Leaching of Coal Fly Ash by Sulphuric Acid For The Synthesis of Wastewater Treatment Polymeric Coagulant
Leaching of Coal Fly Ash by Sulphuric Acid For The Synthesis of Wastewater Treatment Polymeric Coagulant
ISSN No:-2456-2165
Abstract:- Coal fly ash (CFA) sample produced in coal- flowable fill [11], manufacture of ceramics and glass [12,13],
burning power plants contains significant quantities of soil stabilization [14,15], catalysts and catalyst supports
oxides of aluminium, iron and other important elements [16,17], wastewater treatments as an adsorbent for organic
such as magnesium, silicon and calcium for the production removal [18,19], and extraction of metals [20,21].
of coagulant for wastewater treatment. In order to
synthesize a coagulant, the dissolution of these CFA However, despite the various uses listed above, there is
elements was studied in sulphuric acid (H 2SO4) solutions. still a need to discover other means of using CFA productively
The impacts of dissolution time, H2SO4 concentration, in order to protect the environment and to reduce its disposal
temperature and solid/liquid ratio were investigated for on land [22]. Currently, CFA has promising uses in
the leaching process. The treated CFA samples were wastewater treatment due to its physical properties such as
characterized by PSD, XRD, XRF, FTIR and SEM. surface area and porosity, and the presence of chemical
Thermodynamic feasibility was studied using components such as aluminium and iron oxides. The main
Hydra/Medusa software. The dissolution efficiencies of chemical components of CFA are aluminium, iron, calcium,
aluminium, iron, magnesium, silicon and calcium were silicon and magnesium oxides. Iron and aluminium oxides are
33.86, 57.90, 73.21, 11.12 and 25.43%, respectively, in 1.5 important raw materials for the production of coagulants for
M H2SO4, with a pH ranging from 0.5 to 3.9, at 300 rpm, the treatment of wastewater through the coagulation process. It
150 °C, a solid/liquid ratio of 0.20 and a leaching time of 6 is notable that over the years, most coagulant companies have
hours. The PSD results revealed that particle size changes used ores or chemical salts of aluminium and iron as raw
happened during the leaching process, XRD and FTIR materials. Nevertheless, aluminium and iron minerals or
showed the presence of the same mineral phases in the raw chemical salts of iron and aluminium are expensive [23].
and treated CFA samples, and SEM indicated that both a Moreover, several researchers have studied the role of other
porous structure and a stem-like structure were formed elements, such us silicon, magnesium and calcium ions, as
after leaching. The generated dissolution solution potential coagulants for wastewater treatment [24–26]. Coal
containing polymeric sulphates of aluminium, iron, fly ash also contains several other strategic elements, some of
magnesium, silicon and calcium can be utilized as which (silicon, magnesium and calcium) could be extracted
coagulant in the treatment of wastewater. The process can together with aluminium and iron. Thus, CFA has become an
be easily adopted to synthesize complex coagulant, important resource for the synthesis of coagulants and
therefore decreasing CFA pollution and producing a researchers are more interested in this study currently [2].
valuable coagulant. Therefore, the use of CFA to make composite (polymeric)
coagulants can provide significant cost savings, as CFA is
Keywords:- Synthesis; Pressure sulphuric acid-leaching; Coal much cheaper than industrial grade iron or aluminium ores. In
fly ash; Coagulant; Wastewater. addition, such a concept of using these by-products would
reduce the environmental degradation resulting from storage
I. INTRODUCTION and disposal techniques currently used in several countries
[23].
Energy production from coal combustion at 1200–1700
°C generates considerable by-products that create serious Therefore, the aim of this research was to use CFA, a
storage and/or disposal management issues [1]. These by- known source of solid waste currently increasing worldwide,
products consist of bottom ash, fly ash and slag. These waste which is available in South Africa, as synthesis raw material to
by-products are normally dumped and/or disposed of, but produce a polymeric coagulant for wastewater treatment. This
therefore pollute the environment. Due to the limited paper presents a process for the synthesis of a composite
commercial uses of coal fly ash (CFA), in particular, extensive coagulant by direct pressure leaching of aluminium, iron and
research has been conducted to discover some alternative uses other strategic elements from CFA in H2SO4 solution. The
[2,3]. study on the performance of the synthesized CFA-based
coagulant in wastewater treatment is discussed elsewhere [27].
At present, research has shown that only a small part of
the total CFA production (20–30%) is utilized in the following
applications: synthesis of geopolymers [4,5], asphalt filler [3],
production of zeolites [6], substitute material for cement [7],
adsorbent of single contaminants in flue gases [8–10],
Fig. 2: XRD pattern of coal fly ash. Q, M, and H indicate quartz (SiO2), mullite (Al5.65Si0.35O9.175),
and hematite (Fe2O3), respectively
Chemical composition Al2O3 Fe2O3 SiO2 CaO TiO2 MgO K2O P2O5
Content (wt%) 32.15 4.16 49.92 6.25 2.15 1.4 1 1.04
Table 1: Chemical composition of coal ash sample
Batch dissolution tests were carried out for each selected Al3+ + SO42— ↔ AlSO4+ (4)
—
parameter to study the leaching behaviour of iron, aluminium, 3+
Al + 2SO4 2—
↔ Al(SO4)2 (5)
and other elements from CFA material. The dissolution —
solution used for the leaching of elements from CFA sample
+
H + SO4 2—
↔ HSO4 (6)
was an aqueous solution of H2SO4. A sample of CFA Chemistry of H2SO4 leaching of iron and aluminium
containing 17.01% aluminium and 2.91% iron was used. In from Fe2O3 and Al2O3 in coal fly ash
general, iron and aluminium in CFA are found together with
other elements such as magnesium, silicon, calcium, titanium The aim was to leach iron and aluminium from Fe2O3
and potassium. Among these elements, the dissolutions of and Al2O3, respectively, in the CFA sample with H2SO4
silicon, calcium and magnesium were investigated. solutions. Throughout the leaching of iron and aluminium with
H2SO4, the mechanism that describes complexation of iron and
In this study, aluminium and iron in the CFA sample had aluminium is given by (2) – (6). The overall reactions are
to be leached with H2SO4 to produce their soluble forms. In illustrated in (7) and (8) for iron and aluminium, respectively
order to predict the predominance areas of different aluminium [34].
and iron species in an aqueous solution, Eh-pH diagrams for
the Fe–SO42—–H2O system and Al–SO42—–H2O system at 25 Fe2O3 +3H2SO4 ↔ Fe2(SO4)3 +3H2O (7)
°C (for a solution of total sulphate concentration = 1.5 M)
Al2O3 +3H2SO4 ↔ Al2(SO4)3 +3H2O (8)
were drawn using the Hydra/Medusa software and presented in
Fig. 5. The total sulphate concentrations of 1.5 M were chosen H2SO4 reacts with iron and aluminium in CFA to,
according to diluted H2SO4 solutions. It is noticed from Fig. respectively, produce FeSO4+ and AlSO4+ complexes on the
5(a) that for a 1.5 M total sulphate concentration solution, Fe3+ surface of iron and aluminium metals as illustrated in (2) and
(i.e. FeSO42— complex) is the most predominant species at pH (4). Subsequently, FeSO4+ undergoes another complexation
below 3.9 and Eh between 0.67 and 1.00 V; hydrolysis of with the sulphate ion to produce Fe(SO4)2— (3) which passes
Fe(SO4)2— occurs with increasing pH forming species such in solution while AlSO4+ enters in complexation with sulphate
FeS2, Fe2O3, and Fe(HS)3 which are predominant species at pH ion to form Al(SO4)2— which goes into solution (5).
values above 4. Fig. 5(b) shows that leached aluminium Theoretically, the dissolution of iron and aluminium occurs as
species Al3+, AlSO4+ and Al(SO4)2— are stable in the pH presented in (2) – (6) at pH < 3.9. Moreover, the effects of
region below 5 and the Eh range of -1.00 to 1.00 V. Therefore,
Fig. 5: Eh–pH diagram for the (a) Fe–SO42-–H2O system and (b) Al–SO42-–H2O system at 25 °C; Total SO42- concentration = 1.5
M. These diagrams have been drawn using the Hydra/Medusa software.
70
60
50
Recovery (%)
Fe
40 Al
Si
30 Mg
20
10
0
0 1 2 3 4 5 6 7
Time (hour)
50
45
40
35 Fe
Al
Recovery (%)
30
Si
25
Mg
20
15
10
5
0
0 1 2 3 4 5 6 7
H2SO4 Concentration (M)
Fig. 7: Effect of H2SO4 concentration on the leaching of elements from CFA sample
(particle size: −49 µm, RT (23±2 °C), 300 rpm, S/L= 0.33, 1 hour)
C. Effect of temperature 0.20, more than 90% of the iron was extracted. A similar trend
Fig. 8 displays the impact of temperature on the was noticed in the dissolutions of aluminium and other
extraction efficiencies of iron, aluminium, silicon, magnesium elements (silicon, magnesium and calcium) for different S/L
and calcium. The major variation in extraction efficiency with ratios under identical conditions. Maximum extraction
temperature change is observed for iron. The CFA sample efficiencies of 28.88, 7.81, 78.67, and 27.11% were obtained
showed a highly variable leaching behaviour of elements at for aluminium, silicon, magnesium and calcium respectively at
different temperatures. When dissolution was performed at a S/L ratio of 0.20. In comparison to the dissolution behaviour
RT, leaching of iron, aluminium, silicon and magnesium was of iron, the low dissolution efficiencies of aluminium and
slower. The extraction efficiency of iron increased silicon (<30%) are probably due to the structure and property
significantly with increasing temperature from 120 °C to 190 of aluminium and silicon oxides in CFA. The mineralogy of
°C, but there was no significant increase at lower CFA is extremely diverse. The identified phase of iron oxide is
temperatures. For aluminium, from 90 °C, the concentration in hematite which can be easily leached in H2SO4 solution [3]. In
solution is 10.72%. There is no obvious change in the CFA, the Al2O3 is found either as crystalline mullite form and
aluminium leaching as the temperature increases from 90 to non-crystalline amorphous form or bound to an
150 °C. Thereafter, the leaching decreases until the aluminosilicate glass matrix [3,37]. The glass matrix and
temperature reaches 190 °C. The fused structure of mullite phase are not easily accessible to direct acid
aluminosilicate is probably the reason for the relatively low dissolution [36].
extraction efficiency of aluminium. A similar behaviour was
also observed by other researchers [35,36]. A temperature of E. Effect of time on optimal experimental conditions
150 °C was considered optimal for aluminium leaching. A The effect of time on optimal experimental conditions
gradual increase in extraction efficiencies was noticed for was investigated and results are presented in Fig.10.
magnesium, calcium and silicon. Maximum extraction Magnesium dissolved faster than iron and aluminium, while
efficiencies of 68.57, 26.09 and 22.07% were obtained for silicon and calcium showed a surprising difference in
magnesium, calcium and silicon, respectively. dissolution behaviour. The concentrations of iron, aluminium,
silicon, magnesium and calcium in the composite coagulant
D. Effect of solid/liquid ratio solution increased with time up to 57.90, 33.86, 11.12, 73.21
Fig. 9 indicates that the S/L ratio has a substantial effect and 25.43% respectively for 6 hours. It is shown that below 3
on the leaching of iron and magnesium than on the leaching of hours of dissolution time, the concentration of iron decreased
other elements with H2SO4. The concentration of iron in the dramatically in the produced complex coagulant solution. This
leaching solution (composite coagulant) increased with can be explained by the dissolution and precipitation of iron,
increasing S/L ratio from 0.17 to 0.20, then significantly which can be associated with many factors such as
decreased with further increases in S/L ratio. This can be temperature, solution concentration, and the presence of some
justified by the fact that high S/L ratio leads to a starvation of ions in the environment. It is reported that depending on
reagent. For example, it was found that with an S/L ratio of solution concentration and temperature, a large number of iron
100
90
80
70
Recovery (%)
60 Fe
Al
50
Si
40 Mg
Ca
30
20
10
0
0 50 100 150 200
Temperature (oC)
100 Fe
Al
Si
80 Mg
Ca
Recovery (%)
60
40
20
0
0.15 0.20 0.25 0.30 0.35 0.40
S/L
Fig. 9: Effect of S/L ratio on the leaching of elements from CFA sample
(particle size: −49 µm, 1.5 M H2SO4, 150oC, 300 rpm, 1 hour).
F. Characteristics of the synthesized coagulant solution 47 µm and 49 µm were determined for the treated and raw
The complex coagulant produced from the leaching of CFA samples, respectively.
CFA was a dark green colour liquid. Chemical properties of
the coagulant (synthesized under optimal experimental b) XRD and XRF analyses
conditions at 150 °C for 6 hours) are reported in Table 2. It is observed from the XRD pattern in Fig. 12 that the
Moreover, in a study by [27], the synthesized CFA-based characteristics of the mineral matter in the raw CFA sample
complex coagulant was found to be effective in removing were revealed in the treated CFA. However, throughout
impurities from acid mine drainage. reaction with varying times secondary mineral phases such as
jarosite (2Fe3(OH)6(SO4)2), and gypsum (CaSO4.2H2O) were
Properties of the synthesized complex coagulant at formed. It is established that the formation of jarosite is based
150 °C for 6 h on the presence of iron in sulphate medium and the tendency
pH 0.68–0.75 (< 4) of iron sulphate to hydrolyze at pH less than 3 and at
temperatures between 20 and 200 °C [41,42]. Therefore, in
Colour dark green
H2SO4 environment containing CFA, jarosite precipitate can
Fe 21731.89 mg/L be formed according to reaction in (9) [41,42]. The XRD
Al 603.18 mg/L results of the treated CFA are in agreement with the results in
Si 96.00 mg/L Fig. 10. Furthermore, the formation of gypsum is based on the
Mg 1366.70 mg/L presence of calcium in H2SO4 aqueous solution in which CaO
(in CFA) tends to dissolve in water to produce Ca(OH)2 which
Ca mg/L will react with H2SO4 as per (10) [43].
Table 2: Chemical composition of the synthesized coagulant.
3Fe2(SO4)3 + X2SO4 + 12H2O→2Fe3X(OH)6(SO4)2 +
G. Analysis of the treated coal fly ash 6H2SO4 (9)
Treated CFA samples from the optimal experimental Where X is the hydronium ion.
conditions were analysed by PSD, XRD, XRF, FTIR and SEM
in order to compare them with the raw CFA and measure the Ca(OH)2 + 2H+ + SO42— + 2H2O → CaSO4.2H2O + 2H+ +
impact of H2SO4 leaching. 2OH— (10)
a) PSD analysis Table 3 shows that there is not much change in the XRF
Comparison of the PSD results in Figs. 11 and 1 results of the raw and the treated CFA samples. These results
showed that changes in particle size occurred during the are consistent with XRD results (in Fig. 12).
dissolution process as average particle sizes at 80% weight of
Fig. 11: PSD of the treated CFA with H2SO4 under optimal experimental conditions at different leaching stages: (a) 1 hour
leaching, (b) 3 hours leaching, and (c) 6 hours leaching.
Content (wt%)
Chemical
composition Treated CFA
Raw CFA
1h 2h 3h 4h 5h 6h 8h
Al2O3 32.15 28.20 26.50 24.10 25.20 25.20 25.60 25.96
Fe2O3 4.16 2.34 2.60 3.26 2.14 2.36 2.10 2.19
SiO2 49.92 49.50 49.40 49.30 49.26 49.10 49.50 49.22
CaO 6.25 5.59 5.03 5.18 5.95 6.17 5.60 4.81
TiO2 2.15 2.13 2.15 2.15 2.14 2.14 2.15 2.15
MgO 1.40 0.46 0.56 0.57 0.45 0.46 0.45 0.42
K2O 1.00 1.03 1.14 1.11 1.05 1.07 1.05 1.09
P2O5 1.04 0.16 0.18 0.21 0.17 0.19 0.17 0.19
Table 3: Chemical composition of the raw and treated CFA samples.
Only important elements from important phases are presented
c) FTIR analysis
M : mullite
Q
J : jarosite
G Q : quartz
H H H
M Q J 8 hours G
M M M
Q Q
: gypsum
H : hematite
6 hours
5 hours
Intensity (cps)
4 hours
3 hours
2 hours
1 hour
Q
M Q M H H Q H
M M M MM Q Q Raw coal fly ash
10 20 30 40 50 60
2 theta (deg)
Figure 12: Comparison of XRD pattern of the raw to the treated CFA with H2SO4 leaching
under optimal experimental conditions in different times.
Si-O
6 hours
or
Si-O
Al-O
5 hours
Transmittance (%)
4 hours
3 hours
2 hours
1 hour
Fig. 13: Comparison of FTIR spectrum of the raw to the treated CFA by H2SO4
leaching under optimal experimental conditions in different times.
Fig. 14: SEM micrographs of CFA particles at different leaching stages. (a) raw coal fly ash; (b) coal fly ash after 1 hour leaching
(c) coal fly ash after 3 hours leaching, and (d) coal fly ash after 6 hours leaching.
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