Santhi Chandra Jagupilla

Effects of particle size and acid addition on the remediation of chromite ore processing residue using ferrous sulfate

A bench-scale treatability study was conducted to assess the effects of particle size and acid addition on the remediation of chromite ore processing residue (COPR) using ferrous sulfate. The remediation scheme entailed the chemical reduction of hexavalent chromium [Cr(VI)] and the mitigation of swell potential. Leaching tests and the EQ3/6 geochemical model were used to estimate the acid dosage required to destabilize Cr(VI)-bearing and swell-causing minerals. The model predicted greater acid dosage than that estimated from the batch leaching tests. This indicated that mass transfer limitation may be playing a significant role in impeding the dissolution of COPR minerals following acid addition and hence hindering the remediation of COPR. Cr(VI) concentrations determined by alkaline digestion for the treated samples were less than the current NJDEP standard. However, Cr(VI) concentrations measured by X-ray absorption near edge structure (XANES) were greater than those measured by alkaline digestion. Greater Cr(VI) percentages were reduced for acid pretreated and also for smaller particle size COPR samples. Upon treatment, brownmillerite content was greatly reduced for the acid pretreated samples. Conversely, ettringite, a swell-causing mineral, was not observed in the treated COPR.

Leaching mechanisms of Cr(VI) from chromite ore processing residue.

Batch leaching tests, qualitative and quantitative x-ray powder diffraction (XRPD) analyses, and geochemical modeling were used to investigate the leaching mechanisms of Cr(VI) from chromite ore processing residue (COPR) samples obtained from an urban area in Hudson County, New Jersey. The pH of the leaching solutions was adjusted to cover a wide range between 1 and 12.5. The concentration levels for total chromium (Cr) and Cr(VI) in the leaching solutions were virtually identical for pH values >5. For pH values <5, the concentration of total Cr exceeded that of Cr(VI) with the difference between the two attributed to Cr(III). Geochemical modeling results indicated that the solubility of Cr(VI) is controlled by Cr(VI)-hydrocalumite and Cr(VI)-ettringite at pH >10.5 and by adsorption at pH <8. However, experimental results suggested that Cr(VI) solubility is controlled partially by Cr(VI)-hydrocalumite at pH >10.5 and by hydrotalcites at pH >8 in addition to adsorption of anionic chromate species onto inherently present metal oxides and hydroxides at pH <8. As pH decreased to <10, most of the Cr(VI) bearing minerals become unstable and their dissolution contributes to the increase in Cr(VI) concentration in the leachate solution. At low pH ( <1.5), Cr(III) solid phases and the oxides responsible for Cr(VI) adsorption dissolve and release Cr(III) and Cr(VI) into solution.

Particle size and pH effects on remediation of chromite ore processing residue using calcium polysulfide (CaS5)

A long-term bench scale treatability study was performed to assess the ability to remediate chromite ore processing residue (COPR) using calcium polysulfide (CaS(5)). COPR materials were characterized with respect to particle size, pH, curing period and mineralogy. A stoichiometric ratio of sulfide species to hexavalent chromium (Cr(6+)) of 2 was used for the long-term treatment of COPR. The effectiveness of CaS(5) treatment was assessed using the toxicity characteristic leaching procedure (TCLP), alkaline digestion, and X-ray absorption near edge structure (XANES) analyses. The formation of ettringite, known as a heaving agent, was investigated following the treatment of CaS(5), using X-ray powder diffraction (XRPD) and scanning electron microscopy (SEM) along with an energy dispersive X-ray spectroscopy (EDX). Overall, after a curing period of 18 months, the TCLP total chromium (Cr) and alkaline digestion (Cr(6+)) results obtained from the treatability study showed that the concentrations were lower than 5 mg L(-1) and 9 mg kg(-1), respectively. However, XANES results obtained from samples cured for 18 months showed that all of the treated samples had higher Cr(6+) concentrations than shown using alkaline digestion. The lowest XANES Cr(6+) concentration of 610.2 mg kg(-1) was obtained from the sample with a particle size less than 0.075 mm and a pH value of 9. Particle size reduction prior to the addition of the reductant, along with pH reduction was found to be strongly associated with the treatment performance. Ettringite formation, due to pH increase over time in the samples, where the initial pH was adjusted to 9, was verified by XRPD and SEM-EDX analyses, indicating that a pH less than 9 should be maintained to avoid ettringite formation.

Remediation of chromite ore processing residue using ferrous sulfate and calcium polysulfide

Batch tests were conducted to assess the potential use of ferrous sulfate and calcium polysulfide for the remediation of chromite ore processing residue (COPR). The remediation process entails addition of ferrous sulfate or calcium polysulfide to chemically reduce hexavalent chromium [Cr(VI)] to trivalent chromium [Cr(III)] in slurry form and pH adjustment to precipitate Cr(III) as chromium hydroxide. The present study investigates the effects of COPR particle size, treatment pH, and chemical dosage on the performance of the treatment. Smaller particle size resulted in increases in alkaline digestion and Toxicity Characteristic Leaching Procedure (TCLP) Cr(VI) concentrations for the untreated samples. The chemical reduction of Cr(VI) with ferrous iron and sulfides was non-stoichiometric. Four times the stoichiometric amount of ferrous iron of two times the stoichiometric amount of polysulfide were needed to meet both the New Jersey Department of Environmental Protection (NJDEP) regulatory limit of 240 mg/kg for Cr(VI) and EPA TCLP regulatory limit of 5 mg/L for chromium [C,r]. pH adjustment was necessary to prevent the formation of ettringite, a swell causing mineral, upon the introduction of sulfate to the COPR material via ferrous sulfate or calcium polysulfide. The slow hydration of some COPR minerals caused the pH of the treated COPR to creep upward during the curing period. However, when sufficient acid was added, the pH value was controlled at less than 9.27 for a curing period of 1.5 years, which prevented the formation of ettringite.

Assessment of ferrous chloride and Portland cement for the remediation of chromite ore processing residue.

Chromite Ore Processing Residue (COPR) is an industrial waste containing up to 7% chromium (Cr) including up to 5% hexavalent chromium [Cr(VI)]. The remediation of COPR has been challenging due to the slow release of Cr(VI) from a clinker like material and thereby the incomplete detoxification of Cr(VI) by chemical reagents. The use of sulfur based reagents such as ferrous sulfate and calcium polysulfide to detoxify Cr(VI) has exasperated the swell potential of COPR upon treatment. This study investigated the use of ferrous chloride alone and in combination with Portland cement to address the detoxification of Cr(VI) in COPR and the potential swell of COPR. Chromium regulatory tests, X-ray powder diffraction (XRPD) analyses and X-ray absorption near edge structure (XANES) analyses were used to assess the treatment results. The treatment results indicated that Cr(VI) concentrations for the acid pretreated micronized COPR as measured by XANES analyses were below the New Jersey Department of Environmental Protection (NJDEP) standard of 20 mg kg(-1). The Toxicity characteristic leaching procedure (TCLP) Cr concentrations for all acid pretreated samples also were reduced below the TCLP regulatory limit of 5 mg L(-1). Moreover, the TCLP Cr concentration for the acid pretreated COPR with particle size ⩽0.010 mm were less than the universal treatment standard (UTS) of 0.6 mg L(-1). The treatment appears to have destabilized all COPR potential swell causing minerals. The unconfined compressive strength (UCS) for the treated samples increased significantly upon treatment with Portland cement.