Diffusion Dialysis for Acid Recovery from Acidic Waste Solutions: Anion Exchange Membranes and Technology Integration

Comparison of Anion-Exchange Membranes for Diffusion Dialysis of Mixtures of Acids and Their Iron Salts

This study presents the possibility of using diffusion dialysis for the separation of inorganic acids (hydrochloric, nitric, and hydrofluoric) and their ferric salts whose composition corresponds to that of real spent pickling solutions. At a steady state, the transport properties of three different anion-exchange membranes (Fumasep-FAD, Neosepta-AFN, and Neosepta-AHA) are compared using a continuous counter-current dialyzer. At a constant composition of the solutions (acid concentration 3 mol L-1 and iron concentration 30-40 g L-1), the effects of volumetric liquid flow rates on the transport rate of H+ and Fe3+ ions through the membrane are studied. The dialysis process is characterized by the recovery of acids and the rejection of salts. Furthermore, the values of the dialysis coefficients of acids, iron, and the acid/iron separation factors are calculated and compared. The volumetric flow rates of the inlet streams change in limits from 3 × 10-8 to 6 × 10-8 m3 s-1 (from 3 to 6 L h-1 m-2, relative to the membrane area). A comparison of the tested membranes shows slightly better results for acid recovery, iron rejection, and acid/iron separation factors for the Fumasep-FAD membrane than for the Neosepta-AFN membrane. However, the results obtained show that both of these anion-exchange membranes can be considered good separators for tested mixtures that simulate real spent pickling solutions, and there is a good precondition for using diffusion dialysis for processing these solutions in industrial practice. On the contrary, very low values of acid recovery and the overall dialysis coefficient of acid are found for the Neosepta-AHA membrane in the test range of the volumetric flow rate, and, thus, this membrane is insufficient for the adequate separation of these acids and iron salts.

A Viable and sustainable flat- membrane plate-and-frame module for spent acid regeneration and metal ion recovery

This study provides techno-economical insights for acid regeneration and metal recovery from spent acidic wastewater by a diffusion dialysis plate-and-frame module using Quaternized Polyepichlorohydrin - Polyacrylonitrile (QPECH-PAN) membranes. Quaternized Polyepichlorohydrin (QPECH) membranes were synthesized using 1,4-diazobicyclo[2.2.2]octane (DABCO) and blended with polyacrylonitrile (PAN). Said membranes were analyzed in terms of their mechanical, physicochemical, and electrochemical characteristics, providing significant results comparable to the commercial membranes (IEC: 1.76 mmol/g, SD: 60.91%, Permselectivity: 79.5 ± 0.31%, and transport no. t_(-): 0.5). Mechanical characterization reveals that the QPECH-PAN membranes possess comparable mechanical strengths (tensile strength: 329.56 MPa). Further, sheet resistivity (6.11 Ω cm²) and conductivity (0.16 S/cm²) reveal the relative conductive nature of these membranes. Percent acid recovery and metal ion recovery ratios were found to be 72% and 48% respectively, and separation factors were 126.8 and 84.57 respectively. The QPECH-PAN membrane's techno-economic feasibility was also analyzed within the context of a textile industry processing up to 5500 kg/d of acidic wastewater. It indicates a potential cost saving of US $0.53 million on H₂SO₄ and NaOH, as well as an OPEX saving of 40.91% against a semi-continuous acid neutralizer.

Comparative Study of Different Ion-Exchange Membrane Types in Diffusion Dialysis for the Separation of Sulfuric Acid and Nickel Sulfate

The possibility of using various types of ion-exchange membranes in diffusion dialysis for the separation of sulfuric acid and nickel sulfate has been evaluated. The process of the dialysis separation of a real waste solution from an electroplating facility containing 252.3 g/L of sulfuric acid, 20.9 g/L of nickel ions and small amounts of zinc, iron, copper ions, etc. has been studied. Heterogeneous cation-exchange membrane containing sulfonic groups and heterogeneous anion-exchange membranes with different thicknesses (from 145 μm to 550 μm) and types of fixed groups (four samples with quaternary ammonium base and one sample with secondary and tertiary amines) have been used. The diffusion fluxes of sulfuric acid, nickel sulfate, and the total and osmotic fluxes of the solvent have been determined. The use of a cation-exchange membrane does not allow the separation of the components, since the fluxes of both components are low and comparable in magnitude. The use of anion-exchange membranes makes it possible to efficiently separate sulfuric acid and nickel sulfate. Anion-exchange membranes with quaternary ammonium groups are more effective in the diffusion dialysis process, while the thin membrane turns out to be the most effective.

Recent Advanced Development of Acid-Resistant Thin-Film Composite Nanofiltration Membrane Preparation and Separation Performance in Acidic Environments

Membrane filtration technology has attracted extensive attention in academia and industry due to its advantages of eco-friendliness related to environmental protection and high efficiency. Polyamide thin-film composite nanofiltration (PA TFC NF) membranes have been widely used due to their high separation performance. Non-acid-resistant PA TFC NF membranes face tremendous challenges in an acidic environment. Novel and relatively acid-resistant polysulfonamide-based and triazine-based TFC NF membranes have been developed, but these have a serious trade-off in terms of permeability and selectivity. Hence, how to improve acid resistance of TFC NF membranes and their separation performance in acidic environments is a pivotal issue for the design and preparation of these membranes. This review first highlights current strategies for improving the acid resistance of PA TFC NF membranes by regulating the composition and structure of the separation layer of the membrane performed by manipulating and optimizing the construction method and then summarizes the separation performances of these acid-resistant TFC NF membranes in acidic environments, as studied in recent years.

Hybrid Membrane Technology for Acid Recovery from Wastewater in Coated Steel Wire Production: A Pilot Scale Study

In the present study, the problem of sulfuric acid recycling from spent copper plating solution was solved using a hybrid membrane technology, including diffusion dialysis and electrodialysis. A real solution from the production of copper-coated steel wire, containing 1.45 mol/L of sulfuric acid, 0.67 mol/L of ferrous sulfate and 0.176 mol/L of copper sulfate, was processed. Diffusion dialysis with anion-exchange membranes was used to separate sulfuric acid and salts of heavy metals. Then, purified dilute sulfuric acid was concentrated by electrodialysis. The energy consumption for sulfuric acid electrodialysis concentration at a current density of 400 A/m² was 162 W·h/mol, with a current efficiency of 16%. After processing according to the hybrid membrane scheme, the solution contained 1.13 mol/L sulfuric acid, 0.077 mol/L ferrous sulfate and 0.022 mol/L copper sulfate. According to established requirements, the solution of a copper plating bath had to contain from 0.75 to 1.25 M sulfuric acid, 0.16-0.18 M of copper sulfate and ferrous sulfate not more than 0.15 M. The resulting acid solution with a small amount of ferrous sulfate and copper sulfate could be used to prepare a copper plating bath solution.

Polymer Inclusion Membranes with P507-TBP Carriers for Lithium Extraction from Brines

The separation of lithium and magnesium from salt-lake brines with high Mg2+/Li+ ratios is a main challenge for lithium extraction. In this work, novel polymer inclusion membranes (PIMs) were developed by incorporating 2-ethylhexyl phosphonic acid mono 2-ethylhexyl (P507) and tributyl phosphate (TBP) as the carriers into cellulose triacetate (CTA) polymers. The Li+ could be stripped from the P507-TBP extracting carriers using pure water eluents without adding concentrated hydrochloric acid, which can help decrease carriers’ leakage risk from membrane matrixes and keep the stability of PIMs. The morphology, composition, and wettability of P507-TBP-based PIMs were characterized systematically, and the carrier content in the PIM was also optimized. In the transport experiment with the feed of 0.1 mol/L LiCl and 4.0 mol/L MgCl2, the CTA/P507-TBP60% membrane exhibits a Li+ permeability of 4.76 × 10−3 mol·m−2·h−1 and a Li/Mg separation ratio of 10.2. After recycling seven times, the selectivity of the PIM is well-retained (>10), and the permeability of Li+ decreases slightly (less than 15%). With a decent selectivity and excellent stability, PIMs containing P507-TBP carriers show great potential for sustainable and efficient lithium recovery from brines with high Mg/Li ratios.

Recovery of Hydrochloric Acid from Industrial Wastewater by Diffusion Dialysis Using a Spiral-Wound Module

In the present study, the possibility of using a spiral-wound diffusion dialysis module was studied for the separation of hydrochloric acid and Zn2+, Ni2+, Cr3+, and Fe2+ salts. Diffusion dialysis recovered 68% of free HCl from the spent pickling solution contaminated with heavy-metal-ion salts. A higher volumetric flowrate of the stripping medium recovered a more significant portion of free acid, namely, 77%. Transition metals (Fe, Ni, Cr) apart from Zn were rejected by >85%. Low retention of Zn (35%) relates to the diffusion of negatively charged chloro complexes through the anion-exchange membrane. The mechanical and transport properties of dialysis FAD-PET membrane under accelerated degradation conditions was investigated. Long-term tests coupled with the economic study have verified that diffusion dialysis is a suitable method for the treatment of spent acids, the salts of which are well soluble in water. Calculations predict significant annual OPEX savings, approximately up to 58%, favouring diffusion dialysis for implementation into wastewater management.

Synthesis of Porous BPPO-Based Anion Exchange Membranes for Acid Recovery via Diffusion Dialysis

Diffusion dialysis (DD) is an anion exchange membrane-based functional separation process used for acid recovery. TMA (trimethylamine) and BPPO (brominated poly(2,6-dimethyl-1,4-phenylene oxide) were utilized in this manuscript to formulate AEMs (anion exchange membranes) for DD (diffusion dialysis) using the phase-inversion technique. FTIR (Fourier transfer infrared) analysis, proton NMR spectroscopy, morphology, IEC (ion exchange capacity), LER (linear expansion ratio), CR (fixed group concentration), WR (water uptake/adsorption), water contact angle, chemical, and thermal stability, were all used to evaluate the prepared membranes. The effect of TMA content within the membrane matrix on acid recovery was also briefly discussed. It was reported that porous AEMs have a WR of 149.6% to 233.8%, IEC (ion exchange capacity) of 0.71 to 1.43 mmol/g, CR (fixed group concentration) that ranged from 0.0046 mol/L to 0.0056 mol/L, LER of 3.88% to 9.23%, and a water contact angle of 33.10° to 78.58°. The UH (acid dialysis coefficients) for designed porous membranes were found to be 0.0043 to 0.012 m/h, with separation factors (S) ranging from 13.14 to 32.87 at the temperature of 25 °C. These observations are comparable to those found in the DF-120B commercial membrane with UH of 0.004 m/h and S of 24.3 m/h at the same temperature (25 °C). This porous membranes proposed in this paper are excellent choices for acid recovery through the diffusion dialysis process.

Recovery of Spent Sulphuric Acid by Diffusion Dialysis Using a Spiral Wound Module

In this study, we assess the effects of volumetric flow and feed temperature on the performance of a spiral-wound module for the recovery of free acid using diffusion dialysis. Performance was evaluated using a set of equations based on mass balance under steady-state conditions that describe the free acid yield, rejection factors of metal ions and stream purity, along with chemical analysis of the outlet streams. The results indicated that an increase in the volumetric flow rate of water increased free acid yield from 88% to 93%, but decreased Cu²⁺ and Fe²⁺ ion rejection from 95% to 90% and 91% to 86%, respectively. Increasing feed temperature up to 40 °C resulted in an increase in acid flux of 9%, and a reduction in Cu²⁺ and Fe²⁺ ion rejection by 2–3%. Following diffusion dialysis, the only evidence of membrane degradation was a slight drop in permselectivity and an increase in diffusion acid and salt permeability. Results obtained from the laboratory tests used in a basic economic study showed that the payback time of the membrane-based regeneration unit is approximately one year.

Quaternized Diaminobutane/Poly(vinyl alcohol) Cross-Linked Membranes for Acid Recovery via Diffusion Dialysis

Diffusion dialysis (DD) using anion exchange membranes (AEM) is an effective process for acid recovery and requires the preparation of suitable materials for AEMs, characterized by unique ions transport properties. In this work, novel AEMs composed of quaternized diaminobutane (QDAB) and poly(vinyl alcohol) (PVA) were cross-linked by tetraethoxysilane (TEOS) via the sol–gel process. The prepared AEMs were systematically characterized by Fourier-transform infrared (FTIR) spectroscopy, ion-exchange capacity (IEC) analysis, thermo gravimetric analysis (TGA), water uptake, linear expansion ratio (LER), and mechanical strength determination, scanning electron microscopy (SEM), and DD performance analysis for acid recovery using a hydrochloric acid/iron chloride (HCl/FeCl₂) aqueous mixture and varying the QDAB content. The prepared AEMs exhibited IEC values between 0.86 and 1.46 mmol/g, water uptake values within 71.3 and 47.8%, moderate thermal stability, tensile strength values in the range of 26.1 to 41.7 MPa, and elongation from 68.2 to 204.6%. The dialysis coefficient values were between 0.0186 and 0.0295 m/h, whereas the separation factors range was 24.7–44.1 at 25 °C. The prepared membranes have great potential for acid recovery via diffusion dialysis.

Silica Containing Composite Anion Exchange Membranes by Sol-Gel Synthesis: A Short Review

This short review summarizes the literature on composite anion exchange membranes (AEM) containing an organo-silica network formed by sol–gel chemistry. The article covers AEM for diffusion dialysis (DD), for electrochemical energy technologies including fuel cells and redox flow batteries, and for electrodialysis. By applying a vast variety of organically modified silica compounds (ORMOSIL), many composite AEM reported in the last 15 years are based on poly (vinylalcohol) (PVA) or poly (2,6-dimethyl-1,4-phenylene oxide) (PPO) used as polymer matrix. The most stringent requirements are high permselectivity and water flux for DD membranes, while high ionic conductivity is essential for electrochemical applications. Furthermore, the alkaline stability of AEM for fuel cell applications remains a challenging problem that is not yet solved. Possible future topics of investigation on composite AEM containing an organo-silica network are also discussed.

An Investigation of a (Vinylbenzyl) Trimethylammonium and N-Vinylimidazole-Substituted Poly (Vinylidene Fluoride-Co-Hexafluoropropylene) Copolymer as an Anion-Exchange Membrane in a Lignin-Oxidising Electrolyser

Electrolysis is seen as a promising route for the production of hydrogen from water, as part of a move to a wider “hydrogen economy”. The electro-oxidation of renewable feedstocks offers an alternative anode couple to the (high-overpotential) electrochemical oxygen evolution reaction for developing low-voltage electrolysers. Meanwhile, the exploration of new membrane materials is also important in order to try and reduce the capital costs of electrolysers. In this work, we synthesise and characterise a previously unreported anion-exchange membrane consisting of a fluorinated polymer backbone grafted with imidazole and trimethylammonium units as the ion-conducting moieties. We then investigate the use of this membrane in a lignin-oxidising electrolyser. The new membrane performs comparably to a commercially-available anion-exchange membrane (Fumapem) for this purpose over short timescales (delivering current densities of 4.4 mA cm⁻² for lignin oxidation at a cell potential of 1.2 V at 70 °C during linear sweep voltammetry), but membrane durability was found to be a significant issue over extended testing durations. This work therefore suggests that membranes of the sort described herein might be usefully employed for lignin electrolysis applications if their robustness can be improved.

Innovative BPPO Anion Exchange Membranes Formulation Using Diffusion Dialysis-Enhanced Acid Regeneration System

Recycling of acid from aqueous waste streams is crucial not only from the environmental point of view but also for maturing the feasible method (diffusion dialysis). Anion exchange membrane (AEM)–based diffusion dialysis process is one of the beneficial ways to recover acid from aqueous waste streams. In this article, the synthesis of a series of brominated poly (2, 6–dimethyl-1, 4–phenylene oxide) (BPPO)-based anion exchange membranes (AEMs) through quaternization with triphenylphosphine (TPP) were reported for acid recovery via diffusion dialysis process. The successful synthesis of the prepared membranes was confirmed by Fourier transform infrared (FTIR) spectroscopy. The as-synthesized anion exchange membranes represented water uptake (W_R) of 44 to 66%, ion exchange capacity of (IEC) of 1.22 to 1.86 mmol/g, and linear swelling ratio (LSR) of 8 to 20%. They exhibited excellent thermal, mechanical, and acid stability. They showed homogeneous morphology. The acid recovery performance of the synthesized AEMs was investigated in a two compartment stack using simulated mixture of HCl and FeCl₂ as feed solution at room temperature. For the synthesized anion exchange membranes TPP–43 to TPP–100, the diffusion dialysis coefficient of acid (U_H⁺) was in the range of 6.7 to 26.3 (10⁻³ m/h) whereas separation factor (S) was in the range of 27 to 49 at 25 °C. Obtained results revealed that diffusion dialysis performance of the synthesized AEMs was higher than the commercial membrane DF–120B (U_H⁺ = 0.004 m/h, S = 24.3) at room temperature. It showed that the prepared AEMs here could be excellent candidates for the diffusion dialysis process.