Synthesis of chromium containing pigments from chromium galvanic sludges

Steam activation of porous concave polymer nanospheres for high-efficient chromium and cadmium removal

The issue of heavy metal contamination in water is a global concern, and the development of highly efficient adsorbent materials is crucial for the removal and detoxification of heavy metals. Polymer-based materials have emerged as a promising class of adsorbents due to their ability to capture heavy metal pollutants and reduce them to less toxic forms. The limited surface area of conventional polymer adsorbents makes them less effective for high-capacity adsorption. Herein, we present a low-temperature steam activation approach to address this challenge. This activation approach leads to a remarkable increase of over 20 times in the surface area of concave aminophenol-formaldehyde (APF) polymer nanospheres (from 45 to 961 m2/g) while preserving their reductive functional groups. The activated concave APF nanospheres were evaluated for their adsorption capabilities towards two typical heavy metal ions (i.e., Cr(VI) and Cd(II)) in aqueous solutions. The maximum adsorption capacities achieved were 1054 mg g-1 for Cr(VI) and 342 mg g-1 for Cd(II), which are among the highest performances reported in the literature and are much higher than the capacities of the non-activated APF nanospheres. Additionally, approximately 71.5 % of Cr(VI) was simultaneously reduced to Cr(III) through the benzenoid amine pathway during adsorption, highlighting the crucial role of the steam activation strategy in enhancing the capability of polymer adsorbents.

Treatment of galvanic effluent through electrocoagulation process: Cr, Cu, Mn, Ni removal and reuse of sludge generated as inorganic pigment

Galvanic effluents are composed of a wide range of heavy metals, requiring adequate treatment to remove these contaminants and to meet the limits established by environmental agencies. Considering this aspect, the present study had as main objectives: (i) to evaluate the efficiency of the electrocoagulation (EC) in the treatment of a galvanic effluent, with the purpose of removing total Cr, Cu, Mn, Ni and (ii) reuse the sludge generated for inorganic pigment production. EC tests were carried out through factorial design 2³ with triplicate central point. pH (3, 7, 11), reaction time (15, 22.5 and 30 min) and current density (10, 17.5 and 25 mA/cm²) were the control variables. Under ideal experimental conditions (pH 7.00; t = 22.5 min and DC = 17.5 mA/cm²) were removed 96.94% of Mn, 97.63% of Cu and 99.99% of total Cr and Ni, allowing to meet the limits provided in CONAMA Resolution 430/2011. The production of inorganic pigments from a mixture of 10% sludge (generated in the ideal experimental condition) and Al₂O₃ and TiO₂ proved to be technically viable. It was obtained 8.27 g of a brown inorganic pigment, composed mainly of Al_1.82Cr_0.18O₃, Ca_0.999(Ti_0.805Fe_0.201)O_2.899 and Fe_2.18O₄Ti_0.42. Therefore, the results obtained demonstrate that EC is an effective technique in galvanic effluents treatment. The sludge generated in this process showed to be appropriated to be reused in inorganic pigment production and could be considered as an alternative to reduce the environmental impact related to electroplating process.

Pigments from spent Zn, Ni, Cu, and Cd electrolytes from electroplating industry

One of the problems of electroplating industry is the periodic discharge of concentrated spent electrolytes together with rinsing wastewater. This leads to irreversible loss of valuable components, as well as to the risk of heavy metal ions entering the environment, which have toxic, mutagenic, and carcinogenic effects. The paper presents research on the processing of spent electrolytes from electroplating industry of zinc, nickel, copper, and cadmium plating, collected over 3 years. Pigments of various colors were obtained by precipitation of zinc, nickel, copper, and cadmium ions by phosphate, hydroxide, and sodium carbonate. By their properties, i.e., whiteness 95-97%, residue after sieving on a sieve up to 0.04 wt.%, etc., the resulting pigments are not inferior to those currently presented on the world market. Following previous studies, a basic technological scheme for processing waste electrolytes with pigments production is proposed. Processing of spent electrolytes according to the proposed technology will make it possible to reduce the concentration of heavy metal ions to acceptable values (0.13-0.65 mg/L) for discharge. This will ensure stable and uninterrupted operation of local treatment facilities of electroplating industry.

Flow analysis of heavy metals in a pilot-scale incinerator for residues from waste electrical and electronic equipment dismantling

The large amount of residues generated from dismantling waste electrical and electronic equipment (WEEE) results in a considerable environmental burden. We used material flow analysis to investigate heavy metal behavior in an incineration plant in China used exclusively to incinerate residues from WEEE dismantling. The heavy metals tested were enriched in the bottom and fly ashes after incineration. However, the contents of heavy metals in the bottom ash, fly ash and exhaust gas do not have a significant correlation with that of the input waste. The evaporation and recondensation behavior of heavy metals caused their contents to differ with air pollution control equipment because of the temperature difference during gas venting. Among the heavy metals tested, Cd had the strongest tendency to transfer during incineration (TCd=69.5%) because it had the lowest melting point, followed by Cu, Ni, Pb and Zn. The exchangeable and residual fractions of heavy metals increased substantially in the incineration products compared with that of the input residues. Although the mass of residues from WEEE dismantling can be reduced by 70% by incineration, the safe disposal of the metal-enriched bottom and fly ashes is still required.

Ceramic colorant from untreated iron ore residue

This work deals with the development of a ceramic colorant for glazes from an untreated iron ore residue. 6 mass% of the residue was added in suspensions (1.80 g/cm(3) density and 30s viscosity) of white, transparent and matte glazes, which were applied as thin layers (0.5mm) on engobeb and not fired ceramic tiles. The tiles were fired in laboratory roller kiln in a cycle of 35 min and maximum temperatures between 1050 and 1180°C. The residue and glazes were characterized by chemical (XRF) and thermal (DTA and optical dilatometry) analyses, and the glazed tiles by colorimetric and XRD analyses. The results showed that the colorant embedded in the transparent glaze results in a reddish glaze (like pine nut) suitable for the ceramic roof tile industry. For the matte and white glazes, the residue has changed the color of the tiles with temperature.

The bulk composition and leaching properties of electroplating sludge prior/following the solidification/stabilization by calcium oxide

Eighteen samples of electroplating sludge were taken from three vertical profiles of waste storage pond of the zinc plating facility. Dry matter and organic matter content, pH value, bulk concentrations and leachate composition were determined. A sludge sample with the highest zinc value in the leachate was treated with calcium oxide (10% to 70%) and the obtained solidificate was repeatedly tested. There were found significant variations of all measured parameters among the profiles of untreated waste. Dry matter content varied from 125 to 455 mgg(-1), organic matter varied from 94.3 to 293.9 mgg(-1), and pH value varied from 3.42 to 5.90 (mean 4.34). Iron content ranged from 38.4 to 191.4 mgg(-1) (mean 136 mgg(-1); RSD 0.25), while zinc ranged from 10.9 to 58.2 mgg(-1) (mean 33.4 mgg(-1); RSD 0.38). According to its DIN38414-S4 leachate composition, this material was not suitable for landfilling of inert waste since zinc and nickel mean values were 10 and 1.5 times higher, respectively, and maximum values 27 and 2.5 times higher, respectively, compared to the upper permissible limit. Maximum values of Cr(VI), Fe, Ni, Cu, and Zn in the DIN38414-S4 leachate were 0.183 mgL(-1), 34.085 mgL(-1), 1.052 mgL(-1), 0.829 mgL(-1) and 107.475 mgL(-1)L, respectively. Following the solidification/stabilization procedure with CaO (sample/CaO = 90/10), concentrations of Cr(VI), Fe, Cu and Zn were reduced 92, 44, 66 and 57 times, respectively, compared to the untreated sample. The addition of 50% of CaO into the sludge reduced zinc and nickel concentrations 79 and 45 times, respectively, in the DIN38414-S4 leachate of the solidified waste compared to the original sludge, thereby converting an hazardous waste into the inert material suitable for landfilling or reuse in the construction processes.