Crystal regulation of gypsum via hydrothermal treatment with hydrogen ion for Cr(VI) extraction

Enhanced extraction of heavy metals from gypsum-based hazardous waste by nanoscale sulfuric acid film at ambient conditions

Low-cost, low-energy extraction of heavy metal(loid)s (HMs) from hazardous gypsum cake is the goal of the metallurgical industry to mitigate environmental risks and carbon emissions. However, current extracting routes of hydrometallurgy often suffer from great energy inputs and substantial chemical inputs. Here, we report a novel solid-like approach with low energy consumption and chemical input to extract HMs by thin films under ambient conditions. Through constructing a nanoscale sulfuric acid film (NSF) of ∼50 nm thickness on the surface of arsenic-bearing gypsum (ABG), 99.6% of arsenic can be removed, surpassing the 50.3% removal in bulk solution. In-situ X-ray diffraction, infrared spectral, and ab initio molecular dynamics (AIMD) simulations demonstrate that NSF plays a dual role in promoting the phase transformation from gypsum to anhydrite and in changing the ionic species to prevent re-doping in anhydrite, which is not occurred in bulk solutions. The potential of the NSF is further validated in extracting other heavy metal(loid)s (e.g., Cu, Zn, and Cr) from synthetic and actual gypsum cake. With energy consumption and costs at 1/200 and 1/10 of traditional hydrometallurgy separately, this method offers an efficient and economical pathway for extracting HMs from heavy metal-bearing waste and recycling industrial solid waste.

Acid leaching technology for post-consumer gypsum purification

Background

Contaminants and water-soluble salts present in mechanically recycled gypsum from refurbishment and demolition (post-consumer) plasterboard waste limit its use as a secondary raw material in plasterboard manufacturing. This research addresses this limitation, developing a novel acid leaching purification technology combined with an improved mechanical pre-treatment for post-consumer gypsum valorization.

Methods

Laboratory-scale acid leaching purification was performed with a borosilicate beaker, hot plate, and overhead stirrer. Stuccos were produced after calcination of gypsum at 150 °C for 3 hours. Samples were characterized through X-ray fluorescence, X-ray diffraction, thermal gravimetric analysis, scanning electron microscopy and particle size analysis.

Results

Acid leaching at 90 °C for 1 h using a 5 wt% sulfuric acid solution was revealed to be the optimum purification conditions. Stuccos produced from purified gypsum under optimum conditions had similar initial setting times to that of a commercial stucco but with higher water demand, which could be reduced by optimizing the calcination conditions. A magnesium-rich gypsum was precipitated from the wastewater.

Conclusions

Purified post-consumer gypsum with > 96 wt% chemical purity and calcium sulfate dihydrate content was produced. The research recommends acid neutralization prior filtration, use of gypsum particles < 2 mm in size, and stirring speed of 50 rpm to reduce the economic and environmental impacts of the acid leaching purification process at industrial scale. The magnesium-rich gypsum could potentially be marketed as soil fertilizer.

Chromium removal from chromium gypsum through microwave hydrothermal crystal phase regulation

Chromium gypsum (CG) is a common hazardous waste formed in chromium salt or electroplating industries. The trapped or lattice-doped CrO42- in gypsum crystals are difficult to be reduced or removed by traditional methods, which will be re-oxidized or slowly released during long-term hypaethral storage. In this study, microwave hydrothermal treatment was applied to remove chromium in CG. Under optimal conditions (solid-liquid ratio of 1:5, 0.1 M sulfuric acid as liquid media, and 110 °C), over 99% of the chromium in CG can be removed within 10 min. XRD spectra indicated that 59.8% gypsum was transformed to from dihydrate gypsum to hemihydrate gypsum. The toxicity leaching test shows that chromium in CG is 377.0 mg/L before detoxification and 0.55 mg/L after detoxification, which proves that chromium in CG lattice can be efficiently removed. This work enables to significantly advance the dehydration phase transformation process of gypsum and release the heavy metal impurities within it more quickly and provides new possibilities to treat similar solid waste containing gypsum or minerals with hydration water.

Sulfate mineral scaling: From fundamental mechanisms to control strategies

Sulfate scaling, as insoluble inorganic sulfate deposits, can cause serious operational problems in various industries, such as blockage of membrane pores and subsurface media and impairment of equipment functionality. There is limited article to bridge sulfate formation mechanisms with field scaling control practice. This article reviews the molecular-level interfacial reactions and thermodynamic basis controlling homogeneous and heterogeneous sulfate mineral nucleation and growth through classical and non-classical pathways. Common sulfate scaling control strategies were also reviewed, including pretreatment, chemical inhibition and surface modification. Furthermore, efforts were made to link the fundamental theories with industrial scale control practices. Effects of common inhibitors on different steps of sulfate formation pathways (i.e., ion pair and cluster formation, nucleation, and growth) were thoroughly discussed. Surface modifications to industrial facilities and membrane units were clarified as controlling either the deposition of homogeneous precipitates or the heterogeneous nucleation. Future research directions in terms of optimizing sulfate chemical inhibitor design and improving surface modifications are also discussed. This article aims to keep the readers abreast of the latest development in mechanistic understanding and control strategies of sulfate scale formation and to bridge knowledge developed in interfacial chemistry with engineering practice.

Utilization path of bulk industrial solid waste: A review on the multi-directional resource utilization path of phosphogypsum

Phosphogypsum is one of the hottest issues in the field of environmental solid waste treatment, with complex and changeable composition. Meanwhile, phosphogypsum contains a large number of impurities, thus leading to the low resource utilization rate, and it can only be stockpiled in large quantities. Phosphogypsum occupies a lot of land and poses a serious pollution threat to the ecological environment. This paper mainly summarizes the existing pretreatment and resource utilization technology of phosphogypsum. The pretreatment mainly includes dry method and wet method. The resource utilization technology mainly includes building materials, chemical raw materials, agriculture, environmental functional materials, filling materials, carbon sequestration and rare and precious extraction. Although there are many aspects of resource utilization of phosphogypsum, the existing technology is far from being able to consume a large amount of accumulated and generated phosphogypsum. Through the analysis, the comparison and mechanism analysis of the existing multifaceted and multi-level resource treatment technologies of phosphogypsum, the four promising resource utilization directions of phosphogypsum are put forward, mainly including prefabricated building materials, eco-friendly materials and soil materials, and new green functional materials and chemical fillers. Moreover, this paper summarizes the research basis of multi field and all-round treatment and disposal of phosphogypsum, which reduces repeated researches and development, as well as the treatment cost of phosphogypsum. This paper could provide a feasible research direction for the resource treatment technology of phosphogypsum in the future, so as to improve the consumption of phosphogypsum and reduce environmental risks.

Simultaneous separation and immobilization of Cr(VI) from layered double hydroxide via reconstruction of the key phases

Layered double hydroxide (LDH) is one of the key host phases of Cr(VI) in the natural environment and chromite ore processing residue (COPR), causing serious pollution by Cr(VI). Therefore, efficient extraction or immobilization of the incorporated Cr(VI) in LDH is urgently needed. In this work, simultaneous separation and immobilization of Cr(VI) in LDH by using MgCl₂·6H₂O under thermal treatment is innovatively proposed. Cr was volatilized as CrCl₃ and was immobilized as MgCr₂O₄ accounted for 62.2% and 37.8%, respectively, under the optimal condition (the mole ratio of Cl/Cr is 9, 700 °C and 120 min). The underlying reaction mechanisms are as follows: (i) HCl produced by MgCl₂·6H₂O accelerates the destruction of Cr(VI)-LDH layer structure, completely exposing the incorporated Cr(VI), (ii) Cr(VI) is reduced to Cr(III) by Cl^-, part of which is directly immobilized as MgCr₂O₄, and the other part generates CrCl₃, which is volatilized or further combined with Mg²⁺ to form MgCr₂O₄. The total Cr leaching concentration of the practical COPR sample treated by this method dramatically decreases from 421 to 0.7 mg/L, well below the landfill standard limit (4.5 mg/L). This work provides an attainable strategy for thorough remediation of COPR and inspires the treatment of heavy metal-containing LDH.

Hydrothermal treatment of arsenic sulfide slag to immobilize arsenic into scorodite and recycle sulfur

Arsenic sulfide slag (ASS) is typically by-produced from arsenic-containing wastewater treatment. In this work, a novel hydrothermal treatment method with the assistance of Fe(NO₃)₃ (HT-Fe(NO₃)₃) was developed to detoxify ASS by transforming arsenic into scorodite and extracting sulfur in one step. After hydrothermal treatment, As(III) in ASS was oxidized and immobilized into the stable scorodite with a high As immobilization efficiency (~99%), and the toxicity leachability of arsenic-containing solid waste significantly reduced from 634.2 to 2.5 mg/L, well below the discharge standard of solid waste. Further study reveals that the nucleation and growth process was fit well by Avrami-Erofeev model and followed Ostwald step rule, which involved the As₂S₃ dissolution, formation of amorphous ferric arsenate and then crystallization within the amorphous precursor. In this process, sulfur originated from As₂S₃ played an important role by serving as the heterogeneous nuclei to decrease the barrier for the formation of amorphous ferric arsenate, and facilitated the transformation of as-formed scorodite from nano-sheet aggregates to the bulk and dense spherical polymorph, which further increased the stability of the arsenic contained solid product. This study will shed light on the development of new technologies for treatment of industrial solid waste and recycle of useful resources.