidic mine water). In most of the cases, the drawback of the process is the requirement of controlled conditions which involves a continuous supply of oxygen or maintenance of anoxic conditions which make aluminum biorecovery challenging in terms of process design and economical value. Further studies should focus on studying these processes in comparison or in combination to existing economical processes to assess their feasibility.

Field-tested innovation: Sustainable utilization of secondary alumina dross for flash setting admixtures production

Secondary alumina dross (SAD) has emerged as an alternative to bauxite in the production of flash setting admixtures (FSA), a critical admixture in shotcrete. However, the presence of hazardous components has hampered its large-scale adoption. This study conducted field tests at an FSA factory, utilizing SAD as the primary raw material, to evaluate the feasibility and environmental risks. The results confirmed that SAD can effectively replace bauxite in FSA production without compromising quality, as it closely resembled the chemical properties of bauxite. Emissions of fluorides, heavy metals, dioxins in flue gases during production met the relevant Chinese standards. The analysis of hazardous component distribution revealed that more than 50% of volatile components, such as Cl, Cd, Pb, and Zn, were directed into fly ash, exhibiting a significant internal accumulation pattern. In contrast, more than 95% of low-volatility components, including Cu, Cr, Mn, and F, were transferred to the FSA, and the introduction of CaCO3 was confirmed to effectively immobilize F. Moreover, the leaching risk of heavy metals and fluorides in FSA applications slightly increased but remained minimal and within acceptable limits. This technology provides an environmentally sound solution for the disposal of SAD.

Thermal utilization techniques and strategies for secondary aluminum dross: A review

Secondary aluminum ash (SAD) disposal is challenging, particularly in developing countries, and presents severe eco-environmental risks. This paper presents the treatment techniques, mechanisms, and effects of SAD at the current technical-economic level based on aluminum ash's resource utilization and environmental properties. Five recovery techniques were summarized based on aluminum's recoverability in SAD. Four traditional utilization methods were outlined as per the utilization of alumina in SAD. Three new utilization methods of SAD were summarized based on the removability (or convertibility) of aluminum nitride in SAD. The R-U-R (recoverability, utilizability, and removability) theory of SAD was formed based on several studies that helped identify the fingerprint of SAD. Furthermore, the utilization strategies of SAD, which supported the recycling of aluminum ash, were proposed. To form a perfect fingerprint database and develop various relevant techniques, future research must focus on an extensive examination of the characteristics of aluminum ash. This research will be advantageous for addressing the resource and environmental challenges of aluminum ash.

A comprehensive review on the ultrasound-enhanced leaching recovery of valuable metals: Applications, mechanisms and prospects

In recent two decades, ultrasound has been broadly applied to the hydrometallurgical leaching process to recover valuable metals within raw materials, aiming to solve the shortcomings of the conventional leaching process, including relatively low leaching recovery, long leaching duration, high reagent usage, high energy consumption and so on. The present work focuses on a comprehensive overview of the ultrasound-enhanced leaching of various metals, such as common nonferrous and ferrous metals, rare metals, rare earth elements, and precious metals, from raw metal ores and secondary resources. Moreover, the enhanced leaching mechanisms by ultrasound are discussed in detail and summarized based on the improvement of leaching kinetics, enhancement of the mass transfer and diffusion of lixiviants, and promotion of the oxidative conversion of metals from insoluble to soluble states. Lastly, the challenges and outlooks of future research on the leaching recovery for valuable metals with the assistance of ultrasound irradiation are proposed.

Mode of innovative green production for concrete engineering: life cycle assessment of accelerators prepared from aluminum mud wastes

In this study, two types of liquid alkali-free accelerators were prepared by aluminum sulfate (AF₁) and aluminum mud wastes (AF₂), and the life cycle assessment (LCA) in the preparation of AF₁ and AF₂ was compared. The LCA was considered from cradle to gate including raw materials used, transportation, and accelerator preparation based on the method ReCiPe2016. The results indicated that AF₁ had a higher environmental impact in all midpoint impact categories and endpoint indicators than that of AF₂, and AF₂ reduced 43.59% emission of CO₂, 59.09% emission of SO₂, 71% consumption of mineral resources, and 46.67% consumption of fossil resources than that of AF₁ respectively. As an environment-friendly accelerator, AF₂ had a better application performance than traditional accelerator AF_1. When the dosage of accelerators was 7%, the initial setting times of cement pastes containing AF₁ and AF₂ were 4 min 57 s and 4 min 04 s respectively, the final setting times of cement pastes containing AF₁ and AF₂ were 11 min 49 s and 9 min 53 s respectively, and the compressive strengths at 1 d of mortars containing AF₁ and AF₂ were 7.35 MPa and 8.33 MPa respectively. This study aims to provide technical feasibility and environmental impact assessment for exploring new avenues of preparing environment-friendly liquid alkali-free accelerators with aluminum mud solid wastes. It has great potential in reducing carbon and pollution emissions and has a greater competitive advantage due to great application performance.

Composites of Layered Double Hydroxides and ANA-Type Zeolite Synthesized from Hazardous Secondary Aluminum Dross for Cationic Dye Wastewater Treatment

This work first transformed hazardous aluminum waste into low-cost MgAl−layered double hydroxide@ANA zeolite (LDHs@ANA) composite for dye wastewater adsorption, which was meaningful for waste recovery and pollution control. Based on this strategy, the Al(OH)3 extracted from secondary aluminum dross (a hazardous waste in the aluminum industry) was used as an aluminum source to synthesize LDHs@ANA composite, which had more excellent adsorption capacity to methylene blue than MgAl−LDHs and ANA alone. The composite consisted of spherical ANA particles uniformly covered with LDH nanosheets, which effectively avoided a large amount of aggregation between nanosheets and increased specific surface areas and pore volumes. The kinetic results indicated that the adsorption process conformed to the pseudo-second-order kinetic model, and the adsorption site was the main factor affecting the adsorption process. The equilibrium studies showed the adsorption process was exothermic, and the Langmuir model best fitted for the adsorption process, with a maximum adsorption capacity reaching 65.27 mg/g. Meanwhile, the effects of pH, adsorbent concentration, initial methylene blue concentration, and adsorption time on the LDHs@ANA were analyzed. Overall, this work provides a fresh concept for the preparation of low-cost adsorbents from aluminum waste.

Removal of nitrides and fluorides from secondary aluminum dross by catalytic hydrolysis and its mechanism

Secondary aluminum dross (SAD) refers to hazardous waste from secondary aluminum refinement. It contains a large amount of aluminum nitride and fluorides that cause serious environmental pollution for direct discharge and hinder the resource utilization of SAD. However, it is difficult to remove nitride and fluoride simultaneously for their complicated phases. In this paper, the catalytic hydrolysis of SAD using NaOH as a catalyst to remove nitrides and fluorides synchronously was investigated systemically through single factor and response surface experiments. In addition, the chemical speciation and transformation of nitrides and fluorides were analyzed systematically. The catalytic hydrolysis removal mechanism was summarized. The optimal conditions for catalytic hydrolysis were established as follows: reaction temperature 96.60 °C; reaction time 2.85 h; liquid-solid ratio 9.28 mL/g and catalyst addition 12.62 wt %; and removal efficiency of nitrides and fluorides reached 99.03% and 81.93%, respectively. The mechanism of nitrides removal was that aluminum nitride was hydrolyzed to Al(OH)₃ and NH₃. NaOH reacting with Al(OH)₃ covering on the surface of AlN and the rapid escape of NH₃ promoted the hydrolysis of AlN under the catalysis of NaOH. The mechanism of fluorides removal was that the encapsulated fluoride particles were opened by catalytic hydrolysis to be dissolved in the solution. In this research, nitrides and fluorides were removed efficiently and synchronously. The hydrolysis residues can be used to prepare polyaluminum chloride (PAC) and ceramic materials. The hydrolysate can be prepared NH₃·H₂O by evaporative in alkaline solution. Then the solution without NH₄ ⁺ was prepared Al(OH)₃ by precipitation of adjusting pH value using HCl. And the remained liquid after removing NaAlO₂ was used to prepare refining agent by evaporative crystallization. The work in this paper was beneficial for the utilization of SAD.

Effective Extraction of the Al Element from Secondary Aluminum Dross Using a Combined Dry Pressing and Alkaline Roasting Process

Secondary aluminum dross (SAD) is a hazardous solid waste discharged from aluminum electrolysis and processing and the secondary aluminum industries, which causes severe environmental pollution and public health disasters. The stable presence of the α-Al₂O₃ and MgAl₂O₄ phases in SAD makes it difficult for it to be efficiently utilized. A combined dry pressing and alkaline roasting process was proposed for extracting the valuable Al element from SAD. Two alkaline additives (NaOH and Na₂CO₃) were selected as a sodium source for extracting the aluminum source from SAD in order to perform the thermodynamic analysis and roasting experiments. The phase transition behavior and the leaching performance tests were conducted using X-ray diffraction, scanning electron microscopy, X-ray fluorescence, leaching kinetics and thermal analysis. The recovery of Al and Na reached the values of 90.79% and 92.03%, respectively, under the optimal conditions (roasting temperature of 1150 °C, Na₂CO₃/Al₂O₃ molar ratio of 1.3, roasting time of 1 h, leaching temperature of 90 °C, L/S ratio of 10 mL·g^-1 and leaching time of 30 min). Meanwhile, the removal efficiency of N and Cl reached 98.93% and 97.14%, respectively. The leaching kinetics indicated that the dissolution of NaAlO₂ clinkers was a first-order reaction and controlled by layer diffusion process. The green detoxification and effective extraction of the Al element from SAD were simultaneously achieved without any pretreatments.

Waste to Wealth Strategy: Preparation and Properties of Lightweight Al2O3-SiO2-Rich Castables Using Aluminum Dross Waste

Aluminum dross is a well-known industrial waste generated in the aluminium industry, and its recycling and reuse is still a worldwide issue. Herein, aluminum dross waste (ADW) was recycled to progressively replace the aggregate fraction of clay at 70, 75, 80, 85, and 90 wt% for the fabrication of Al₂O₃-SiO₂-rich porous castable refractories. Their physical properties and mechanical behavior were assessed by the measurement of linear shrinkage rate, bulk density, apparent porosity, cold crushing strength, and thermal conductivity. The microstructure and phase evolutions were analyzed via scanning electron microscopy (SEM) and X-ray diffraction (XRD). The incorporation of 85 wt% of ADW allowed the development of a waste-containing conventional refractory castable with improved properties as compared to those of the other samples. The sustainable refractory castable exhibited decent thermal conductivity and physical and mechanical characteristics, and is suitable for application as reheating furnace lining. It is a "green" practice to partially replace the traditional raw materials with industrial waste in the manufacture of conventional refractory castables and provides environmental and economic benefits.

Research on the Preparation Parameters and Basic Properties of Premelted Calcium Aluminate Slag Prepared from Secondary Aluminum Dross

Secondary aluminum dross is a byproduct of the electrolytic aluminum industry, whose main components are Al₂O₃, AlN and Na₃AlF₆. Secondary aluminum dross is a type of hazardous waste, with a tremendous yield every year. Realizing the harmless treatment or resource utilization of secondary aluminum dross has important economic and social benefits. In the present research, the process of preparing premelted calcium aluminate slag used for molten steel refining from secondary aluminum dross was studied in detail. Firstly, the chemical composition and phase component of secondary aluminum dross were analyzed systematically. Then, according to phase diagram analysis and melting point measurement, the appropriate mixing ratio of CaO and secondary aluminum dross and the appropriate calcination temperature were determined. On this basis, an experiment of premelted calcium aluminate slag preparation was carried out in a tubular resistance furnace. The phase component and micromorphology of the premelted slag were analyzed by XRD and SEM. The results show that the main component of the premelted calcium aluminate slag is 11CaO·7Al₂O₃·CaF₂ phase with a low melting point. The original Na₃AlF₆ phase, which is the cause of leachable fluoride in secondary aluminum dross, disappears totally, and there is no water-soluble fluoride detected in the leaching toxicity detection. The research indicates that the process of preparing premelted calcium slag from secondary aluminum dross is feasible, which provides a helpful reference for the resource utilization of secondary aluminum dross.

Effect of Alumina Additives on Mechanical and Fresh Properties of Self-Compacting Concrete: A Review

Self-compacting concrete (SCC) has been increasingly used in the construction sector due to its favorable characteristics in improving various durability and rheology aspects of concrete such as deformability and segregation resistance. Recently, the studies on the application of nano-alumina (NA) produced from factory wastes have been significantly considered to enhancing the performance, and mechanical strength, of SCC. Many experimental works show that NA can be used in SCC with appropriate proportion to enjoy the benefits of improved microstructure, fresh and hardened properties, durability, and resistance to elevated temperature. However, a limited detailed review is available to particularly study using NA to improve the performance of SCC, so far. Hence, the present study is conducted to fill the existing gap of knowledge. In this study, the effect of using NA in improving rheological, mechanical parameters, and elevated temperature resistance of SCC is reviewed. This research summarized the studies in this area, which have been different from the previous researches, and provided a discussion on limitations, practical implications, and suggestions for future studies.

Harmless disposal and resource utilization for secondary aluminum dross: A review

Secondary aluminum dross (SAD) is solid waste of primary aluminum dross extracted aluminum, which contains approximately 40-60 wt% alumina, 10-30 wt% aluminum nitride (AlN), 5-15 wt% salts and other components. The salts include sodium chloride, potassium chloride and fluorine salts. SAD has dual attributes as resource and pollutant. SAD landfill disposal has the disadvantages of occupying land, wasting resources, a high cost and great environmental impact. SAD utilization methods are currently pyrometallurgy and hydrometallurgy. In pyrometallurgy, AlN is oxidized and the salts are evaporated at high temperature. After mixing, molding and calcination, firebricks and ceramics can be manufactured from SAD. In hydrometallurgy, AlN is hydrolyzed and salts are dissolved in water. After dissolving, filtrating, precipitating, washing and calcination, γ-Al₂O₃ can be prepared from SAD. Resource consumption and emission from both utilization methods were assessed. A ton of magnesium aluminum titanate based ceramics by pyrometallurgy consumes 1043 kg raw materials and releases 69 kg of waste gas, 4.17 t of waste water and no solid waste. A ton of γ-Al₂O₃ by hydrometallurgy consumes 3389 kg raw materials and releases 111 kg of waste gas, 12.98 t of waste water and 267 kg of solid waste. Therefore, the resource consumption and emission of SAD utilization by pyrometallurgy is lower than that by hydrometallurgy. We should focus on reducing the emission of the three wastes from pyrometallurgy. We are sure that SAD can be utilized for glass ceramics by pyrometallurgy. AlN and salts can be transformed into alumina and glass phases at high temperature with no emission. We should clarify mechanisms for SAD composition adjustment to lower the glass ceramics' melting point, AlN and salts transformed into alumina and glass phases respectively, and nucleation and crystal growth of glass ceramics at high temperature.

Using sodium D-gluconate to suppress hydrogen production in wet aluminium waste dust collection systems

The reaction of aluminium dust and water generated in the production of aluminium products generates hydrogen, which poses a risk to wet collection systems for hydrogen explosions. In this paper, non-toxic and environmentally friendly sodium D-gluconate is used to suppress the hydrogen production reaction of aluminium waste dust and water. The results of the hydrogen evolution curves and chemical kinetics of 7 different concentrations of sodium D-gluconate showed that when the sodium D-gluconate concentration reached 0.25 g L^-1, there was almost no hydrogen generation, and the rate constant was almost zero. The scanning electron microscopy (SEM) results showed that the surface of the reaction product became smoother with increasing solution concentration. The energy dispersive spectroscopy (EDS) results showed that increasing the solution concentration slowed the formation of aluminium oxide in the product, confirming the effectiveness of sodium D-gluconate in inhibiting the reaction of aluminium waste dust particles with water. The Fourier transform infrared (FTIR) results showed that sodium D-gluconate formed a chemical adsorption film on the surface of aluminium waste dust particles to prevent the dust from contacting water, thus suppressing hydrogen production. This method provides a new approach to design safe wet collection systems by suppressing hydrogen production.

Synthesis of Cryolite (Na3AlF6) from Secondary Aluminum Dross Generated in the Aluminum Recycling Process

Secondary aluminum dross (SAD) is regarded as a solid waste of aluminum recycling process that creates serious environmental and health concerns. However, SAD can also be used as a good source of aluminum, so that utilizing the SAD for the production of valuable products is a promising approach of recycling such waste. In the present work, a novel eco-friendly three-step process was proposed for the synthesis of cryolite (Na3AlF6) from the SAD, and it consisted of (1) water-washing pretreatment of SAD, (2) extraction of Al component via pyro-hydrometallurgy, including low-temperature alkaline smelting, water leaching and purification of leachate in sequence, (3) precipitation of cryolite from the purified NaAlO2 solution using the carbonation method. By analysis of the parameter optimization for each procedure, it was found that the maximum hydrolysis efficiency of aluminum nitride (AlN) in the SAD was around 68.3% accompanied with an extraction efficiency of Al reaching 91.5%. On this basis, the cryolite of high quality was synthesized under the following optimal carbonation conditions: reaction temperature of 75 °C, NaAlO2 concentration of 0.11 mol/L, F/(6Al) molar ratio of 1.10, and 99.99% CO2 gas pressure, and flow rate of 0.2 MPa and 0.5 L/min respectively. The formation of Na3AlF6 phase can be detected by XRD. The morphological feature observed by SEM revealed that the as-synthesized cryolite had a polyhedral shape (~1 μm size) with obvious agglomeration. The chemical composition and ignition loss of the as-synthesized cryolite complied well with the requirements of the Chinese national standard (GB/T 4291-2017).

Electrokinetic remediation of uranium(VI)-contaminated red soil using composite electrolyte of citric acid and ferric chloride

In the process of electrokinetic (EK) remediation of uranium-contaminated soil, the existence form of uranium in soil pore fluid will affect on its migration behavior. In this paper, a novel type of electrolyte (citric acid + ferric chloride, CA+ FeCl₃) has been investigated for the EK remediation of uranium-contaminated red soil. The effects of different electrolyte and the concentrations of FeCl₃ on migration behavior of U(VI) and environmental risks were investigated after EK remediation. The result showed that the optimum concentration was 0.1 mol/L CA mixed with 0.03 mol/L FeCl₃ in this study. At this time, the removal efficiency of uranium was about 61.55 ± 0.41%, and the cumulative energy consumption was 0.2559 kWh. Compared with deionized water and single CA, combined CA with FeCl₃ has the advantages of high removal efficiency, low leaching toxicity, and less damage to the soil after the electrokinetic remediation treatment.

Gas quantity and composition from the hydrolysis of salt cake from secondary aluminum processing

A systematic approach to understanding the hydrolysis of salt cake from secondary aluminum production in municipal solid waste landfill environment was conducted. Thirty-nine (39) samples from 10 Aluminum recycling facilities throughout the USA were collected. A laboratory procedure to assess the gas productivity of SC from SAP under anaerobic conditions at 50 °C to simulate a landfill environment was developed. Gas quantity and composition data indicate that on average 1400 µmol g^-1 (35 mL g^-1) of gas resulted from the hydrolysis of SC. Hydrogen was the dominant gas generated (79% by volume) followed by methane with an average of 190 µmol g^-1 (21% by volume). N₂O was detected at a much lower concentration (1.2 ppmv). The total ammonia released was 680 µmol g^-1, and because of the closed system nature of the experimental setup, the vast majority of ammonia was present in the liquid phase (570 mg L^-1). In general, the productivity of both hydrogen and total ammonia (the sum of gas and liquid forms ammonia) was a fraction of that expected by stoichiometry indicating an incomplete hydrolysis and a potential for re-hydrolysis when conditions are more favorable. The result provides substantial evidence that SC can be hydrolyzed to generate a gas with relative long-lasting implications for municipal solid waste landfill operations.

Hazardous aluminum dross characterization and recycling strategies: A critical review

By finding appropriate recycling approaches, the volume of wastes, corresponding disposal cost, and the pollution of environment could be diminished. Also, such promising approaches can result in the conservation of natural sources and economic benefits. Aluminum dross as a hazardous solid waste in aluminum production industries has caused serious environmental and public health challenges. Various methods have been introduced for management, utilization, and recycling of the waste. The present review describes, firstly, different types of aluminum dross, their environmental and health hazards, composition, and production process and then focuses on the direct and indirect recycling approaches and recovery strategies.

Plasma assisted synthesis of γ-alumina from waste aluminium dross

Aluminium dross, a waste generated from aluminium melting process, contains aluminium metal, aluminium oxide, aluminium oxy-nitride and impurities such as sodium chloride and potassium chloride. Since aluminium dross is land filled without treatment, it is hazardous to the environment. Conventional methods for the metal recovery from the recycling of aluminium dross involve chemicals and are time consuming. In this study, an attempt was made to treat aluminium dross using plasma arc melting process. The aluminium dross was melted and evaporated by the plasma arc established between a crucible anode and a rod type hollow cathode made of graphite. Raw dross and products of plasma treated dross such as slag and fine powder were characterized. The generation of ultrafine alumina powder and slag are explained using simulation of the plasma arc inside the crucible and free energy minimization calculations. High temperature and air entrainment into the plasma inside the crucible converted the dross into alumina slag and fine powder. The amount of fine alumina powder produced increased substantially with plasma power initially as seen from the results of alumina obtained at 5 kW and 10 kW. However, further increase in plasma power resulted only in marginal increase in the conversion of Al dross to alumina. Results of this study indicate that arc plasma technology can be effectively applied to convert Al dross into value added fine alumina powder.