Leaching zinc from spent catalyst: process optimization using response surface methodology

A Novel Approach for Comprehensive Utilization by Leaching Pyrite Cinder with Titanium Dioxide Waste Acid by Response Surface Methodology

Comprehensive utilization of two industrial wastes by leaching pyrite cinder with titanium dioxide waste acid was proposed by using response surface methodology of the Box-Behnken design method. The effects of leaching conditions such as leaching temperature, leaching time, and waste acid/pyrite cinder ratio on the leaching yield were examined. The prediction model including the leaching variables with a good fitting result was established to predict the leaching yield or optimize the leaching variable values. The regression equation model was significant and reliable with an actual correlation coefficient R2 of 0.9856. The leaching conditions greatly affected the leaching rate, reaction equilibrium, solubility of the acid decomposed substances, and the common ion effects, influenced the leaching process, and finally improved the leaching yield. The variables such as leaching temperature and waste acid/pyrite cinder ratio had the greatest collaborative interactions, and the effects of the waste acid/pyrite cinder ratio were larger than the other two. The verification experiments confirmed that the leaching yield values could be achieved at 82.68 % under the optimal conditions.

Study on the Roasting Process of Guisha Limonite Pellets

In this paper, a pelletizing method has been researched to enhance the subsequent iron-making process applying Guisha limonite, with advantages including large reserves and low price. The purpose is to provide an alternative for the sinter, thus reducing the greenhouse gas emission during the iron-making process. The response surface method is used to optimize the experimental design of the pelleting process. A multivariate regression model for estimating the compressive strength of pellets was developed using Box-Behnken experimental methodology, where the relevant factors were the roasting temperature, pellet diameter, and bentonite content. The maximum influencing factors of each experimental design response are determined using analysis of variance (ANOVA). Under optimum conditions, the compressive strength of pure limonite pellets is 2705 N, similar to the response goal value of 2570.3 N, with a relative error of 5.20%. Since the high-grade iron ore resources are depleted, the comprehensive utilization of ore resources is becoming increasingly important. The aim of this paper was to provide a valuable technical foundation for lignite pellet-roasting processes in the iron and steel industries, since steel companies is increasing its imports of Guisha limonite.

A Study on the Mechanism and Kinetics of Ultrasound-Enhanced Sulfuric Acid Leaching for Zinc Extraction from Zinc Oxide Dust

As an important secondary zinc resource, large-scale reserves of zinc oxide dust (ZOD) from a wide range of sources is of high comprehensive recycling value. Therefore, an experimental study on ultrasound-enhanced sulfuric acid leaching for zinc extraction from zinc oxide dust was carried out to investigate the effects of various factors such as ultrasonic power, reaction time, sulfuric acid concentration, and liquid-solid ratio on zinc leaching rate. The results show that the zinc leaching rate under ultrasound reached 91.16% at a temperature of 25 °C, ultrasonic power 500 W, sulfuric acid concentration 140 g/L, liquid-solid ratio 5:1, rotating speed 100 r/min, and leaching time 30 min. Compared with the conventional leaching method (leaching rate: 85.36%), the method under ultrasound increased the zinc leaching rate by 5.8%. In a kinetic analysis of the ultrasound-enhanced sulfuric acid leaching of zinc oxide dust, the initial apparent activation energy of the reaction was 6.90 kJ/mol, indicating that the ultrasound-enhanced leaching process was controlled by the mixed solid product layers. Furthermore, the leached residue was characterized by XRD and SEM-EDS, and the results show that, with ultrasonic waves, the encapsulated mineral particles were dissociated, and the dissolution of ZnO was enhanced. Mostly, the zinc in leached residue existed in the forms of ZnFe₂O₄, Zn₂SiO₄, and ZnS.

Optimization of operating parameters for xylose reductase separation through ultrafiltration membrane using response surface methodology

The application of the xylose reductase (XR) enzyme in the development of biotechnology demands an efficient and large scale enzyme separation technique. The aim of this present work was to optimize xylose reductase (XR) purification process through ultrafiltration membrane (UF) technology using Central composite design (CCD) of response surface methods (RSM). The three effective parameters analyzed were filtration time (0-100), transmembrane pressure (TMP) (1-1.6 bar), cross flow velocity (CFV) (0.52-1.2 cm/s-1) and its combined effect to obtain high flux with less possibility of membrane fouling. Experimental studies revealed that the best range for optimization process for filtration time, operational transmembrane pressure and cross flow velocity was 30 min, 1.4 bars and 1.06 cm/s, respectively as these conditions yielded the highest membrane permeability (56.03 Lm-2h-1 bar-1) and xylitol content (15.49 g/l). According to the analysis of variance (ANOVA), the p-value (<0.0001) indicated the designed model was highly significant. The error percentage between the actual and predicted value for membrane permeability and xylitol amount (2.21 % and 4.85 % respectively), which both were found to be close to the predicted values. The verification experiments gave membrane actual permeability of 57.3 Lm-2h-1 bar-1 and 16.29 g/l of xylitol production, thus indicating that the successfully developed model to predict the response.

Statistical optimization of titanium recovery from drinking water treatment residue using response surface methodology

Water treatment plants generate vast amounts of sludge and its disposal is one of the most expensive and environmentally problematic challenges worldwide. As sludge from water treatment plants contains a considerable amount of titanium, both can create serious environmental concerns. In this study, the potential to recover titanium from drinking water treatment residue was explored through acid leaching technique. Statistical design for the optimization of titanium recovery was proposed using response surface methodology (RSM) based on a five-level central composite design (CCD). Three independent variables were investigated, namely the acid concentration (3 M-7 M), temperature (40 °C - 80 °C) and solid/liquid ratio (0.005-0.02 g/mL). According to the analysis of variance (ANOVA), the p-value (<0.0001) indicated the designed model was highly significant. Optimization using RSM gave the best fit between validated and predicted data as elucidated by the coefficient of determination with R² values of 0.9965. However, acid concentration and solid/liquid ratio showed an initial increase in titanium recovery followed by recovery reduction with increasing concentration and ratio. Quadratic RSM predicted the maximum recovery of titanium to be 67.73% at optimal conditions of 5.5 M acid concentration, at a temperature of 62 °C with a solid/liquid ratio of 0.01 g/mL. The verification experiments gave an average of 66.23% recovery of titanium, thus indicating that the successfully developed model to predict the response. This process development has significant importance to reduce the cost of waste disposal, environmental protection, and recovery of economically valuable products.

Study of the factors influencing the metals solubilisation from a mixture of waste batteries by response surface methodology

This paper presents an innovative process for the recovery of valuable metals from a mixture of spent batteries. Different types of batteries, including alkaline, zinc-carbon (Zn-C), nickel cadmium (Ni-Cd), nickel metal hydride (Ni-MH), lithium ion (Li-ion) and lithium metallic (Li-M) batteries, were mixed according to the proportion of the Canadian sales of batteries. A Box-Behnken design was applied to find the optimum leaching conditions allowing a maximum of valuable metal removals from a mixture of spent batteries in the presence of an inorganic acid and a reducing agent. The results highlighted the positive effect of sodium metabisulfite on the performance of metals removal, especially for Mn. The solid/liquid ratio and the concentration of H₂SO₄ were the main factors affecting the leaching behavior of valuable metals (Zn, Mn, Cd, Ni) present in spent batteries. Finally, the optimum leaching conditions were found as follows: one leaching step, solid/liquid ratio = 10.9%, [H₂SO₄] = 1.34 M, sodium metabisulfite (Na₂S₂O₅) = 0.45 g/g of battery powder and retention time = 45 min. Under such conditions, the removal yields achieved were 94% for Mn, 81% for Cd, 99% for Zn, 96% for Co and 68% for Ni.

Recovery of metals from a mixture of various spent batteries by a hydrometallurgical process

Spent batteries contain hazardous materials, including numerous metals (cadmium, lead, nickel, zinc, etc.) that are present at high concentrations. Therefore, proper treatment of these wastes is necessary to prevent their harmful effects on human health and the environment. Current recycling processes are mainly applied to treat each type of spent battery separately. In this laboratory study, a hydrometallurgical process has been developed to simultaneously and efficiently solubilize metals from spent batteries. Among the various chemical leaching agents tested, sulfuric acid was found to be the most efficient and cheapest reagent. A Box-Behnken design was used to identify the influence of several parameters (acid concentration, solid/liquid ratio, retention time and number of leaching steps) on the removal of metals from spent batteries. According to the results, the solid/liquid ratio and acid concentration seemed to be the main parameters influencing the solubilization of zinc, manganese, nickel, cadmium and cobalt from spent batteries. According to the results, the highest metal leaching removals were obtained under the optimal leaching conditions (pulp density = 180 g/L (w/v), [H2SO4] = 1 M, number of leaching step = 3 and leaching time = 30 min). Under such optimum conditions, the removal yields obtained were estimated to be 65% for Mn, 99.9% for Cd, 100% for Zn, 74% for Co and 68% for Ni. Further studies will be performed to improve the solubilization of Mn and to selectively recover the metals.

Using mixture design of experiments to assess the environmental impact of clay-based structural ceramics containing foundry wastes

This work describes the leaching behavior of potentially hazardous metals from three different clay-based industrial ceramic products (wall bricks, roof tiles, and face bricks) containing foundry sand dust and Waelz slag as alternative raw materials. For each product, ten mixtures were defined by mixture design of experiments and the leaching of As, Ba, Cd, Cr, Cu, Mo, Ni, Pb, and Zn was evaluated in pressed specimens fired simulating the three industrial ceramic processes. The results showed that, despite the chemical, mineralogical and processing differences, only chrome and molybdenum were not fully immobilized during ceramic processing. Their leaching was modeled as polynomial equations, functions of the raw materials contents, and plotted as response surfaces. This brought to evidence that Cr and Mo leaching from the fired products is not only dependent on the corresponding contents and the basicity of the initial mixtures, but is also clearly related with the mineralogical composition of the fired products, namely the amount of the glassy phase, which depends on both the major oxides contents and the firing temperature.

Kinetics of Mo, Ni, V and Al leaching from a spent hydrodesulphurization catalyst in a solution containing oxalic acid and hydrogen peroxide

The kinetics of molybdenum, nickel, vanadium and aluminium leaching from a spent hydrodesulphurization catalyst in a solution containing oxalic acid and hydrogen peroxide was investigated. The effects of temperature and particle size were examined. In addition, the reaction mechanism for the dissolution of the spent catalyst was discussed. The results of the kinetic analysis for various experimental conditions indicated that the reaction rate of leaching process is controlled by chemical reaction at the particle surface. The values of the activation energies of 31±2, 36±4, 30±4 and 57±3 kJ mol(-1) for Mo, Ni, V and Al, respectively, are characteristic for mechanism controlled by chemical reaction.