Processing of Egyptian boiler-ash for extraction of vanadium and nickel

Valorization of fly ash by nickel ferrite and vanadium oxide recovery through pyro-hydrometallurgical processes: Technical and environmental assessment

The fly ash (FA) from the combustion of heavy oil in power stations is characterized by fine particles containing toxic metals. The sample utilized in this study was gathered from the dust precipitators of seven heavy-oil-consuming Iranian power plants. Substantial quantities of heavy metals, particularly vanadium, iron, and nickel, have been detected in the sample, indicating both its potential utility and hazard to the soil and groundwater. The harmful consequences of FA disposal on the environment have led to the adoption of recycling as a treatment approach in this study. The valorization of FA was investigated by producing nickel ferrite (NiFe2O4) and vanadium pentoxide (V2O5) through a novel approach using a combination of pyro-hydrometallurgical processes, which resulted in proposing a recycling closed-loop flowsheet. Roasting was first practiced to form NiFe2O4 by reacting the nickel and iron content of the FA. The NiFe2O4 showed a low dissolution against inorganic acids (H2SO4, HCl, and HNO3). The vanadium content of the FA showed a remarkable recovery in H2SO4 (91%) and HCl (95.6%), while the dissolution of Ni was limited to 16.85% and 17.5%, respectively. The produced NiFe2O4 acted well in response to the magnetic field, and its purity was further increased to 95-96% through a two-stage process consisting of grinding and magnetic separation. The nano-sized spherical NiFe2O4 with saturation magnetization of 34.66 and 30.82 emu. g-1 was obtained from H2SO4 and HCl residues, respectively. The dissolved vanadium was recovered as V2O5 via oxidation-precipitation in sulfate media and oxidation-ammonium precipitation in chloride solution. The purity of V2O5 in sulfate and chloride media was 93% and 98.5%, respectively. Finally, a life cycle assessment (LCA) study was performed on the suggested methods to track the ecological effects of extracting V and Ni from oil combustion FA. According to the performed LCA, H2SO4 was determined as the proper leaching reagent considering the environmental and technical aspects.

Recovery of vanadium and nickel from heavy oil fly ash (HOFA): a critical review

Heavy oil fly ash "HOFA" is the fly ash generated in power stations using heavy oil as fuel. HOFA is considered a hazardous waste because it contains considerable amounts of heavy metals. However, it contains significant amounts of vanadium "V" and nickel "Ni", which are precious metals for manufacturing processes. This paper presents a critical review of various approaches described in the literature for the recovery of V and Ni from HOFA, including processes of leaching, chemical precipitation, solvent extraction, and ion exchange. The optimum operational parameters and their effects on recovery efficiency are discussed. The digestion mixtures of strong mineral acids used for dissolving all metals present in HOFA are also highlighted. The leaching processes of V and Ni use mainly acidic and alkaline solutions. Bioleaching is a promising environmentally friendly approach for the recovery of V and Ni through using appropriate bacteria and fungi. After leaching, V and Ni compounds are recovered and purified using various techniques, including chemical precipitation, solvent extraction, and ion exchange. In most cases, V and Ni are recovered as thermally decomposable compounds that undergo calcination to produce V₂O₅ and NiO. Eventually, V and Ni are recovered as pure oxides in most approaches, but pure metals are obtained in exceptional procedures.

Ecological treatment of El Kriymat boiler ash for recovering vanadium, nickel and zinc from sulfate leach liquor

The primary goal of this work is to develop a technology that allows for the recovery of metal values from waste products, thereby promoting the wise and efficient use of our nation's resources. To achieve this goal, an industrial waste of El Kriymat boiler fly Ash was used for recovering its content of vanadium, nickel and zinc. About 97, 95 and 99% respectively of these economic elements were first dissolved from boiler fly ash magnetic concentrate (after physical concentration). Leaching experiments using optimum conditions include: 180 g/L sulfuric acid concentration and 4% solid/solid proportion manganese dioxide acts as an oxidant at 80 °C. The recovery of vanadium (V) metal ions was carried out using 3% Alamine 336 in kerosene at an equilibrium pH value of 0.9. Subsequently, 15% sodium sulfide solution was used for co-precipitation of nickel and zinc metal ions in the raffinate solution at pH value of 3.5.

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Ultrasonic-assisted synthesis of SiO2 nanoparticles and SiO2/chitosan/Fe nanocomposite and their application for vanadium adsorption from aqueous solution

The husk of brown rice, as a source of silica, was applied to synthesize natural SiO₂ nanoparticles via sonochemical method. SiO₂/CH/Fe nanocomposite was synthesized from SiO₂, chitosan (prepared from shrimp shells via sonochemical method), and iron functional groups and detected using BET, EDX-SEM, and FTIR techniques. These natural-based nanostructures (SiO₂ and SiO₂/CH/Fe) have been applied for vanadium adsorption. The influences of initial pH, initial concentration, and adsorption time were studied via a batch process. The analysis of the kinetics data indicated that the chemical adsorption is predominant. The analysis of the equilibrium data indicated the single layer and exothermic adsorption process. The mono-layer adsorption capacity of SiO₂/CH/Fe was 199.540 mg g^-1. The performance of SiO₂/CH/Fe in a continuous column system was investigated in four adsorption and desorption cycles. Results showed that SiO₂/CH/Fe nanocomposite synthesized with the sonochemical method is a candidate with high adsorption ability for use as an industrial adsorbent.

Carbonaceous Adsorbent Derived from Sulfur-Impregnated Heavy Oil Ash and Its Lead Removal Ability from Aqueous Solution

A novel carbonaceous adsorbent was prepared from sulfur-impregnated heavy oil ash via pyrolysis using potassium sulfide (K2S) solution, and its ability to remove lead (Pb2+) from aqueous solutions was examined. It was compared with an adsorbent synthesized by conventional pyrolysis using potassium hydroxide (KOH) solution. Specifically, the raw ash was immersed in 1 M K2S solution or 1 M KOH solution for 1 day and subsequently heated at 100–1000 °C in a nitrogen (N2) atmosphere. After heating for 1 h, the solid was naturally cooled in N2 atmosphere, and subsequently washed and dried to yield the product. Regardless of the pyrolysis temperature, the product generated using K2S (Product-K2S) has a higher sulfur content than that obtained using KOH (Product-KOH). Moreover, Product-K2S has a higher lead removal ability than Product-KOH, whereas the specific surface area of the former is smaller than that of the latter. Product-K2S obtained at 300 °C (Product-K2S-300) achieves the highest lead adsorption and a high selective lead removal from a ternary Pb2+–Cu2+–Zn2+ solution. The equilibrium capacity of Product-K2S-300 was found to fit the Langmuir model better than the Freundlich model, and its calculated maximum adsorption capacity is 0.54 mmol/g. From the ternary Pb2+–Cu2+–Zn2+ solution, the order of adsorption by Product-K2S-300 is Pb2+ > Cu2+ > Zn2+, and the removal of Pb2+ and Cu2+ increases as the pH of the solution increases.

Recycle, Recover and Repurpose Strategy of Spent Li-ion Batteries and Catalysts: Current Status and Future Opportunities

The disposal of hazardous waste of any form has become a great concern for the industrial sector due to increased environmental awareness. The increase in usage of hydroprocessing catalysts by petrochemical industries and lithium-ion batteries (LIBs) in portable electronics and electric vehicles will soon generate a large amount of scrap and create significant environmental problems. Like general electronic wastes, spent catalysts and LIBs are currently discarded in municipal solid waste and disposed of in landfills in the absence of policy and feasible technology to drive alternatives. Such inactive catalyst materials and spent LIBs not only contain not only hazardous heavy metals but also toxic and carcinogenic chemicals. Besides polluting the environment, these systems (spent catalysts and LIBs) contain valuable metals such as Ni, Mo, Co, Li, Mn, Rh, Pt, and Pd. Therefore, the extraction and recovery of these valuable metals has significant importance. In this Review, we have summarized the strategies used to recover valuable (expensive) as well as cheap metals from secondary resources-especially spent catalysts and LIBs. The first section contains the background and sources of LIBs and catalyst scraps with their current recycling status, followed by a brief explanation of metal recovery methods such as pyrometallurgy, hydrometallurgy, and biometallurgy. The recent advances achieved in these methods are critically summarized. Thus, the Review provides a guide for the selection of adequate methods for metal recovery and future opportunities for the repurposing of recovered materials.

czcD gene from Bacillus megaterium and Microbacterium liquefaciens as a potential nickel-vanadium soil pollution biomarker

Metals are among the most prevalent pollutants released into the environment. For these reasons, the use of biomarkers for environmental monitoring of individuals and populations exposed to metal pollution has gained considerable attention, offering fast and sensitive detection of chemical stress in organisms. There are different metal resistance genes in bacteria that can be used as biomarkers, including cation diffusion facilitators carrying metal ions; the prototype is the cobalt-zinc-cadmium transporter (czcD). The present study reports the expression changes in the czcD gene in Bacillus megaterium and Microbacterium liquefaciens under nickel and vanadium exposure by real-time polymerase chain reaction. The nickel-vanadium-resistant strains of B. megaterium and M. liquefaciens used in this study were isolated from mine tailings in Guanajuato, Mexico. The czcD gene showed high expression under exposure to 200 ppm of Ni and 200 ppm of V during the logarithmic growth phase of M. liquefaciens in PHGII liquid media. In contrast, no changes were observed in B. megaterium during logarithmic and stationary growth, perhaps due to the gene having differential expression during the growth phases. The expression profiles obtained for czcD show the possibility of using this gene from M. liquefaciens as a biomarker of nickel and vanadium pollution in microorganisms.

Direct recovery of boiler residue by combustion synthesis

Boiler residue (BR) of thermal power plants is one of the important secondary sources for vanadium production. In this research, the aluminothermic self-propagating high-temperature synthesis (SHS) was used for recovering the transition metals of BR for the first time. The effects of extra aluminum as reducing agent and flux to aluminum ratio (CaO/Al) were studied and the efficiency of recovery and presence of impurities were measured. Aluminothermic reduction of vanadium and other metals was carried out successfully by SHS without any foreign heat source. Vanadium, iron, and nickel principally were reduced and gone into metallic master alloy as SHS product. High levels of efficiency (>80%) were achieved and the results showed that SHS has a great potential to be an industrial process for BR recovery. SHS produced two useful products. Metallic master alloy and fused glass slag that is applicable for ceramic industries. SHS can also neutralize the environmental threats of BR by a one step process.

Expression Analysis of Ni- and V-Associated Resistance Genes in a Bacillus megaterium Strain Isolated from a Mining Site

Bacillus megaterium strain MNSH1-9K-1 was isolated from a mining site in Guanajuato, Mexico. This B. megaterium strain presented the ability to remove Ni and V from a spent catalyst. Also, its associated metal resistance genes nccA, hant, VAN2, and smtAB were previously identified by a PCR approach. The present study reports for the first time, in B. megaterium, the changes in the expression of the genes nccA (Ni-Co-Cd resistance); hant (high-affinity nickel transporter); smtAB, a metal-binding protein gene; and VAN2 (V resistance) after exposure to 200 ppm of Ni and 200 ppm of V during the stationary phase of the microorganism in PHGII liquid media. The data presented here may contribute to the knowledge of the genes involved in the Ni and V resistances of B. megaterium, and the possible pathways implicated in the Ni-V removal processes, which may be potentiated for the biological treatment of high metal content residues.

A review of metal recovery from spent petroleum catalysts and ash

With the increase in environmental awareness, the disposal of any form of hazardous waste has become a great concern for the industrial sector. Spent catalysts contribute to a significant amount of the solid waste generated by the petrochemical and petroleum refining industry. Hydro-cracking and hydrodesulfurization (HDS) catalysts are extensively used in the petroleum refining and petrochemical industries. The catalysts used in the refining processes lose their effectiveness over time. When the activity of catalysts decline below the acceptable level, they are usually regenerated and reused but regeneration is not possible every time. Recycling of some industrial waste containing base metals (such as V, Ni, Co, Mo) is estimated as an economical opportunity in the exploitation of these wastes. Alkali roasted catalysts can be leached in water to get the Mo and V in solution (in which temperature plays an important role during leaching). Several techniques are possible to separate the different metals, among those selective precipitation and solvent extraction are the most used. Pyrometallurgical treatment and bio-hydrometallurgical leaching were also proposed in the scientific literature but up to now they did not have any industrial application. An overview on patented and commercial processes was also presented.

Simultaneous recovery of vanadium and nickel from power plant fly-ash: optimization of parameters using response surface methodology

Simultaneous recovery of vanadium (V) and nickel (Ni), which are classified as two of the most hazardous metal species from power plant heavy fuel fly-ash, was studied using a hydrometallurgical process consisting of acid leaching using sulfuric acid. Leaching parameters were investigated and optimized in order to maximize the recovery of both vanadium and nickel. The independent leaching parameters investigated were liquid to solid ratio (S/L) (5-12.5 wt.%), temperature (45-80 °C), sulfuric acid concentration (5-25 v/v%) and leaching time (1-5h). Response surface methodology (RSM) was used to optimize the process parameters. The most effective parameter on the recovery of both elements was found to be temperature and the least effective was time for V and acid concentration for Ni. Based on the results, optimum condition for metals recovery (actual recovery of ca.94% for V and 81% for Ni) was determined to be solid to liquid ratio of 9.15 wt.%, temperature of 80 °C, sulfuric acid concentration of 19.47 v/v% and leaching time of 2h. The maximum V and Ni predicted recovery of 91.34% and 80.26% was achieved.

An overview of metals recovery from thermal power plant solid wastes

Thermal power plants (TPPs) that burn fossil fuels emit several pollutants linked to the environmental problems of acid rain, urban ozone, and the possibility of global climate change. As coal is burned in a power plant, its noncombustible mineral content is partitioned into bottom ash, which remains in the furnace, and fly ash, which rises with flue gases. Two other by-products of coal combustion air-pollution control technologies are flue gas desulfurization (FGD) wastes and fluidized-bed combustion (FBC) wastes. This paper analyzed and summarized the generation, characteristics and application of TPP solid wastes and discussed the potential effects of such solid wastes on the environment. On this basis, a review of a number of methods for recovery of metals from TPP solid wastes was made. They usually contain a quantity of valuable metals and they are actually a secondary resource of metals. By applying mineral processing technologies and hydrometallurgical and biohydrometallurgical processes, it is possible to recover metals such as Al, Ga, Ge, Ca, Cd, Fe, Hg, Mg, Na, Ni, Pb, Ra, Th, V, Zn, etc., from TPP solid wastes. Recovery of metals from such wastes and its utilization are important not only for saving metal resources, but also for protecting the environment.