Metal Foam Electrode as a Cathode for Copper Electrowinning

Electrodeposited Fe on Cu foam as advanced fenton reagent for catalytic mineralization of methyl orange

In many countries, the textile industry remains the major contributor to environmental pollution. Untreated textile dyes discharged into water negatively impact the performance of aquatic organisms and may cause a variety of serious problems to their predators. Effective wastewater treatment is a key to reducing environmental and human health risks. In this work, the Fe/Cu catalysts were used in heterogeneous Fenton’s reaction for the degradation of high concentrations of methyl orange (model azo dye) in aqueous solutions. For the first time, the catalysts were prepared onto commercial copper foams by potentiostatic electrodeposition of iron using an environmentally friendly electrolyte. The influence of electrodeposition conditions, H₂O₂ concentration, dye concentration and temperature on the model dye degradation was investigated. It was revealed that both the surface area and the catalyst loading play the major role in the effective dye degradation. The experimental results involving spectrophotometric measurements coupled with total carbon and nitrogen quantification suggest that a solution containing up to 100 mg/L of methyl orange can be successfully decolorized within 90 s at 50°C using porous Fe/Cu catalyst in the presence of hydrogen peroxide that largely surpasses the current state-of-the-art performance. Already within the first 10°min, ∼ 30% of total methyl orange concentration is fully mineralized. The described process represents a cost-efficient and environmentally friendly way to treat azo dyes in aqueous solutions.

Catalysing electrowinning of copper from E-waste: A critical review

Smart technologies and digitalisation have increased the consumption of scarce metals that threaten the sustainability of intricated industries. Additionally, the growing streams of waste electrical and electronic equipment (e-waste) are significant hazards to public health and the environment. Thus, there is an escalating need to recover metals from e-waste for sustainable management of metal resources. Hydrometallurgical processing of e-waste, involving copper (Cu) leaching and its subsequent recovery from pregnant leach solution (PLS) via electrowinning, has emerged as an efficient strategy to close the recycling loop. Electrowinning from PLS demonstrated higher Cu recovery efficiency and operational feasibility with a lower reagent use and lesser waste generation. Nevertheless, multiple issues challenged its practical implementation, including selective recovery of Cu from PLS containing mixed metals and high energy consumption. This review (1) identifies the factors affecting Cu electrowinning from PLS; (2) evaluates the composition of lixiviants influencing Cu electrowinning; (3) appraises various catalysts developed for enhancing Cu electrodeposition; and (4) reviews coupled systems that minimised process energy consumption. From the literature review, electrocatalysts are prospective candidates for improving Cu electrowinning as they reduced the cathodic reduction overpotentials, enhanced surface reaction kinetics and increased current efficiency. Other catalysts, including bioelectrocatalysts and photoelectrocatalysts, are applicable for dilute electrolytes with further investigations required to validate their feasibility. The coupled systems, including slurry electrolysis, bioelectrochemical systems and coupled redox fuel cells, minimise process energy requirements by systematically coupling the cathodic reduction reaction with suitable anodic oxidation reactions having thermodynamically low overpotentials. Among these systems, slurry electrolysis utilising a single-step processing of e-waste is feasible for commericalisation though operational challenges must be addressed to improve its sustainability. The other systems require further studies to improve their scalability. It provides an important direction for energy-efficient Cu electrowinning from PLS, ultimately promoting a circular economy for the scarce metal resources.

Nickel Wick by Continuous Freeze-Casting: Influences of the Particle Size on the Capillarity and Mechanical Properties

The aim of this work was to study the effect of the particle size range, the freeze casting temperature and sintering temperature on the capillarity performance and mechanical properties of Ni wicks manufactured by freeze-casting. The use of Ni/camphene-polystyrene suspensions creates wicks with an open porosity above 80% and average pore sizes of 38 μm to 17 μm by tailoring the particle size ranges and freezing temperatures employed. The incorporation of PS and the use of a continuous freeze-casting process reduces the particle sedimentation and generates a highly interconnected pore structure with regular pore sizes across the sample. The capillarity performances exhibit a fast and complete water adsorption, especially in Ni wicks freeze-casted at 10 °C and sintered at 800 °C, but only when the smaller particle size range is used do Ni wicks achieve sufficient mechanical strength.