Removal of arsenic in acidic wastewater using Lead-Zinc smelting slag: From waste solid to As-stabilized mineral

Degradation of typical flotation reagents using lead-zinc smelting slag as mediator for persulfate activation: Effect of gallic acid and Cr(VI) on the removal performance and fate of reactive oxygen species

To remediate the Cr(VI)-organic co-contaminants in a non-ferrous mining area, a gallic acid (GA) accelerated lead-zinc smelting slag (LZSS, a mine-sourced waste) mediated peroxodisulfate (PDS) Fenton-like system was constructed for degradation of two typical flotation reagents (benzotriazole and N-hydroxyphthalimide). LZSS acting as an in-situ Fe source in the Fenton-like process, could continuously release Fe species, while GA as a chelate with reducing properties was able to accelerate the rate-limiting step of Fe(III)/Fe(II) cycle to enhance the production of reactive oxygen species (ROS). In the LZSS/PDS/GA system, produced SO4•-, •OH and Fe(IV) jointly contributed to the contaminant removal through radical/nonradical pathways. However, when Cr(VI) coexisted with organic pollutants in the LZSS/PDS/GA system, the reduction of Cr(VI) consumed the electrons that otherwise would have been available for activation of PDS, resulting in fewer different ROS being produced. The increased concentration of GA, as an electron donor, promoted the production of SO4•-, but this promoting effect gradually diminished with increasing Cr(VI). Overall, the dominant ROS gradually transformed from Fe(IV) to SO4•-/•OH as the GA level increased or the Cr(VI) level decreased. Therefore, regulation of the relative roles of ROS by adjusting either the GA dosage or the Cr(VI) levels in the wastewater can improve availability of ROS for further specific removal of pollutants. This study offers an all-in-one solution for utilization of LZSS industrial waste and degradation of flotation reagents, and it also provides a new insight into the advanced environmental application of GA in remediation of Cr(VI)-organic co-contamination.

Application of dirty-acid wastewater treatment technology in non-ferrous metal smelting industry: Retrospect and prospect

Dirty-acid wastewater (DW) originating from the non-ferrous metal smelting industry is characterized by a high concentration of H2SO4 and As. During the chemical precipitation treatment, a significant volume of arsenic-containing slag is generated, leading to elevated treatment expenses. The imperative to address DW with methods that are cost-effective, highly efficient, and safe is underscored. This paper conducts a comprehensive analysis of three typical methods to DW treatment, encompassing technical principles, industrial application flow charts, research advancements, arsenic residual treatment, and economic considerations. Notably, the sulfide method emerges as a focal point due to its minimal production of arsenic residue and the associated lowest overall treatment costs. Moreover, in response to increasingly stringent environmental protection policies targeting new pollutants and carbon emissions reduction, the paper explores the evolving trends in DW treatment. These trends encompass rare metal and sulfuric acid recycling, cost-effective H2S production methods, and strategies for reducing, safely disposing of, and harnessing resources from arsenic residue.

Effective removal of As from a high arsenic-bearing ZnSO4 solution by ultrasonic enhanced ozonation in a one-pot method

Currently, removing arsenic (As) from ZnSO4 solution using lime presents several drawbacks, including high wet precipitate content, long reaction time, and the introduction of new impurities. In this study, we propose a novel ultrasonic (US) ozone one-pot method for effectively removing As from a high-arsenic ZnSO4 solution. In this method, as in ZnSO4 solution was removed by ultrasound enhanced ozone oxidation combined with zinc roasting dust (ZRD). No secondary pollution will occur with the addition of ZRD and ozone, as neither introduces new impurities. The experimental results show that under the conditions of initial As and Fe concentrations of 1640 mg/L and 2963 mg/L, US power of 480 W, frequency of 20 kHz, reaction temperature of 60 °C, reaction time of 1 h, ZRD dose of 12 g/L and gas flow rate of 900 mL/min, the removal rate of As can reach 99.4%. The introduction of US can further enhance the oxidation effect of ozone on As(III) and Fe2+ by increasing the solubility of ozone and promoting the production of OH radicals. Additionally, US cavitation and mechanical action increase the probability of contact between various reactants in the solution, facilitating the occurrence of reactions. US also reduces the aggregation of arsenic-containing precipitates and the encapsulation of ZRD by arsenic containing precipitates, thereby decreasing the amount of arsenic-containing precipitates. In comparison to the traditional lime method, this approach results in a significant reduction in the amount of arsenic-containing precipitate by 54.5% and a 60% decrease in the total reaction time. The As removal mechanism of our method encompasses ZRD neutralization, US-enhanced ozone mass transfer and decomposition, oxidation of As(III) and Fe2+, and adsorption and coprecipitation. Consequently, the proposed method provides a cost-effective, fast, safe and environmentally friendly alternative for treating arsenic-contaminated ZnSO4 solutions.

Recycling lead from copper plant residue (CPR) using brine leaching - Precipitation - Calcination process

Copper plant residue (CPR) is a hazardous industrial by-product possessing both high toxicity and valuable metal content, necessitating its high value-added utilization. Traditional practices in smelters involve stockpiling and landfilling of CPR, leading to substantial land occupation and water contamination. This study focused on the preparation of PbO and Pb3O4 using the HCl-NaCl leaching-conversion-thermal decomposition process, employing CPR as the primary raw material. The effect of various leaching process conditions on the metal leaching rate was explored. A maximum lead leaching rate of 87.65% was achieved under optimal conditions including leaching temperature, liquid-solid ratio, leaching time, HCl molar concentration, NaCl mass concentration, and particle size. The lead content in the leachate was 15.85 g/L. Experimental data indicated that ash diffusion control served as the rate-limiting step in the HCl-NaCl leaching process. The apparent activation energy was determined to be 18.374 kJ mol-1, with a reaction order of 0.8986 concerning the HCl concentration and an L/S ratio of 0.8124. Additionally, response surface methodology enabled the determination of technological parameters for refining PbCl2 into PbCO3 precursors, yielding a conversion rate exceeding 96.50%. Moreover, the technical indicators of PbO and Pb3O4 obtained through low-temperature thermal decomposition of PbCO3 were investigated. The fabricated PbO and Pb3O4 exhibited purities of 99.65% and 99.26%, respectively, effectively transforming CPR from hazardous waste residue into valuable products. The process ensures the efficient recovery of lead to its maximum extent and promotes residue recycling.

Chloride converts lead slag into a bifunctional material to remove heavy metals

Efficient and safe removal of arsenic and lead from industrial wastewater is essential for ecological protection. In this study, we developed a novel method using lead slag as a purifying agent and sodium chloride as a reinforcing agent to remove arsenic and lead from industrial wastewater. Through a combination of experiments and simulations, we elucidated the mechanisms involved in this reaction. The initial concentrations of As and Pb ions in the industrial wastewater were 4333 and 188 mg/L, respectively. After the reaction at 25 °C and a pH ranging from 9.7 to 10, the concentrations of arsenic and lead were reduced to 4.9 mg/L and 0.008 mg/L, respectively, achieving a removal rate of 99.9%. Our experimental results demonstrated that Pb2+ and AsO43- ions released from the lead slag and industrial wastewater reacted with Cl- ions to form Pb5(AsO4)3Cl precipitates, thus effectively eliminating a significant amount of As and Pb species. Simulation studies indicated that Pb5(AsO4)3Cl exhibited exceptional stability below 400 °C and could be directly stored. Additionally, the lead slag, which is rich in silica, played a crucial role in removing and stabilizing As and Pb ions. Under alkaline conditions, silica encapsulated the As and Pb species, adhering to the surface of the Pb-As co-precipitates and forming dense, irregular, small particles with internal and external structures that impeded the efflux of As and Pb ions. This phenomenon was confirmed through scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The kinetics of As and Pb ion removal was consistent with the pseudo-second-order kinetic model, indicating that the removal process was primarily governed by chemical interactions. Lead slag exhibits significant potential and advantages in the removal of As and Pb. This innovative method offers an effective approach to address heavy metal contamination in industrial wastewater, thus contributing to ecological protection.

Characteristics of solid waste from common generation source in nonferrous smelting industry reveal a new classification method

Solid waste produced by the nonferrous smelting industry has a significant number of notable differences. The lack of recognition of solid waste characteristics is the main factor restricting its disposal and utilization. In this study, we analyzed the main production processes of the nonferrous smelting industry; identified the key production nodes of solid waste; and clarified the characteristics, including the physical, chemical, and pollution characteristics of solid wastes, through a large sample statistical analysis. We found similarities among solid wastes from a common generation source as well as notable differences among the different generation sources: slags and sludges from waste acid treatment and wastewater treatment units had a water content of 27.43-52.71% and 51.14-68.27%, respectively, which were significantly higher than those of other metallurgy and dust collection units; the pH of slags from an electrorefining unit was strongly alkaline; the mineral phase of sludges from wastewater treatment was only calcite; slags from a waste acid treatment unit were mainly in phase of gypsum, claudetite, and anglesite; the chemical composition of slags from pyrometallurgy and hydrometallurgy units was mainly SiO2 and Fe2O3. In this paper, we discuss a new classification method based on a common generation source for the first time. These results are beneficial to guide the disposal, utilization, and management of solid waste.

Effective reduction and recovery of As(III) and As(V) from alkaline wastewater by thiourea dioxide: Efficiency and mechanism

For alkaline wastewater with high arsenic concentration, the traditional lime precipitation inevitably produces large amounts of hazardous waste. Herein, a heat-activated reduction method employing thiourea dioxide (TDO) as the reductant was proposed to efficiently remove and recover As(III)/As(V) from alkaline wastewater in the form of valuable As(0). More than 99.9% of As(III)/As(V) (2-400 mM) were reduced to As(0) with a high purity of more than 99.5 wt% by TDO within 30 min. The highly reductive eaq- and SO2- radical generated during TDO decomposition contribute to the arsenic reduction, and the contribution ratios of eaq- and SO2- radical were estimated to be approximately 57.6% and 42.4% for As(III) removal and 62.2% and 37.8% for As(V) removal, respectively. The arsenic reduction was greatly improved by increasing pH and temperature, which could accelerate the cleavage of C-S bond in TDO for the eaq- and SO2- formation. The presence of dissolved oxygen, which can not only scavenge eaq-/SO2- but also directly oxidize SO22-, had a negative effect on the arsenic removal. The presence of CO32- slightly suppressed the arsenic removal due to the eaq- scavenging effect while SiO32-, PO43-, Cl-, SO42- and NH4+ had negligible effects. The proposed method was a potential technology for the efficient removal and reduction of arsenic in alkaline wastewater.

In situ prepared Chlorella vulgaris-supported nanoscale zero-valent iron to remove arsenic (III)

Nanoscale zero-valent iron (nZVI) has a high removal affinity toward arsenic (As). However, the agglomeration of nZVI reduces the removal efficiency of As and, thus, limit its application. In this study, we report an environmentally friendly novel composite of Chlorella vulgaris-supported nanoscale zero-valent iron (abbreviated as CV-nZVI) that exhibits a fast and efficient removal of As(III) from As-contaminated water. Scanning electron microscopy-energy-dispersive spectroscopy (SEM-EDS), X-ray diffractometry (XRD), attenuated total reflection Fourier-transform infrared spectroscopy (ATR-FTIR), and X-ray photoelectron spectroscopy (XPS) were used to characterize and analyze the CV-nZVI. These results indicated that the stabilization effect of C. vulgaris reduced the nZVI agglomeration and enhanced the reactivity of nZVI. The experiments showed a removal efficiency of 99.11% for As(III) at an optimum pH of 7.0. The adsorption kinetics and isotherms followed the pseudo-second-order kinetic model and Langmuir adsorption isotherm with the superior maximum adsorption capacities of 34.11 mg/g for As(III). The FTIR showed that the As(III) was adsorbed on the CV-nZVI surface by complexation reaction, and XPS indicated that oxidation reaction was also involved. After five reuse cycles, the removal efficiency of As(III) by CV-nZVI was 32.93%, suggesting that the CV-nZVI had some reusability and regeneration. Overall, this work provides a practical and highly efficient approach for As remediation in As-contaminated water, and simultaneously resolves the agglomeration problems of nZVI nanoparticles.

Toxic metals and the risks of sludge from the treatment of wastewater from beryllium smelting

The release of highly toxic beryllium in sludge (BCS) produced by physico-chemical treatment of beryllium-containing wastewater from Be smelting production has become a growing concern with the widespread use of Be in the defense industry. This work investigated the potential mobility of Be in BCS. The toxicity characteristic leaching procedure (TCLP) of BCS showed that the amount of leached Be was up to 202 mg L^-1, which exceeded the regulated limit by nearly 10,000 times. The chemical fractionation analysis further revealed that the excessive amount of Be leached from BCS was contributed to the high content of acid-soluble fraction and reducible fraction of Be, which accounted for over 70% of the Be content. The results obtained from mineralogical automatic analyzer (MLA) showed that gypsum (23.23%) and epidote (19.55%) were the two major mineralogical phases of BCS. Both were small and loosely structured agglomerated particles with a D₅₀ of 6.61 μm and 3.31 μm. ToF-SIMS results revealed that the Be distribution on the surface of BCS particles was relatively dispersed, with no aggregation or encapsulation. Be co-precipitated with gypsum and chlorite in the form of unstable Be(OH)₂, which attached to the surface of these small particles. The unstable state of Be and the small size, loose structure and high liberation of the host material phases are the main reasons for the high leaching mobility of Be. The results of the risk assessment indicated that BCS posed an extremely high potential ecological risk, with Be being the most significant contributor.

Study on the Effect of Calcium Alloy on Arsenic Removal from Scrap-Based Steel Production

Scrap steel is a kind of resource that can be recycled indefinitely. However, the enrichment of arsenic in the recycling process will seriously affect the performance of the product, making the recycling process unsustainable. In this study, the removal of arsenic from molten steel using calcium alloys was investigated experimentally, and the underlying mechanism was explored based on thermodynamic principles. The results show that the addition of calcium alloy is an effective means of reducing the arsenic content in molten steel, with the highest removal percentage of 56.36% observed with calcium aluminum alloy. A thermodynamic analysis revealed that the critical calcium content required for arsenic removal reaction is 0.0037%. Moreover, ultra-low levels of oxygen and sulfur were found to be crucial in achieving a good arsenic removal effect. When the arsenic removal reaction occurs in molten steel, the oxygen and sulfur concentrations in equilibrium with calcium were wO=0.0012% and wS=0.00548%, respectively. After successful arsenic removal, the arsenic removal product of the calcium alloy is Ca₃As₂, which usually does not appear alone. Instead, it is prone to combining with alumina, calcium oxide, and other inclusions to form composite inclusions, which is beneficial for the floating removal of inclusions and the purification of scrap steel in molten steel.

Hydrothermal synthesis temperature induces sponge-like loose silica structure: A potential support for Fe2O3-based adsorbent in treating As(V)-contaminated water

Low cost Fe₂O₃-based sorbents with an exceptional selectivity toward the targeted As(V) pollutant have gained extensive attention in water treatment. However, their structural features often influence removal performance. In this respect, we present herein a rational design of silica-supported Fe₂O₃ sorbents with an enhanced morphological structure based on a simple temperature-induced process. Low-hydrothermal temperature synthesis (60 and 100 °C) provided a large silica-cluster size with a close packed structure (S-60 and S-100), contributing to an increase in mass transport resistance. Fe₂O₃/S-60 with 6.2-nm pore width silica achieved a maximum As(V) uptake capacity (q_m) of only 3.5 mg g^-1. Supporting Fe₂O₃ on S-100 with an approximately two-fold increase in the pore size (13 nm) did not lead to any evident enhancement in q_e (3.7 mg g^-1). However, expanding the pore window up to 22.6 nm (S-140) and 39.5 nm (S-180), along with changing from close-packed to sponge-like loose structures induced by high-temperature synthesis (140 °C and 180 °C), resulted in substantial increases in q_m. Fe₂O₃/S-140 had 1.7 and 1.6 times higher q_m (5.9 mg g^-1) than Fe₂O₃/S-100 and Fe₂O₃/S-60, respectively. The highest q_m (7.4 mg g^-1) was achieved for Fe₂O₃/S-180, which was attributed to its relatively small-sized silica cluster and the largest cavities that facilitated easier access by As(V) to adsorbing sites.

Utilization of Lead Slag as In Situ Iron Source for Arsenic Removal by Forming Iron Arsenate

In situ treatment of acidic arsenic-containing wastewater from the non-ferrous metal smelting industry has been a great challenge for cleaner production in smelters. Scorodite and iron arsenate have been proved to be good arsenic-fixing minerals; thus, we used lead slag as an iron source to remove arsenic from wastewater by forming iron arsenate and scorodite. As the main contaminant in wastewater, As(III) was oxidized to As(V) by H₂O₂, which was further mineralized to low-crystalline iron arsenate by Fe(III) and Fe(II) released by lead slag (in situ generated). The calcium ions released from the dissolved lead slag combined with sulfate to form well-crystallized gypsum, which co-precipitated with iron arsenate and provided attachment sites for iron arsenate. In addition, a silicate colloid was generated from dissolved silicate minerals wrapped around the As-bearing precipitate particles, which reduced the arsenic-leaching toxicity. A 99.95% removal efficiency of arsenic with initial concentration of 6500 mg/L was reached when the solid-liquid ratio was 1:10 and after 12 h of reaction at room temperature. Moreover, the leaching toxicity of As-bearing precipitate was 3.36 mg/L (As) and 2.93 mg/L (Pb), lower than the leaching threshold (5 mg/L). This work can promote the joint treatment of slag and wastewater in smelters, which is conducive to the long-term development of resource utilization and clean production.

The mechanistic insights into the leaching behaviors of potentially toxic elements from the indigenous zinc smelting slags under the slag dumping site scenario

Since lager quantities of the zinc (Zn) smelting slags were traditionally dumped at the indigenous Zn smelting sites, the release characterization of potentially toxic elements (PTEs) from the Zn smelting slags under various environmental conditions were of great significance for an environmental risk analysis. The acidification of the Zn smelting slags to pH= 4 and 6 would result in the leaching concentrations of Cd and Mn exceeding the fourth-class standard of surface water quality standard in China (GB3838-2002). Notably, most metals exhibited an amphoteric leaching pattern, where the highest leached concentrations of As, Cd, Cu, Mn, Pb, and Zn were 4.15, 4.21, 140.0, 78.1, 156.9 and 477.0 mg/L, respectively. In addition, the highest release of toxic metals within 96 h reached 0.17 % of As, 3.50 % of Cd, 2.77 % of Cu, 6.92 % of Mn, 0.13 % of Pb, and 2.57 % of Zn, respectively. The combined results of various characterization techniques suggested that the PTEs remobilization effected by rhizosphere-like organic acids were mainly controlled by the precipitation of newly formed Fe, Mn and Al (hydr) oxides and the complexation of organic ligands. The present study results could provide valuable insights into the long-term leaching behaviors of PTEs from the Zn smelting slags to reduce ecological hazard.