Study on simultaneous recycling of EAF dust and plastic waste containing TBBPA

Selective removal of zinc and lead from electric arc furnace dust by chlorination-evaporation reactions

Re-melting of scrap in an electric arc furnace (EAF) results in the accumulation of filter dust from off-gas treatment that predominantly consists of iron and zinc oxides. Filter dust is classified as hazardous waste due to its high contents of potentially toxic or ecotoxic elements such as Pb, Cr, Cd, and As. A promising processing route for this waste is selective chlorination, in which the non-ferrous metal oxides are chlorinated and selectively evaporated in form of their respective chlorides from the remaining solids via the process gas flow. Here, we investigate stepwise thermochemical treatment of EAF dust with either waste iron(II) chloride solution or hydrochloric acid at 650, 800, and 1100 °C. The Zn and Pb contents of the thermochemically processed EAF dust could be lowered from 29.9% and 1.63% to 0.09% and 0.004%, respectively. Stepwise heating allowed high separation between zinc chloride at the 650 °C step and sodium-, potassium-, and lead-containing chlorides at higher temperatures. Furthermore, the lab-scale results were transferred to the use of an experimental rotary kiln highlighting the possibilities of upscaling the presented process. Selective chlorination of EAF dust with liquid chlorine donors is, therefore, suggested as a potential recycling method for Zn-enriched steelworks dusts.

Recent Advancements in Pyrolysis of Halogen-Containing Plastics for Resource Recovery and Halogen Upcycling: A State-of-the-Art Review

Plastic waste has emerged as a serious issue due to its impact on environmental degradation and resource scarcity. Plastic recycling, especially of halogen-containing plastics, presents challenges due to potential secondary pollution and lower-value implementations. Chemical recycling via pyrolysis is the most versatile and robust approach for combating plastic waste. In this Review, we present recent advancements in halogen-plastic pyrolysis for resource utilization and the potential pathways from "reducing to recycling to upcycling" halogens. We emphasize the advanced management of halogen-plastics through copyrolysis with solid wastes (waste polymers, biomass, coal, etc.), which is an efficient method for dealing with mixed wastes to obtain high-value products while reducing undesirable substances. Innovations in catalyst design and reaction configurations for catalytic pyrolysis are comprehensively evaluated. In particular, a tandem catalysis system is a promising route for halogen removal and selective conversion of targeted products. Furthermore, we propose novel insights regarding the utilization and upcycling of halogens from halogen-plastics. This includes the preparation of halogen-based sorbents for elemental mercury removal, the halogenation-vaporization process for metal recovery, and the development of halogen-doped functional materials for new materials and energy applications. The reutilization of halogens facilitates the upcycling of halogen-plastics, but many efforts are needed for mutually beneficial outcomes. Overall, future investigations in the development of copyrolysis and catalyst-driven technologies for upcycling halogen-plastics are highlighted.

Recycling and reutilization of smelting dust as a secondary resource: A review

Smelting dust is a toxic waste produced in metal-mineral pyrometallurgical processes. To eliminate or reduce the adverse environmental impacts of smelting dust, valuable components need to be selectively separated from the toxic components present in the waste. This paper reviews the chemical composition, phase composition and particle size distribution characteristics of smelting dust, and the results show that smelting dust has excellent physicochemical characteristics for recovering valuable metals. The process flow, critical factors, development status, advantages and disadvantages of traditional technologies such as pyrometallurgy, hydrometallurgy and biometallurgy were discussed in depth. Conventional treatment methods typically prioritize separating and reclaiming specific elements with high concentrations. However, these methods face challenges such as excessive chemical usage and limited selectivity, which can hinder the sustainable utilization of smelting dust. With the increasing scarcity of resources and strict environmental requirements, a single treatment process can hardly fulfil the demand, and a physical field-enhanced technology for releasing and separating valuable metals is proposed. Through analysing the effect of electric field, microwave and ultrasound on recovering valuable metals from smelting dust, the enhancement mechanism of physical field on the extraction process was clarified. This paper aimed to provide reference for the resource utilization of smelting dust.

Resource utilization of hazardous solid waste blast furnace dust: Efficient wet desulfurization and metal recovery

Hazardous solid waste blast furnace dust (BFD) is rich in valuable metal components such as iron (Fe), zinc (Zn), manganese (Mn), and its recycling or harmless treatment is a major challenge. This paper creatively proposes the strategy of "treating waste with waste" by using BFD for desulfurization. The experimental results show that BFD slurry can achieve high-efficiency desulfurization and recovery of Zn resources. The characterization results indicate that ZnO and Fe₂O₃ in BFD slurry are the main active components of desulfurization, and the consumption of active components is the main reason for the decline of BFD slurry activity. Further semi-continuous experimental research shows that Zn, Fe, and Mn ions in BFD slurry play a crucial role in the catalytic oxidation of sulfur dioxide (SO₂). Additionally, the effects of reaction temperature, stirring speed, inlet SO₂ concentration, and inlet gas flow rate on the leaching rate of Zn and Fe were investigated. Under optimal conditions (SO₂ concentration = 3000 mg‧m^-3, reaction temperature = 40 °C, inlet gas flow rate = 300 mL‧min^-1, solid-liquid ratio = 0.5 g/300 mL, stirring speed = 600 rpm), the desulfurization rate reaches 100%, and the maximum leaching rate of Zn can reach 44.6%. Based on the experimental and characterization results, the possible mechanism of BFD slurry desulfurization was proposed. This study provides a reference for the application of BFD in the field of wet desulfurization.

Current Trends in Waste Plastics’ Liquefaction into Fuel Fraction: A Review

Polymers and plastics are crucial materials in many sectors of our economy, due to their numerous advantages. They also have some disadvantages, among the most important are problems with the recycling and disposal of used plastics. The recovery of waste plastics is increasing every year, but over 27% of plastics are landfilled. The rest is recycled, where, unfortunately, incineration is still the most common management method. From an economic perspective, waste management methods that lead to added-value products are most preferred—as in the case of material and chemical recycling. Since chemical recycling can be used for difficult wastes (poorly selected, contaminated), it seems to be the most effective way of managing these materials. Moreover, as a result this of kind of recycling, it is possible to obtain commercially valuable products, such as fractions for fuel composition and monomers for the reproduction of polymers. This review focuses on various liquefaction technologies as a prospective recycling method for three types of plastic waste: PE, PP and PS.

Nanoscale design of 1D metal oxides derived from mixed Ni-MH battery/transition metal dust

Controllable recycling of End-of-life rechargeable nickel-metal hydride (Ni-MH) batteries and by-products of steelmaking to added-value functional nanostructures is desired but challenging. The present work introduces an innovative and high-yield microrecycling strategy to simultaneous synthesis of TM alloy (i.e., Ni-based superalloy) and RE oxide (REO) nanostructures from obsolete Ni-MH batteries mixed with zinc-rich electric arc furnace dust (EAFD). This strategy involves integration of high-temperature thermal isolation followed by thermal nanowiring techniques. The impure thermally-isolated REOs were purified and transformed into one dimensional (1D) nanorods of hybrid REOs. Besides, during high-temperature thermal isolation, defect-rich ZnO with tailored structures of nanorods and nanoribbons were fabricated using controllable vapour deposition. The electrochemical performance of ZnO nanoribbons for oxygen evolution reaction (OER) revealed a considerable overpotential reduction of 131 mV (18%) compared to pure commercial nano-ZnO. This approach is transformational in providing a scalable and cost-effective pathway to facilitate recycling of the challenging, yet critical, waste materials into functional nanostructures for energy and environmental applications.

Recycling of blast-furnace sludge by thermochemical treatment with spent iron(II) chloride solution from steel pickling

One of the typical wastes produced in blast-furnace (BF) ironmaking is BF sludge, which mostly consists of carbon and iron oxides, but also contains toxic trace metals such as Zn, Pb, Cd, As, and Hg that render the material hazardous. Due to the lack of an established recycling process, BF sludges are landfilled, which is ecologically questionable and costly. Here, we investigate selective removal of Zn, Pb, and Cd from BF sludge by chlorination-evaporation reactions using thermodynamic modelling and laboratory-scale experiments. Specifically, BF sludge was thermochemically treated at 650-1000 °C with a spent iron(II) chloride solution from steel pickling and the effects of process temperature and retention time on removal of Zn, Pb, and Cd were investigated. Zinc and Pb were quantitatively removed from BF sludge thermochemically treated at 900-1000 °C, whereas Fe and C as well as other major elements were mostly retained. The Zn, Pb, and Cd contents in the thermochemically treated BF sludge could be lowered from ∼56 g/kg, ∼4 g/kg, and ∼0.02 g/kg to ≤0.7 g/kg, ≤0.02 g/kg, and ≤0.008 g/kg, respectively, thus rendering the processed mineral residue a non-hazardous raw material that may be re-utilized in the blast furnace or on the sinter band.

A novel approach of accurately rationing adsorbent for capturing pollutants via chemistry calculation: Rationing the mass of CaCO3 to capture Br-containing substances in the pyrolysis of nonmetallic particles of waste printed circuit boards

Pyrolysis technology is advised to dispose nonmetallic particles of waste printed circuit boards to produce oils and gases. During pyrolysis, brominated flame retardants in nonmetallic particles are converted into small-molecular Br-containing substances. They disperse into oil and gas so as to cause secondary pollution. Then, CaCO₃ is suggested to be employed to capture the small-molecular Br-containing substances. However, too much CaCO₃ will produce over solid wastes. Less CaCO₃ might not capture the total Br-containing substances. How to ration the mass of adsorbent for capturing pollutant has not been detailed investigated. This paper found HBr was the main Br-containing substances during high temperature pyrolysis of nonmetallic particles. The capture process of HBr was detailed investigated by the method of computational chemistry. At the condition of 973 K and 100 Pa, HBr was captured by chemical reaction and physical absorption of CaCO₃. Unit cell of CaCO₃ reacted with two HBr to form CaBr₂, and the generated unit cell of CaBr₂ can adsorb 0.011 HBr. 0.0106 g CaCO₃ can absorb all HBr produced by high temperature vacuum pyrolysis of 1 g nonmetallic particles. This paper contributes a novel approach to accurately ration the mass of adsorbents employed for capturing pollutants.

Novel process for decontamination and additional valorization of steel making dust processing using two-step correlative leaching

Recycling of steel making dusts often targets Zn removal. Other heavy metals such as Mo, W or Cr do not receive as much attention, and the decontamination of the dusts from these constituents is scarcely addressed in the literature. This study presents a novel approach of the selective separation of Mo from steel making dusts using alkaline solutions with low concentrations, before Zn removal using concentrated alkaline medium. Such an approach has never been reported before and can contribute to more efficient decontamination of the steel making dusts and will increase the value of recovered components since Mo can be significantly preconcentrated. Two samples originating from two steel producers were investigated. One sample contained 2.65% of Mo and 1.87% of Zn, and the second sample had 0.61% of Mo and 35.9% of Zn. Temperature was found to have a low impact on the leaching efficiency of Mo, while increased NaOH concentration promoted leaching of Zn. Excellent pre-concentration of Mo was achieved by using a S:L ratio of 1:3. Almost 5170 mg/L Mo, 1000 mg/L W, no Fe and only 2 mg/L Zn were present in the solution after leaching at 30 °C for 30 min. For the samples containing lower concentrations of Mo and high concentrations of Zn, the selectivity of the process was affected when using higher concentrations of NaOH. A final leachate containing 797 mg/L of Mo and only 11 mg/L Zn was obtained after leaching with 0.05 M NaOH. DFT computations showed that the 2D layered structures of MoO₃ and WO₃ are decisive factors that account for their high solubilites.

Lab-scale thermal analysis of electronic waste plastics

In this work, we experimentally revealed the thermochemical decomposition pathway of Decabromodiphenyl ethane (DBDPE) and tetrabromobisphenol A (TBBPA) containing electronic waste plastics using an online thermogravimetric-fourier transform infrared-mass spectroscopy (TG-FTIR-MS) system, a high resolution gas chromatography/high resolution mass (HRGC-MS) spectroscopy, and a fixed-bed reactor. We found the distribution and species of produced bromides can be easily controlled by adjusting pyrolytic temperature, which is particularly crucial to their recycle. From the analysis of the liquid and solid phase obtained from the fixed-bed reactor, we proposed that the Br radicals formed during the pyrolysis process may be captured by organic species derived from the depolymerization of plastics to form brominated compounds or by the inorganic species in the plastics, and that these species remained in the char residue after pyrolysis. Our work for the first time demonstrates intramolecular oxygen atoms play a pivotal role in the formation of PBDD/Fs that pyrolysis of oxygen-free BFRs is PBDD/Fs-free, whereas pyrolysis of oxygen-containing BFRs is PBDD/Fs-reduced.

Brominated flame retardants and the formation of dioxins and furans in fires and combustion

The widespread use and increasing inventory of brominated flame retardants (BFRs) have caused considerable concern, as a result of BFRs emissions to the environment and of the formation of both polybrominated dibenzo-p-dioxins and dibenzofurans (PBDD/Fs) and mixed polybromochloro-dibenzo-p-dioxins and dibenzofurans (PBCDD/Fs or PXDD/Fs). Structural similarities between PBDD/Fs and polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) suggest the existence of comparable formation pathways of both PBDD/Fs and PCDD/Fs, yet BFRs also act as specific precursors to form additional PBDD/Fs. Moreover, elementary bromine (Br2) seems to facilitate chlorination by bromination of organics, followed by Br/Cl-exchange based on displacement through the more reactive halogen. Overall, PBDD/Fs form through three possible pathways: precursor formation, de novo formation, and dispersion of parts containing BFRs as impurities and surviving a fire or other events. The present review summarises the formation mechanisms of both brominated (PBDD/Fs) and mixed dioxins (PXDD/Fs with X=Br or Cl) from BFRs, recaps available emissions data of PBDD/Fs and mixed PXDD/Fs from controlled waste incineration, uncontrolled combustion sources and accidental fires, and identifies and analyses the effects of several local factors of influence, affecting the formation of PBDD/Fs and mixed PXDD/Fs during BFRs combustion.

Waste-to-energy: Dehalogenation of plastic-containing wastes

The dehalogenation measurements could be carried out with the decomposition of plastic wastes simultaneously or successively. This paper reviewed the progresses in dehalogenation followed by thermochemical conversion of plastic-containing wastes for clean energy production. The pre-treatment method of MCT or HTT can eliminate the halogen in plastic wastes. The additives such as alkali-based metal oxides (e.g., CaO, NaOH), iron powders and minerals (e.g., quartz) can work as reaction mediums and accelerators with the objective of enhancing the mechanochemical reaction. The dehalogenation of waste plastics could be achieved by co-grinding with sustainable additives such as bio-wastes (e.g., rice husk), recyclable minerals (e.g., red mud) via MCT for solid fuels production. Interestingly, the solid fuel properties (e.g., particle size) could be significantly improved by HTT in addition with lignocellulosic biomass. Furthermore, the halogenated compounds in downstream thermal process could be eliminated by using catalysts and adsorbents. Most dehalogenation of plastic wastes primarily focuses on the transformation of organic halogen into inorganic halogen in terms of halogen hydrides or salts. The integrated process of MCT or HTT with the catalytic thermal decomposition is a promising way for clean energy production. The low-cost additives (e.g., red mud) used in the pre-treatment by MCT or HTT lead to a considerable synergistic effects including catalytic effect contributing to the follow-up thermal decomposition.