Characterization of sinter flue dust to enhance alternative recycling and environmental impact at disposal

A green process for the conversion of hazardous sintering dust into K2SO4 and NH4Cl fertilizers

Sintering dust from the steelmaking industry is a hazardous waste that is rich in valuable metals. The purpose with the present study has been to design an efficient process for the preparation of K₂SO₄ and NH₄Cl fertilizers by using sintering dust as raw material. The K, S, and Cl in the sintering dust were selectively and efficiently leached using water. The leaching of Ca impurities was then greatly reduced and the appearance of Zn and Mg was avoided. The Cl^- ions in the leachate were, thereafter, adsorbed by a 201 × 7 resin to form a K₂SO₄ solution. Finally, the loaded Cl^- on the resin was desorbed to form a NH₄Cl solution, and the resin was regenerated and recycled. The purified solutions were crystallized to prepare K₂SO₄(s) and NH₄Cl(s) products, which met the national standard of China for superior potassium sulfate and ammonium chloride, to be used for agricultural use. The recoveries of K, Cl, and S from the sintering dust were 80.78%, 92.63%, and 93.92%, respectively. Notably, the Mn content in the leaching residue increased from 9.08% to 14.19%. This could be used for the conversion of Mn impurities into recyclable manganese-rich raw materials. This green process enables an effective extraction of important impurities in hazardous sintering dust, thereby providing a new potassium source for potash fertilizer manufacturing with notable economic and environmental benefits.

The Physico-Chemical and Mineralogical Characterization of Mg-Rich Synthetic Gypsum Produced in a Rare Earth Refining Plant

The physical, chemical and mineralogical characterization of the constituents of magnesium-rich synthetic gypsum produced in a rare earth-refining plant located in Gebeng, Pahang, Malaysia was conducted through elemental chemical analysis, scanning electron microscopy with Energy Dispersive X-ray (EDX)-analyzer, thermal analysis, X-ray fluorescence and X-ray diffraction. The crystalline nature of the by-product was studied using FTIR spectroscopy. Elemental analysis confirmed the presence of Ca and Mg, which are essential macronutrients required by plants and this Ca alongside the high pH (9.17) of MRSG may confer on the material a high acid neutralization capacity. From the result, it was observed that the studied by-product is a heterogeneous crystalline material comprising of gypsum (CaSO4.2H2O) and other major components such as calcium (magnesium) compounds (hydroxide, oxide, silicates, and carbonate) and sulfur. These aggregates may contribute to give an acid neutralization capacity to MRSG. The XRD study of MRSG indicated a high content of gypsum (45.4%), shown by the d-spacing of 7.609 Å (2-theta 11.63) in the diffractogram. The infrared absorption spectra of MRSG indicate close similarities to mined gypsum. The results of the characterization indicated that MRSG has valuable properties that can promote its use in amending soil fertility constraints on nutrient-deficient tropical acid soils.

Life cycle assessment of ultra-low treatment for steel industry sintering flue gas emissions

The largest contributor to pollutant emissions is the sintering process in steel industry. Ultra-low emission policy for the Chinese steel industry states that emission concentrations of particulate matter, SO₂ and NO_x should not exceed 10, 35 and 50 mg/m³ respectively. The emission concentrations of the steel industry are the same as the ultra-low emission policy for the coal-fired power industry, but the pollutant control technologies of the two industries are different. Life cycle assessment method is applied to analyze the latest ultra-low treatment process for sintering flue gas emissions which includes electrostatic precipitation, ozone oxidation, wet desulfurization, wet denitration, condensation dehumidification and wet electrostatic precipitation. Following this novel ultra-low emission treatment, the concentrations of particulate matter, SO₂, NO_x, and PCDDs in the sintering flue gas decreased very significantly, attaining the new emission standard. With 1 ton of sinter as the functional unit and "cradle to gate" as the system boundary, the environmental impact of the process is 0.1811 and the total economic cost is 172.79 RMB, of which internal cost is 34.64 RMB and external cost is 138.15 RMB. The main environmental impacts result from applying the wet denitration and ozone oxidation processes. Sodium sulfite in the wet denitration process, and electricity and liquid oxygen in the ozone oxidation process are the key inputs that cause environmental impact. These findings are useful for a further optimization of the ultra-low emissions process from both the environmental and economic perspective, which is applicable in other regions of the world.

Comprehensive characterization on Ga (In)-bearing dust generated from semiconductor industry for effective recovery of critical metals

Gallium (indium)-bearing dust generated from semiconductor industry is an important secondary resource for critical metal recycling. However, the diverse and distinct physicochemical natures of such waste material have made its recycling less effective, e.g. low extraction rate and complex treatment procedures. This research is devoted to gaining in-depth knowledge of the physical and chemical properties of such waste, including the chemical composition, physical phases, particle size distribution and chemical-thermal properties with a series of technologies. As a consequence, the occurrence and distribution of GaN and metallic indium phases are found to be crucial to efficient metal recycling. The thermal-chemical behavior shows that continuous oxidation occurred in the air atmosphere, indicating that heat-treatment followed by acid leaching is feasible to improve their recycling efficiencies. This process is able to leach 80.35% of gallium and 95.78% of indium with one-step operation. Furthermore, different treatment strategies for the waste material are preliminarily evaluated and discussed for the aim of metal recovery. The results show that gallium can be selectively recycled with recycling rate of 89.59% using alkaline leaching. With this research, the understanding on the recyclability of different metals and possibilities of selective recovery can be improved. It provides guidelines during the stage of decision-making for critical metal recycling in order to achieve efficient resource circulation.