B D Pandey

Chemical and microbial remediation of hexavalent chromium from contaminated soil and mining/metallurgical solid waste: A review

Chromium is a highly toxic non-essential metal for microorganisms and plants, and its occurrence is rare in nature. Lower to higher chromium containing effluents and solid wastes released by activities such as mining, metal plating, wood preservation, ink manufacture, dyes, pigments, glass and ceramics, tanning and textile industries, and corrosion inhibitors in cooling water, induce pollution and may cause major health hazards. Besides, natural processes (weathering and biochemical) also contribute to the mobility of chromium which enters in to the soil affecting the plant growth and metabolic functions of the living species. Generally, chemical processes are used for Cr- remediation. However, with the inference derived from the diverse Cr-resistance mechanism displayed by microorganisms and the plants including biosorption, diminished accumulation, precipitation, reduction of Cr(VI) to Cr(III), and chromate efflux, bioremediation is emerging as a potential tool to address the problem of Cr(VI) pollution. This review focuses on the chemistry of chromium, its use, and toxicity and mobility in soil, while assessing its concentration in effluents/wastes which becomes the source of pollution. In order to conserve the environment and resources, the chemical/biological remediation processes for Cr(VI) and their efficiency have been summarised in some detail. The interaction of chromium with various microbial/bacterial strains isolated and their reduction capacity towards Cr(VI) are also discussed.

Bio-processing of solid wastes and secondary resources for metal extraction – A review

Metal containing wastes/byproducts of various industries, used consumer goods, and municipal waste are potential pollutants, if not treated properly. They may also be important secondary resources if processed in eco-friendly manner for secured supply of contained metals/materials. Bio-extraction of metals from such resources with microbes such as bacteria, fungi and archaea is being increasingly explored to meet the twin objectives of resource recycling and pollution mitigation. This review focuses on the bio-processing of solid wastes/byproducts of metallurgical and manufacturing industries, chemical/petrochemical plants, electroplating and tanning units, besides sewage sludge and fly ash of municipal incinerators, electronic wastes (e-wastes/PCBs), used batteries, etc. An assessment has been made to quantify the wastes generated and its compositions, microbes used, metal leaching efficiency etc. Processing of certain effluents and wastewaters comprising of metals is also included in brief. Future directions of research are highlighted.

REMEDIATION OPTIONS FOR THE TREATMENT OF ELECTROPLATING AND LEATHER TANNING EFFLUENT CONTAINING CHROMIUM—A REVIEW

Chromium used in the electro plating and tanning industries causes environmental pollution through the generation of effluent. Various methods such as precipitation–flocculation coupled with pre/post-oxidation, reduction, and concentration are often employed to control environmental pollution. Though these techniques, referred to as “removal–disposal,” serve the purpose of satisfying water pollution norms, they produce solid residues containing Cr(OH)3 as the sludges, which are usually dumped as landfill. Besides the possibility of mobility of the metal as Cr(VI) by the biological and chemical oxidation, the dumping of sludges also leads to the loss of metal values exerting pressure on the corresponding primary reserves. Therefore, processes based on “recovery–reuse” are now being increasingly projected and used. In this article, streams/wastes containing chromium relevant to electroplating have been identified and the applicability of conventional and promising techniques to treat such substances have been reviewed. Earlier developments and recent modifications on the most common routes, such as precipitation, evaporation, bioremediation, etc., are highlighted. Other methods such as electrolysis, solvent extraction, membrane separation, ion exchange, etc. are discussed with respect to their applicability, status, and scope.

Selective recovery of gold from waste mobile phone PCBs by hydrometallurgical process

The leaching of gold from the scrap mobile phone PCBs by electro-generated chlorine as an oxidant and its recovery by ion exchange process was investigated. The leaching experiments were carried out by employing separate leaching reactor connected with the anode compartment of a Cl(2) gas generator. The leaching of gold increased with increase in temperature and initial concentration of chlorine, and was favorable even at low concentration of acid, whereas copper leaching increased with increase in concentration of acid and decrease in temperature. In a two-stage leaching process, copper was mostly dissolved (97%) in 165 min at 25°C during the 1st stage leaching in 2.0 mol/L HCl by electro-generated chlorine at a current density of 714A/m(2) along with a minor recovery of gold (5%). In the 2nd stage gold was mostly leached out (93% recovery, ∼67 mg/L) from the residue of the 1st stage by the electro-generated chlorine in 0.1 mol/L HCl. Gold recovery from the leach liquor by ion exchange using Amberlite XAD-7HP resin was found to be 95% with the maximum amount of gold adsorbed as 46.03 mg/g resin. A concentrated gold solution, 6034 mg/L with 99.9% purity was obtained in the ion exchange process.

Recovery of valuable metals from cathodic active material of spent lithium ion batteries: Leaching and kinetic aspects

This work is focussed on the processing of cathodic active material of spent lithium ion batteries (LIBs) to ensure resource recovery and minimize environmental degradation. The sulfuric acid leaching of metals was carried out for the recovery of all the valuable metals including nickel and manganese along with the frequently targeted metals like lithium and cobalt. The process parameters such as acid concentration, pulp density, time and temperature for the leaching of metals from the cathode powder containing 35.8% Co, 6.5% Li, 11.6% Mn and 10.06% Ni, were optimized. Results show the optimized leach recovery of 93.4% Li, 66.2% Co, 96.3% Ni and 50.2% Mn when the material was leached in 1M H2SO4 at 368 K and 50 g/L pulp density for 240 min. The need of a reductant for improved recovery of cobalt and manganese has been explained by the thermodynamic analysis (Eh-pH diagram) for these metals. Leaching of the valuable metals was found to follow the logarithmic rate law controlled by surface layer diffusion of the lixiviant reacting with the particles. The mode of leaching of the metals from the spent LIBs was further examined by chemical analysis of the samples at various stage of processing which was further corroborated by characterizing the untreated sample and the leach residues by XRD phase identification and the SEM-EDS studies.

Ammoniacal leaching of roast reduced deep-sea manganese nodules

The paper describes the reduction-roast ammonia leach process developed at NML for recovery of copper, nickel and cobalt from polymetallic sea nodules. A brief account of the development of a two stage ammoniacal leaching scheme with a prior pre-conditioning step is given. The necessity of monitoring redox potential in the first stage leaching to control cobalt recovery has been emphasized. Based on the two stage leaching scheme, recycle leaching has been carried out to generate leach liquor having suitable composition for the subsequent solvent extraction–electrowinning operation. The average recovery of metals in 16 cycles of leaching has been found to be 92% Cu, 90% Ni and 56% Co.

Hydrometallurgical Process for Copper Recovery from Waste Printed Circuit Boards (PCBs)

Present paper focuses on the selective recovery of copper from the enriched ground printed circuit boards (PCBs) using leaching and solvent extraction. The metal-enriched ground sample obtained from the beneficiation of the sized PCBs in a laboratory scale column type air separator contained mainly 49.3% Cu, 3.83% Fe, 1.51% Ni, 5.45% Sn, 4.71% Pb, and 1.85% Zn. The leaching of the enriched sample with 3.5 mol/L nitric acid dissolved 99% copper along with other metals at 323 K temperature and 120 g/L pulp density in 1 h time. The composition of the leach liquor with wash solution was found to be 42.11 g/L Cu, 2.12 g/L Fe, 4.02 g/L Pb, 1.58 g/L Zn, and 0.4 g/L Ni. The McCabe–Thiele plot indicated the requirements of three counter-current stages for maximum extraction of copper from the leach liquor at pH 1.5 using 30, 40, and 50% (v/v) LIX 984 N at the phase ratios (A/O) of 1:3, 1:2, and 1:1.5, respectively. The counter-current simulation studies show the selective extraction of 99.7% copper from the leach liquor feed of 1.5 pH in three stages with 50% LIX 984 N at A/O phase ratio of 1:1.5. The stripping of copper from the loaded organic with sulfuric acid produced copper sulfate solution from which copper metal/powder could be recovered by electrolysis/ hydrogen reduction.

Nickel recovery from spent nickel catalyst.

A process for nickel recovery from a spent catalyst of definite composition has been developed using the hydro-metallurgical route. The processing steps includes direct sulphuric acid leaching followed by separation of iron as well as silica and other impurities. For a 152 μm particle size catalyst, extraction of about 98% nickel was achieved at 363 K in 2 h using a sulphuric acid concentration (v/v) of 8% and a pulp density of 10%. The dissolution of nickel followed diffusion-controlled leaching kinetics. Increase in temperature and sulphuric acid concentration resulted in increase in the nickel recovery. The activation energy for nickel dissolution was calculated to be 62.8 kJ mol-1. Finally, nickel was recovered as value-added products such as sulphide and oxalate with overall recovery of 90 and 88% of nickel, respectively.

Process optimization and kinetics for leaching of rare earth metals from the spent Ni-metal hydride batteries.

Nickel-metal hydride batteries (Ni-MH) contain not only the base metals, but valuable rare earth metals (REMs) viz. La, Sm, Nd, Pr and Ce as well. In view of the importance of resource recycling and assured supply of the contained metals in such wastes, the present study has focussed on the leaching of the rare earth metals from the spent Ni-MH batteries. The conditions for the leaching of REMs from the spent batteries were optimized as: 2M H2SO4, 348K temperature and 120min of time at a pulp density (PD) of 100g/L. Under this condition, the leaching of 98.1% Nd, 98.4% Sm, 95.5% Pr and 89.4% Ce was achieved. Besides the rare earth metals, more than 90% of base metals (Ni, Co, Mn and Zn) were also leached out in this condition. Kinetic data for the dissolution of all the rare earth metals showed the best fit to the chemical control shrinking core model. The leaching of metals followed the mechanism involving the chemical reaction proceeding on the surface of particles by the lixiviant, which was corroborated by the XRD phase analysis and SEM-EDS studies. The activation energy of 7.6, 6.3, 11.3 and 13.5kJ/mol was acquired for the leaching of neodymium, samarium, praseodymium and cerium, respectively in the temperature range 305-348K. From the leach liquor, the mixed rare earth metals were precipitated at pH∼1.8 and the precipitated REMs was analyzed by XRD and SEM studies to determine the phases and the morphological features.

Selective recovery of cobalt, nickel and lithium from sulfate leachate of cathode scrap of Li-ion batteries using liquid-liquid extraction

This paper focuses on the extractive separation and selective recovery of cobalt, nickel and lithium from the sulfate leachate of cathode scrap generated during manufacture of lithium ion batteries (LIBs). The conditions for extraction, scrubbing and stripping of cobalt from nickel and lithium are optimized with an aqueous feed containing 25.1 g·dm−3 cobalt, 2.54 g·dm−3 nickel and 6.2 g·dm−3 lithium using Na-PC-88A. 99.8% Co is extracted with 60% Na-0.56 mol·dm−3 PC-88A in two counter-current stages at an O/A phase ratio of 3/1 and an equilibrium pH of 4.5. The “crowding effect” shown for the first time provides effective scrubbing of impurities (Ni and Li) with 2.0 g·dm−3 CoSO4 solution. The McCabe-Thiele diagram predicts the scrubbing of 99.9% Ni and 99.9% Li at an equilibrium pH of 4.75 and O/A of 2/1 in two stages. High purity (99.9%) cobalt sulfate along with Ni and Li from the leach liquor of cathode scrap is recovered by solvent extraction. The proposed process ensures complete recycling of the waste of the manufacturing process of LIBs.