Reduction-melting combined with a Na₂CO₃ flux recycling process for lead recovery from cathode ray tube funnel glass

Lead recovery from waste CRT funnel glass by mechanochemical reaction with reductive Al powder

The safe disposal of waste cathode ray tubes (CRTs) has always been a serious problem due to the stable microstructure of toxic lead (Pb) located in glass. Thousands of researches have been trying to explore environmental and efficient ways to dispose of waste CRTs. To recycle lead from waste CRT funnel glass effectively, a mechanochemical reduction method has been developed in this research. Aluminum was used as a reductant, and the hydrochloric acid solution was used in the leaching process to separate lead from the solution. After mechanochemical ball milling with aluminum, lead ion in CRT funnel glass was transferred into nano-sized element lead. Lead recovery from CRT funnel glass increased significantly as compared to non-activated leaded glass. Approximately 40 % of lead was leached after mechanical activation without aluminum, while over 96 % of lead in the CRT funnel glass could be recovered after mechanochemical reduction with aluminum. Lead chloride (PbCl2) can be recycled from the leaching solution after cooling crystallization. Nano-sized Pb formation and the structural changes of leaded CRT funnel glass by mechanochemical reduction process contributed to obvious improvement in lead recovery. This research provided a high-efficiency and feasible approach for recovering lead in form of PbCl2 crystal from leaded glass.

The lead removal evolution from hazardous waste cathode ray tube funnel glass under enhancement of red mud melting and synthesizing value-added glass-ceramics via reutilization of silicate resources

Waste CRT funnel glass (FG) is a typical hazardous waste produced by the electronics industry that contains toxic lead oxide, red mud (RM) is the first waste produced during alumina production. Both of these are extremely difficult to reuse. Here, we report a method to control FG waste, in which RM was used to enhance the removal of Pb from FG via a vacuum thermal process. The removed residual glass was utilized to create glass-ceramics. The results showed that RM can enhance the lead removal from waste CRT funnel glass by the vacuum thermal process. When 30% RM was added, the removal rate reached 98.54%. A significant mechanism of enhancing delead is investigated by a Fourier transform infrared (FTIR) spectrometer and X-ray photoelectron spectroscopy (XPS). The results showed that the -Pb-O-Si-O- network structure was broken by the free calcium ions of RM. Afterward, valuable glass-ceramics with tetragonal-KAlSi₂O₆ and triclinic-CaSiO₃ crystals were synthesized using the residual glass. The Pb, Ba, Cr, and Cu leaching concentrations of the glass-ceramics were well below the regulatory limit (5 mg/L) of the CA-EPA, as measured by the toxicity characteristic leaching procedure (TCLP) test. Overall, the results indicated that RM enhanced the removal of lead during the vacuum thermal process. The synthesis of value-added glass-ceramics reutilized silicate resources from waste cathode ray tube (CRT) funnel glass and RM.

Reutilization of silicon- and aluminum- containing wastes in the perspective of the preparation of SiO2-Al2O3 based porous materials for adsorbents and catalysts

The waste materials available as sources of silicon and aluminum for producing porous materials like amorphous silicas, aluminas, amorphous silica-aluminas, and zeolites, to be used as catalyst and adsorbents, are briefly summarized. The procedures for preparing these materials from wastes are also taken into account. The limits of this approach in terms of economy and environmental protection are also briefly considered. It is concluded that mesoporous materials can be prepared from wastes, but care to product quality and to overall process efficiency is needed.

Development of a novel recycling system for waste cathode ray tube funnel glass based on the integration of nanoscale Fe0 with ball milling

A novel and effective system was developed for recycling cathode ray tube (CRT) funnel glass wastes. Initially, the combination of nanoscale Fe⁰ with ball milling promoted lead transfer that was strongly encapsulated in the glass inner structure to the surface of funnel glass and/or adhere to iron substance due to the collapse of SiO bonds. This condition enhanced the dissolution of lead in the acid solution. A high lead extraction rate of 97.8% from funnel glass was achieved through nitric acid leaching by optimizing the operational parameters (Fe⁰/funnel glass mass ratio, 0.5:1; ball milling time; 72 h). Subsequently, lead sulfate, iron hydroxides, and sodium nitrate were gradually recovered from the acid leachate by using three simple operations, namely, sulfation, alkali neutralization, and salt evaporation. Meanwhile, the leaching results of short-term toxicity characteristic leaching (TCLP) and long-term multiple extraction procedures (MEP) clearly demonstrated that the residual high silica products (after acid leaching) had no impact on the environment and could be used to synthesize high value-added zeolites as raw materials. With the addition of Al sources, the complete conversion of high silica residues into high crystalline zeolites with high cation exchange capacity value was realized by applying an alkaline fusion method during the hydrothermal treatment. Furthermore, lead, NO^-₃, and SO^2-₄ concentrations of the resulting drainage were considerably lower than the relevant standard for surface water quality. Therefore, the proposed recycling system provided an eco-friendly and feasible technique for complete reutilization of obsolete CRT funnel glass.

Lead extraction and glass-ceramics synthesis from waste cathode ray tube funnel glass through cooperative smelting process with coal fly ash

In this study, a novel process was developed for extracting lead from the hazardous waste cathode ray tube (CRT) funnel glass and simultaneously producing glass-ceramics. CRT funnel glass was mixed with coal fly ash and subjected to carbon thermal reduction with the addition of CaO. The homogeneous glass melt and reduced metallic lead were quenched in water. Glass-ceramics were produced from the parent glass through an appropriate heat treatment. The optimum carbon loading amount (calculated as the molar ratio of C/PbO), CaO/SiO₂ ratio, smelting temperature and holding time for lead recovery were 1.0, 0.3-0.6, 1450 °C and 2 h, respectively. Under these conditions, more than 95% of lead can be extracted from the funnel glass and a low lead content of the resultant parent glass below 0.6 wt% was successfully achieved. CaO behaved as a network modifier to reduce the viscosity of the glass and also acted as a substitution to release lead oxide from the silicate network structure, resulting in a high lead separation efficiency. X-ray diffraction (XRD) analysis revealed that the main crystalline phase was gehlenite when 50-70 wt% funnel glass was added. Scanning electron microscopy (SEM) observation showed that well-crystallized crystals occurred in the specimens with 50-70 wt% funnel glass additions, whereas the specimens with 40 wt% and 80 wt% glass additions exhibited a relative low crystallization degree. Furthermore, property measurements, chemical resistance tests and leaching characteristics of heavy metals confirmed the possibility of engineering and construction applications of the superior glass-ceramic products. Overall results indicate that the process proposed in this paper is an effective and promising approach for reutilization of obsolete CRT funnel glass.

Lead recovery from waste CRT funnel glass by high-temperature melting process

In this research, a novel and effective process for waste CRT funnel glass treatment was developed. The key to this process is removal of lead from the CRT funnel glass by high-temperature melting process. Sodium carbonate powder was used as a fusion agent, sodium sulfide serves as a catalytic agent and carbon powder acts as reducing agent. Experimental results showed that lead recovery rate increased with an increase in the amount of added sodium carbonate, sodium sulfide, carbonate, temperature and holding time initially, and then reached a stable value. The maximum lead recovery rate was approximately 94%, when the optimum adding amount of sodium carbonate, sodium sulfide, carbonate, temperature and holding time were 25%, 8%, 3.6%, 1200°C and 120min, respectively. In the high-temperature melting process, lead silicate in the funnel glass was firstly reduced, and then removed. The glass slag can be made into sodium and potassium silicate by hydrolysis process. This study proposed a practical and economical process for recovery of lead and utilization of waste glass slag.

Extraction of lead from waste CRT funnel glass by generating lead sulfide - An approach for electronic waste management

Waste cathode ray tube (CRT) funnel glass is the key and difficult points in waste electrical and electronic equipment (WEEE) disposal. In this paper, a novel and effective process for the detoxification and reutilization of waste CRT funnel glass was developed by generating lead sulfide precipitate via a high-temperature melting process. The central function in this process was the generation of lead sulfide, which gathered at the bottom of the crucible and was then separated from the slag. Sodium carbonate was used as a flux and reaction agent, and sodium sulfide was used as a precipitating agent. The experimental results revealed that the lead sulfide recovery rate initially increased with an increase in the amount of added sodium carbonate, the amount of sodium sulfide, the temperature, and the holding time and then reached an equilibrium value. The maximum lead sulfide recovery rate was approximately 93%, at the optimum sodium carbonate level, sodium sulfide level, temperature, and holding time of 25%, 8%, 1200°C, and 2h, respectively. The glass slag can be made into sodium and potassium silicate by hydrolysis in an environmental and economical process.

Recovery of palladium, cesium, and selenium from heavy metal alkali borosilicate glass by combination of heat treatment and leaching processes

Reductive heat-treatment and leaching process were applied to a simulated lead or bismuth soda-potash-borosilicate glass with palladium, cesium, and selenium to separate these elements. In the reductive heat treatment, palladium is extracted in liquid heavy metal phase generated by the reduction of the heavy metal oxides, whereas cesium and selenium are concentrated in phase separated Na-K-rich materials on the glass surface. From the materials, cesium and selenium can be extracted in water, and the selenium extraction was higher in the treatment of the bismuth containing glass. The chemical forms of palladium in the glass affected the extraction efficiencies of cesium and selenium. Among the examined conditions, in the bismuth glass treatment, the cesium and selenium extraction efficiencies in water were over 80%, and that of palladium in liquid bismuth was over 80%.

Recycling of typical difficult-to-treat e-waste: Synthesize zeolites from waste cathode-ray-tube funnel glass

The disposal of waste cathode ray-tubes (CRTs) from old televisions and discarded computer monitors has become a major environmental concern worldwide. In this work, an open-loop recycling method was developed to synthesize zeolites using CRT funnel glass as the raw material. The effects of hydrothermal temperatures and pressure, n(SiO₂/Al₂O₃) molar ratios and hydrothermal time on the resulting products were investigated. The results indicated that hydrothermal temperatures and pressure played critical roles in zeolite synthesis. Amorphous phases were detected at lower temperatures (80-100°C) and pressure (0.47-1.01bar) with n(SiO₂/Al₂O₃)=2.0. At the temperature of 110°C (pressure 1.43bar), NaA formed with a mixture of NaP1 and Faujasite. With further increase in the temperature and pressure, the unstable NaA and Faujasite disappeared, and Hydroxysodalite developed. The influence of n(SiO₂/Al₂O₃) ratios on resulting products revealed a single phase of NaA was formed at the ratio of 1.5 and a mixture of NaA and Faujasite at the ratio of 2.0. Prolonging hydrothermal time, however, could promote zeolite crystallization, and NaA gradually developed with an increase in the time from 2 to 6h at n(SiO₂/Al₂O₃)=1.5. By comparison, crystallization phases were observed only when the time was longer than 8h at n(SiO₂/Al₂O₃)=2.0.

Mechanochemical processing of molybdenum and vanadium sulfides for metal recovery from spent catalysts wastes

This work describes the mechanochemical transformations of molybdenum and vanadium sulfides into corresponding molybdate and vanadate, to serve as a new environment-friendly approach for processing hazardous spent hydrodesulphurization (HDS) catalysts solid waste to achieve an easy recovery of not only molybdenum and vanadium but also nickel and cobalt. Co-grinding the molybdenum and vanadium sulfides with oxidants and sodium carbonate stimulates solid-state reactions without any heating aid to form metal molybdates and vanadates. The reactions proceed with an increase in grinding time and were enhanced by using more sodium carbonate and stronger oxidant. The necessary conditions for the successful transformation can be explained on the basis of thermodynamic analyses, namely a negative change in Gibbs free energy.

Lead recovery and high silica glass powder synthesis from waste CRT funnel glasses through carbon thermal reduction enhanced glass phase separation process

In this study, a novel process for the removal of toxic lead from the CRT funnel glass and synchronous preparation of high silica glass powder was developed by a carbon-thermal reduction enhanced glass phase separation process. CRT funnel glass was remelted with B₂O₃ in reducing atmosphere. In the thermal process, a part of PbO contained in the funnel glass was reduced into metallic Pb and detached from the glass phase. The rest of PbO and other metal oxides (including Na₂O, K₂O, Al₂O_3, BaO and CaO) were mainly concentrated in the boric oxide phase. The metallic Pb phase and boric oxide phase were completely leached out by 5mol/L HNO₃. The lead removal rate was 99.80% and high silica glass powder (SiO₂ purity >95wt%) was obtained by setting the temperature, B₂O₃ added amount and holding time at 1000°C, 20% and 30mins, respectively. The prepared high silicate glass powders can be used as catalyst carrier, semipermeable membranes, adsorbents or be remelted into high silicate glass as an ideal substitute for quartz glass. Thus this study proposed an eco-friendly and economical process for recycling Pb-rich electronic glass waste.

Phase separation of cesium from lead borosilicate glass by heat treatment under a reducing atmosphere

A phase-separation technique for removing sodium from glass using a heat-treatment method under a reducing atmosphere was previously developed for sodium recovery from waste glass. In this study, this technique was applied to cesium-containing lead borosilicate glass to concentrate the cesium in phase-separated sodium-rich materials for efficient cesium extraction. The theoretical phase-separation temperature of the sodium-rich phase was simulated by thermodynamic equilibrium calculations and was predicted to occur below 700°C for lead borosilicate glass. Experimentally, a simulated lead borosilicate glass was melted at 1000°C and subsequently annealed below 700°C under a CO-containing reducing atmosphere. The phase separation of cesium was found to occur with sodium enrichment on the glass surface that was in contact with the gas phase, promoting cesium extraction from the treated glass using water. The cesium extraction efficiency was affected by the surface area of the treated glass that was in contact with water, and under the examined conditions, the cesium extraction efficiency was up to 66%. Phase separation using reductive heat treatment, combined with a water leaching technique, is suggested to be effective for extracting cesium incorporated in borosilicate glass waste.

Recent development of recycling lead from scrap CRTs: A technological review

Cathode ray tubes (CRTs) contain numerous harmful substances with different functions. Lead is found in the funnel glass of CRTs. Improperly treated toxic lead may pose significant risks to human health and the environment. This paper reviews and summarizes existing technological processes on the recycling of lead from waste CRTs, including pyrometallurgy, hydrometallurgy, and product-regeneration. The present situation, advantages, and disadvantages of these techniques are described in detail. Generally, pyrometallurgy shows better practicability in recovery lead from waste CRT than hydrometallurgy and hydrometallurgy, in view of environmental impact, energy-consumption, product formats and safety and maturity of technology. Moreover, the gaps in the existing technologies were identified and recommendations for future research were provided.

Water-soluble lead in cathode ray tube funnel glass melted in a reductive atmosphere

In the reduction-melting process, lead can be recovered from cathode ray tube funnel glass (PbO=25wt%); however, resulting glass residues still contain approximately 1-2wt% of unrecovered lead. For environmental protection in the residue disposal or recycling, it is important to evaluate the quantities of water-soluble species among the unrecovered lead. This study examined water-soluble lead species generated in the reduction-melting process of the funnel glass and factors determining their generation. In the reduction-melting, metallic lead was generated by reducing lead oxides in the glass, and a part of the metallic lead remained in the glass residue. Such unrecovered metallic lead can dissolve in water depending on its pH level and was regarded as water-soluble lead. When 10g Na2CO3 was added to 20g funnel glass during reduction-melting, the resulting glass contained high concentrations of sodium. In a water leaching of the glass, the obtained leachate was alkalized by the sodium-rich glass (pH=12.7-13.0). The unrecovered metallic lead in the glass was extracted in the alkalized leachate. The quantity of the unrecovered metallic lead (water-soluble lead) in the glass decreased when the melting time, melting temperature, and carbon dosage were controlled during reduction-melting.

Lead recovery and glass microspheres synthesis from waste CRT funnel glasses through carbon thermal reduction enhanced acid leaching process

In this study, a novel process for detoxification and reutilization of waste cathode ray tube (CRT) funnel glass was developed by carbon thermal reduction enhanced acid leaching process. The key to this process is removal of lead from the CRT funnel glass and synchronous preparation of glass microspheres. Carbon powder was used as an isolation agent and a reducing agent. Under the isolation of the carbon powder, the funnel glass powder was sintered into glass microspheres. In thermal reduction, PbO in the funnel glass was first reduced to elemental Pb by carbon monoxide and then located on the surface of glass microspheres which can be removed easily by acid leaching. Experimental results showed that temperature, carbon adding amount and holding time were the major parameters that controlled lead removal rate. The maximum lead removal rate was 94.80% and glass microspheres that measured 0.73-14.74μm were obtained successfully by setting the temperature, carbon adding amount and holding time at 1200°C, 10% and 30min, respectively. The prepared glass microspheres may be used as fillers in polymer materials and abrasive materials, among others. Accordingly, this study proposed a practical and economical process for detoxification and recycling of waste lead-containing glass.

Removal of lead from cathode ray tube funnel glass by combined thermal treatment and leaching processes

The reduction melting process is useful to recover toxic lead from cathode ray tube funnel glass; however, this process generates SiO2-containing residues that are disposed in landfill sites. To reduce the volume of landfill waste, it is desirable to recycle the SiO2-containing residues. In this study, SiO2 powder was recovered from the residue generated by reduction melting. The funnel glass was treated by a process combining reduction melting at 1000°C and annealing at 700°C to recover a large quantity of lead from the glass. The oxide phase generated by the thermal treatment was subjected to water leaching and acid leaching with 1M hydrochloric acid to wash out unwanted non-SiO2 elements for SiO2 purification. In the water washing, the oxide phase was microparticulated, and porous structures formed on the oxide surfaces. This increased the surface area of the oxide phase, and the unwanted elements were effectively washed out during the subsequent acid leaching. By controlling the acid leaching time and the amount of added acid, porous and amorphous SiO2 (purity >95 wt%) was recovered. In the obtained SiO2-concentrated product, unrecovered lead remained at concentrations of 0.25-0.79 wt%. When the Na2CO3 dosage in the thermal treatment was increased, the lead removal by acid leaching was enhanced, and the lead concentration in the obtained product decreased to 0.016 wt%.

Lead extraction from cathode ray tube funnel glass melted under different oxidizing conditions

Lead was extracted into hydrochloric acid from cathode ray tube funnel glass melted under reducing atmosphere, oxidizing atmosphere, or a sequential combination of both to mechanistically investigate effects of the melting atmosphere on lead extraction. Melting funnel glass in a reductive atmosphere led to the generation of metallic lead particles that were readily soluble in the acid, increasing the quantity of lead extracted into the acid. Meanwhile, the glass product obtained after melting funnel glass in an oxidative atmosphere exhibited higher corrosion resistance in the acid, and the quantity of lead extracted from the treated glass decreased. However, Na2CO3 addition to the glass during melting hindered the enhancement of corrosion resistance and the immobilization of lead in the acid. X-ray photoelectron spectroscopic analysis of the treated glass samples showed that the positions of the peak or the profiles of the spectra attributed to Pb 4f, Si 2p, and O 1s signals were modified by oxidative melting, an indication that oxidative melting results in structural changes in the SiO2 framework of the glass.

Exposure to hazardous substances in Cathode Ray Tube (CRT) recycling sites in France

The Waste Electrical and Electronic Equipment (WEEE) or e-waste recycling sector has grown considerably in the last fifteen years due to the ever shorter life cycles of consumables and an increasingly restrictive policy context. Cathode Ray Tubes (CRTs) from used television and computer screens represent one of the main sources of e-waste. CRTs contain toxic materials such as lead, cadmium, barium, and fluorescent powders which can be released if recycling of CRTs is not appropriate. Exposure to these harmful substances was assessed in nine workshops where CRT screens are treated. Particulate exposure levels were measured using a gravimetric method and metals were analysed by plasma emission spectrometry. The maximum levels of worker exposure were 8.8mg/m(3), 1504.3μg/m(3), 434.9μg/m(3), 576.3μg/m(3) and 2894.3μg/m(3) respectively for inhalable dust, barium, cadmium, lead and yttrium. The maximum levels of airborne pollutants in static samples were 39.0mg/m(3), 848.2μg/m(3), 698.4μg/m(3), 549.3μg/m(3) and 3437.9μg/m(3) for inhalable dust, barium, cadmium, lead and yttrium. The most harmful operations were identified, and preventive measures for reducing the chemical risk associated with screen recycling were proposed. Workplace measurements were used to define recommendations for reducing the chemical risks in CRT screens recycling facilities and for promoting the design and development of "clean and safe" processes in emerging recycling channels.