Environmentally friendly approach to recover vanadium and tungsten from spent SCR catalyst leach liquors using Aliquat 336

Sustainable separation of molybdenum from mixed mineral acids generated as semiconductor industry waste streams using tributyl phosphate (TBP) by effects of hybrid machine learning models

This study explores the separation and optimization of molybdenum (Mo) from mixed mineral acids derived from semiconductor industry waste streams with tributyl phosphate (TBP) by implementing machine learning (ML) models. Considerable experimental tests were performed to evaluate the impact of various operational variables on the effectiveness of Mo extraction and stripping. The support vector regression (SVR) paired with harmony search algorithm (HSA), genetic algorithm (GA), and shuffled frog leaping algorithm (SFLA) were employed for enhancement in the separation process and structural optimization. The SVR-SFLA model yielded the most meticulous predictions, identifying optimal extraction conditions with a TBP concentration, mixing time, temperature, and O/A ratio of 50%, 30 min, 25 °C, and 1, respectively, achieving 77.8% efficiency. The derived results from the SVR-SFLA model, in tandem with the McCabe-Theil diagram, indicated a four-stage counter-current extraction process required to achieve a yield exceeding 99%. For the stripping process, the hybrid model indicated optimal conditions with 3 M NH4OH and an A/O ratio of 0.5 at 50 °C for 20 min, requiring two counter-current stages for nearly complete stripping. Feature importance analysis using a random forest algorithm (RFA) highlighted the NH4OH concentration and phase ratio as the most significant factors, contributing 40.3% and 29.1%, respectively, to the stripping from the loaded TBP phase. The final product, obtained after crystallization and thermal decomposition of the strip solutions, was characterized by X-ray diffraction (XRD), thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS), revealing 99.74% purity for molybdenum trioxide.

Strategy and Technical Progress of Recycling of Spent Vanadium-Titanium-Based Selective Catalytic Reduction Catalysts

Selective catalytic reduction denitration technology, abbreviated as SCR, is essential for the removal of nitrogen oxide from the flue gas of coal-fired power stations and has been widely used. Due to the strong demand for energy and the requirements for environmental protection, a large amount of SCR catalyst waste is produced. The spent SCR catalyst contains high-grade valuable metals, and proper disposal or treatment of the SCR catalyst can protect the environment and realize resource recycling. This review focuses on the two main routes of regeneration and recycling of spent vanadium-titanium SCR catalysts that are currently most widely commercially used and summarizes in detail the technologies of recycling, high-efficiency recycling, and recycling of valuable components of spent vanadium-titanium SCR catalysts. This review also discusses in depth the future development direction of recycling spent vanadium-titanium SCR catalysts. It provides a reference for promoting recycling, which is crucial for resource recovery and green and low-carbon development.

Extraction of W, V, and As from spent SCR catalyst by alkali pressure leaching and the pressure leaching mechanism

Spent selective catalytic reduction (SCR) catalysts are environmentally hazardous and resource-enriching. In this work, V, W, and As in a spent SCR catalyst was extracted by alkali pressure leaching. Results showed that the V, W, and As were loaded on the anatase TiO2 crystal grains as amorphous oxides. The optimum pressure leaching conditions were NaOH concentration of 20 wt%, reaction temperature of 180 °C, reaction time of 120 min, L/S of 10 mL/g, and stirring speed of 300 rpm. The leaching efficiency of W, V, and As reached 98.83%, 100%, and 100%, respectively. The experiment revealed the preferential leaching of V and As rather than W, and the leaching mechanisms of V, W, and As were studied through experiment and density functional theory (DFT). The leaching kinetics of W conformed to a variant of the shrinking core model and the leaching process of W is controlled by both chemical reactions and diffusion processes. During the leaching process, Na2Ti2O4(OH)2 product powder layer was generated, which affects the mass transfer of W. The destruction of the TiO2 skeleton in the spent SCR catalyst is essential for adequate W extraction, especially for the extraction of W embedded in the TiO2 lattice. The DFT simulation result indicated that the V and As loaded onto the TiO2 support are easier to absorb hydroxide ions rather than W, and the leaching reaction energy of V and As was lower than W, As, and V has leaching priority over the leaching of W. Furthermore, an anatase TiO2 photocatalyst with the {001} crystal surface exposed was successfully prepared from the alkali pressure leaching residue. This work provides theoretical support for the metal leaching and utilization of spent SCR catalysts via alkali pressure leaching.

A Review on Resource Utilization of Spent V-W-Ti Based Selective Catalytic Reduction Catalysts

To address the environmental pollution caused by nitrogen oxides, V₂O₅-WO₃/TiO₂ is widely used as a catalyst based on selective catalytic reduction (SCR) technology. However, spent SCR catalysts pose a potential hazard to the environment due to the presence of heavy metals. This problem continues to plague countries with predominantly thermal power generation, and landfills as the dominant disposal method wastes significant metal resources. Previous research into the recovery of these metal resources has received considerable attention. Here, we summarise the methods of recovery and find that research trends are beginning to move towards improving the added value of recovered products. One very promising application is photocatalysts; however, the atomic efficiency of current methods is not satisfactory. Therefore, this review first focuses on the regeneration of spent SCR catalysts and the processes used for elemental extraction to clarify what forms of V, W and Ti can be obtained from existing processes. This is followed by providing directions for the conversion of spent SCR catalysts into photocatalysts with improvements based on such processes. From a different perspective, this also provides a new resource for photocatalysts and is expected to significantly reduce the cost of photocatalyst production.

Vanadium recovery by electrodialysis using polymer inclusion membranes

Industrial applications and environmental awareness recently prompted vanadium recovery spell from secondary resources. In this work, a polymer inclusion membrane containing trioctylmethylammonium chloride as carrier was successfully employed in electrodialysis for vanadium recovery from acidic sulfate solutions. The permeability coefficient of V(V) increased from 0.29 µm·s^-1 (without electric field) to 4.10 µm·s^-1 (with the 20 mA·cm^-2 current density)_. The transport performance of VO₂SO₄^-, which was the predominant species containing V(V) in the acidic region (pH <3), was influenced by the aqueous pH value and sulfate concentration. Under an electric field, a low concentrated H₂SO₄ solution (0.2 M) effectively stripped V(V) from the membranes, avoiding the requirement of a highly concentrated H₂SO₄ without electric field. Under the optimum conditions, the permeability coefficient and flux reached 6.80 µm·s^-1 and 13.34 µmol·m^-2·s^-1, respectively. High selectivity was observed for the separation of V(V) and Mo(VI) from mixed solutions of Co (II), Ni (II), Mn (II), and Al (III). Additionally, the separation between Mo(VI) and V(V) was further improved by adjusting the acidity of the stripping solution. The V(V) selectivity for the resulting membrane was higher than that of commercial anion exchange membranes.

Environmental friendly approach for selective extraction and recovery of molybdenum (Mo) from a sulphate mediated spent Ni-Mo/Al2O3 catalyst baked leach liquor

Solvent extraction separation of molybdenum (Mo) from the sulphate mediated leach solution bearing Aluminium (Al) and Nickel (Ni) was carried out using N-Methyl-N, N, N-tri-octyl-ammonium chloride. Extensive investigation for extraction study molybdenum in the function of time, Eq.pH, extractant concentration, diluents, temperature, strip solution concentration and phase ratio(A:O) for both extraction and stripping was examined to attain a suitable condition on its selective and enriched extraction. As per the equilibrium study and increasing trend of Eq. pH (pH_e) at the correspondence initial pH, it was apparent about association of 1 mol of H⁺ ion during extraction which with was further supported on extraction of Mo as HMO₄^- at the pH_e of 3.48. The association of 1 mol of exrractant during the extraction of Mo was also well evident from the slope analysis study. This indicates about anion exchange phenomenon due to Cl^- ion of the N-Methyl-N, N, N-tri-octyl-ammonium chloride (extractant) with HMo₄^- from aqueous phase during complex formation reaction. The FTIR of the organic sample before and after extraction further confirms in support of the complex formation of the molybdenum with the extractant during extraction. The extraction isotherm was constructed at optmum extraction condition: pH_e of 3.48 with 0.08M N-Methyl-N, N, N-tri-octyl-ammonium chloride predicts on need of 2-counter current stages for quantitative extraction of Mo at A:O = 3:1. To investigate the regeneration behaviour of adopted extractant along with enriched stripping of molybdenum, ammoniacal reagents were used in stripping study. The stripping of Mo showed promising and efficient using the mixture of the ammoniacal reagents (NH₄OH + NH₄Cl) over the either of the solo reagents. The stripping Mc-Cabe Thiele diagram was plotted using 2M NH₄OH + NH₄Cl ensures on quantitative stripping of Mo at SO: SS = 2:1 at 2 no. of stages. Both extraction and stripping isotherm results are validated at predicted isotherm conditions by 6-cycles counter current simulation (CCS) study leading to obtain 6-fold enrichment of Mo in stripped solution phase. The subsequent enriched content of Mo (∼60 g/L) in stripped solution phase was precipitated out followed by calcinations 400 °C to obtain a high pure MoO₃. The recovered calcined product as MoO₃ resulted through the proposed processing approach was as ascertained from XRD analysis.

Separation of vanadium and tungsten from synthetic and spent catalyst leach solutions using an ion-exchange resin

Vanadium and tungsten ion adsorption and desorption characteristics and separation conditions were investigated using a simple porous anion-exchange resin. Initially, systematic experimental research was performed using synthetic aqueous vanadium and tungsten solutions. To evaluate the vanadium and tungsten (50-500 mg L-1) isotherm parameters, adsorption was performed at pH 7.0 using 0.5 g of ion-exchange resin at 303 K for 24 h. Well-known adsorption models such as Langmuir, Freundlich, and Temkin were used. Vanadium was desorbed from the resin using HCl and NaOH solutions. In contrast, tungsten was not desorbed by the HCl solution, which enabled the separation of the two ions. The desorption reaction reached equilibrium within 30 min of its start, yielding over 90% desorption. We investigated the adsorption mechanism and resin stability with the aid of spectroscopic and microscopic analysis, as well as adsorption results. The applicability and feasibility of the resin was tested via recovery of both metals from real spent catalysts. The applicability and reusability results indicated that the resin can be used for more than five cycles with an efficacy of over 90%.

Highly efficient sorption of molybdenum from tungstate solution with modified D301 resin

The separation of molybdenum (Mo) from tungstate solution is a bottleneck problem in tungsten (W) metallurgy, and it hinders the development of high-purity tungsten materials. In this research, a modified D301 resin was used to adsorb and separate molybdenum from tungstate solution. The maximum sorption capacity (Q e) of modified D301 for MoS4 2- was found to be 428 mg g-1 and the separation coefficient (β) was 108.9 when the contact time was 4 h and the reaction temperature was 25 °C and the pH value of the tungstate solution was 7.2. The sorption process conforms to Langmuir isotherm models and the quasi-second-order kinetic model. The sorption mechanism was also discussed, which was a single layered spontaneous sorption process. Theoretical calculations infer bonding behavior between the N atom on the resin and the S atom on the MoS4 2- molecule. The sorption energy is -7.67 eV, which indicated that the sorption process is stable chemical sorption. The desorption experiment showed that more than 90% molybdenum could be desorbed from the loaded resin when the concentration of sodium hydroxide solution was 5 w%. Finally, after three-stage sorption-desorption, almost all molybdenum in the solution was adsorbed, achieving better separation of tungsten and molybdenum.