United States Environmental Protection Agency Water Engineering Research Laboratory Cincinnati OH 45268 Research and Development EPA/600/S2-87/103 Jan. 1988 &ERA Project Summary Reclamation of Aluminum Finishing Sludges F. Michael Saunders The reclamation of aluminum- anodizing sludges produced as a result of finishing extruded architectural aluminum using etching and anodizing processes was studied by Georgia Tech Research Corporation. Two sequential phases focused on (1) enhanced dewa- tering of aluminum-anodizing sludges with recessed-chamber filter presses and (2) acidic extraction of dewatered aluminum-anodizing sludges to pro- duce commercial-strength solutions of aluminum sulfate, i.e., liquid alum. A high-pressure (14 to 15 bar) and a diaphragm filter press were effective in dewatering aluminum anodizing sludges to cake solids contents of 27% to 29% and 25% to 31%, respectively. These values were well above the 21 % value required to justify pursuit of direct acidic extraction of aluminum. Commercial-strength solutions of aluminum sulfate with concentrations of 8% as AI2Oa were produced using conventional-neutralization, segre- gated-neutralization, etch-recovery sludge cakes. The trace metal contents of the alum products were, in general, typical of commercial products. This Project Summary was devel- oped by EPA's Water Engineering Research Laboratory, Cincinnati. OH. to announce key findings of the research project that is fully docu- mented in a separate report of the same title (see Project Report ordering information at back). Introduction Aluminum anodizing plants may pro- duce up to 500 metric tons/month of finished architectural aluminum extru- sions. In the finishing process, approx- imately 3% to 5% of the mass of the extrusions is discharged as soluble aluminum metal to plant wastewaters. These aluminum-bearing wastewaters are typically neutralized, resulting in the production of a highly gelatinous, aluminum-hydroxide suspension. When these suspensions are thickened and dewatered, the remaining wet residue can equal or exceed the mass of finished aluminum extrusions produced at a plant. This solid waste residue must then be disposed of in a landfill or by other acceptable methods. Solid waste reduc- tion, therefore, has an extremely high priority in this industry and can be addressed through alterations in aluminum-finishing and waste- treatment procedures or by reclamation of the aluminum value in the dewatered solid waste residue. A major deterrent to the reclamation of the aluminum value in aluminum- anodizing sludges is the high levels of moisture associated with dewatered sludge cakes. Moisture generally consti- tutes more than 80% of the total mass of dewatered sludges, thereby increasing sludge hauling and ultimate disposal costs and contributing to the dilution of the aluminum value. The high moisture content is attributable to the gelatinous, hydrophilic nature of the aluminum hydroxide precipitate formed during conventional neutralization of alumi- num-anodizing wastewaters. To investi- gate the extent to which sludge moisture content could be reduced, recessed- chamber filter presses were selected for mechanical dewatering studies because of the high pressure differentials (e.g., 6 to 15 bar) typically achieved with these systems and their ability to produce dewatered sludge cakes with the lowest moisture content achievable by conven- tional mechanical dewatering systems. ------- The production of liquid alum from aluminum-anodizing sludges can be represented by the addition of sulfuric acid (H2SO«) to an aluminum-anodizing sludge containing dry fixed solids, represented by AI(OH)3, and moisture. In an equation format, the acidic extraction of aluminum is represented by: 2AI(OH)3 + xH2O + 3H2S04 — - (1) To produce a commercial-strength solu- tion of liquid alum containing 26.8% AI2(S04)3 (i.e., 8% as AI203), the aluminum-hydroxide content of a sludge would have to be equal to 1 6% on a fixed solids basis. This value is indicative of a total dry {1Q3°Q solids content of approximately 21% for a dewatered sludge cake. This is an exceptionally high value that, when compared to current practice, is not routinely achieved. Therefore, effective dewatering of sludge solids was a critical step in establishing the potential for reclamation of aluminum-anodizing sludges. Without the ability to produce a dewatered sludge cake with a solids content of > 21%, further consideration of direct reclama- tion of the aluminum value of aluminum- anodizing sludge was futile. Previous studies have been conducted in the laboratory to establish the feas- ibility of producing liquid alum from aluminum-anodizing sludges. The pur- pose of this study was to conduct extractions with three types of aluminum-anodizing wastes, to establish the kinetics of the acidic extraction, and to evaluate the quality of the products produced. Procedures Two recessed-chamber, fixed-volume filter presses (i.e., 470 mm and 250 mm) were employed in the study to establish the extent to which aluminum-anodizing sludges could be dewatered. Low- and high-pressure filtration studies were conducted with the presses, and the larger press was operated with variable- volume diaphragm plates. Constant operational pressure ranges of 6 to 7 bar (87 to 102 psi) and 14 to 15 bar (203 to 218 psi) were employed throughout the studies and are typical, respectively, of low- and high-pressure systems marketed for waste treatment practice. Pressure filtration studies were con- ducted at the site of an aluminum- anodizing facility producing architectural aluminum extrusions. Aluminum finish- ing processes included alkaline cleaning, caustic etching, acidic desmut, conven- tional and two-step sulfuric acid anod- izing, and hot-water sealing. Wastewater treatment included neutralization with spent acid and virgin caustic; polymer flocculation; gravity sedimentation; rotary vacuum filtration of thickened sludge; and recycle of clarified water into finishing rinses. Samples of the under- flow suspension from the clarifier were collected from the influent line to the rotary vacuum filter and were examined intensively on the filter presses. These sludge suspensions were identified as conventional neutralization (CN) suspen- sions. A CN suspension from a similar aluminum-anodizing plant was also examined. One other type of suspension was examined during the pressure filtration studies. Suspensions formed by batch neutralization of spent caustic etch from the aluminum-finishing line with spent anodizing acid were identified as segre- gated neutralization (SN) suspensions. These suspensions were not produced in the plant treatment systems, but were produced experimentally in0.2-m3(~50- gal) volumes for use in the filtration and acidic extraction portions of the study. These suspensions were formed by pumping anodizing acid into an inten- sively mixed, lined reactor containing spent caustic etch until a pH of 9 to 10 was achieved. These suspensions were then blended with CN suspensions or used directly in pressure filtration studies. Acidic extraction of aluminum- anodizing sludges was conducted in a laboratory-scale reactor equipped with a mixer and temperature control system used to maintain post-acid-addition temperatures at 50°C to 90°C. Following addition of acid, samples were collected at 30- to 60-min intervals to monitor the progress of the reaction. A detailed material balance was conducted on total reaction mass and on the mass of aluminum in each reactor. Three types of suspensions were examined. The CN and SN suspensions as included in filter-press dewatering studies were examined. In addition, an etch recovery (ER) sludge provided by an aluminum-anodizing plant was exam- ined. This residue was produced from a patented system designed to remove aluminum from caustic etching suspensions allowing for the continuous recovery and reuse of the caustic etch suspension. The aluminum is crystallized as an aluminum hydrate (e.g., AlzO3 -x H2O) at temperatures of 55°C to 65°C, removed from the caustic etch, and water washed using, for example, a vacuum filtration system. The dewatered residue was provided as one sample in 0.2-m3 volume and had a solids content of 91.6% and an aluminum content of 43.6 g/100 g fixed solids. Filter Press Dewatering Typical characteristics of the suspen- sions obtained from or experimentally produced at two aluminum-anodizing plants and examined during the filter press studies are included in Table 1. The two clarifier underflow suspensions, the primary focus of the dewatering studies, were slightly alkaline and relatively dilute. The specific resistance values for all suspensions were similar, although that for the SN suspension was the lowest, indicating slightly improved dewatering characteristics. Although not directly indicative of final cake solids content for a mechanical dewatering system, the dewatered cake solids concentration (Ck) determined as a part of the specific resistance test is effective in indicating the relative potential to which a suspension can be dewatered. The clarifier underflow from plant X had the lowest Ck value and was approxi- mately 50% to 60% of that for the neutralization basin effluent and clarifier underflow from plant A. Furthermore, the solids content values for all CN suspen- sions ranged from 7% to 13%, well below the minimum desired value of 21%, indicating indirectly the nature of the problem with respect to aluminum recovery as liquid alum. SN suspensions produced experimentally had exception- ally high suspended solids concentra- tions and the lowest and highest values for specific resistance and specific- resistance cake solids (Ck), respectively. This indicated the high potential for use of SN suspensions in the production of liquid alum. High-pressure and low-pressure filtra- tion studies were conducted at constant feed pressures of 6 to 7 bar (87 to 102 psi) and 14 to 15 bar (203 to 218 psi) using two pilot-scale filter presses. Replicate runs were usually performed for an individual suspension at each feed pressure with each replicate run being conducted for a variable time of filtration. For example, a CN suspension from plant A was examined in one series of runs at two concentrations and three filtration ------- time intervals for each operational pressure, as indicated in Table 2. Filtrate volume data were also collected as a function of time, as presented in Figure 1 for runs 24 through 29. The runs were highly reproducible with respect to filtrate volume. This allowed for evalua- tion of the effect of filtration time on dewatered cake solids, evaluation of the ultimate filtrate volume that could be produced at infinite filtration time, and, thereby, the ultimate dewatered-cake solids concentration, (Ck)uLT. Using a procedure developed in conjunction with this study, the ultimate filtrate volume was established using a procedure illustrated in Figure 2. With the projected ultimate filtrate volume (i.e., filtrate volume at a projected filtration rate of zero), both the ultimate cake solids concentration, (CK)ULT, and the cake solids concentration at the point of collection of 90% of the ultimate filtrate volume, (Ck)o.9, were calculated. This is illustrated in Table 3 for all low-pressure and high- pressure runs with CN suspensions from plant A. The ultimate cake solids con- centrations, (Ck)uLT, for both low- and high-pressure filtration were at or above the desired value of 21%, as were all (Ck)og values, indicating that it was feasible to explore the acidic extraction of sludge aluminum. Data collected for a similar CN sludge from plant X indi- cated that high- and low-pressure filtra- tion produced(Ck)uLT values of 24.5% and 17.6%, respectively, indicating that only high-pressure filtration would be accep- table. Therefore, in general, CN sludges can be dewatered to solids concentra- tions ranging from 18% to 29% using filter-press systems. Furthermore, high- pressure systems appear most suitable for production of dewatered sludge cakes that are suitable for direct production of liquid alum. SN suspensions, produced by direct neutralization of spent caustic etch suspensions (containing elevated con- centrations of aluminum, e.g., 50 to 150 g/L) with spent desmut or anodizing acids, have better dewatering properties than CN suspensions, as shown in Table 1. Samples of these experimentally Table 1. Typical Characteristics of Aluminum-Anodizing Suspensions from Participating Plants Suspended Solids SS, g/L Specific Resistance r. Tm/kg+ a . Capillary Suction Time Seconds Plant A Neutralization basin 8.2 effluent Clarifier underflow 8.2 Segregated 9.6 neutralization* Plant C Clarifier underflow 7.6 2.4 41 143 21 4 1.4 12 13 47 60 150 530 66 *Suspension produced experimentally at plant A but not a typical part of plant waste flow. +TM/kg = 1012 meters/kg Table 2. Results for Filter Press Dewatering of CN Suspensions (Plant A, Runs 24-29) Influent Suspension Runs 24,25.26 27.28.29 Suspended Solids 9/L 73 37 Specific Resistance r. Tm/kg* Ck. % 3.6 15.4 2.6 14.7 Filtration Pressure bar 14-15 14-15 Time of Filtration min 75,50,35 156.90.68 Cake Solids % 28.1,26.4.25.3 28.9.25.1.23.6 * Tm/kg =10 meters/kg produced suspensions were blended with CN suspensions, since both would be produced at a plant employing SN, to determine the impact on dewatering. Data in Table 4 indicate a dramatic impact of SN solids on ultimate solids concentration, as well as the high level of cake solids concentration, i.e., 51%, that can be achieved with SN suspen- sions alone. The use of variable-volume, or dia- phragm, plates was examined on the 470-mm press using a low-pressure (6 to 7 bar) addition of a suspension to the press followed by a high-pressure (15.5 bar) squeeze cycle, in which the contents of each chamber were compressed until no filtrate was released. Examples of the filtrate volume collected with time during the fill (or filter) and squeeze portions of several replicate runs are presented in Figure 3. Following filtration with the diaphragm plates, the CN suspensions from plant A had final cake solids concentrations that ranged from 25% to 31% and averaged 29%. These values were equivalent to or slightly higher than the analogous (Ck)ui_T values obtained for high pressure filtration (see Table 3). The limited increase in cake solids concen- tration would not appear to warrant the use of diaphragm plates, although a comparison of capital and operating costs may dictate otherwise. Acidic Extraction of Sludges Extractions were conducted on numer- ous aluminum anodizing sludges, follow- ing dewatering by pressure filtration, and on blends of dewatered sludges. Each extraction was initiated by addition of a fixed mass of sulfuric acid to a known mass of dewatered sludge. A tempera- ture control system was used to maintain a prescribed control temperature. The temperature, however, was not con- trolled during the initial acid addition phase but was controlled at tempera- tures of 50°C to 90°C following dissi- pation of heat associated with the initial exothermic reaction. The characteristics of the sludges extracted are summarized in Table 5. The aluminum content of the sludges, expressed on a mass basis in terms of the fixed (550°C) solids, varied from 31 % to 43.6%, comparing favorably with the AI(OH)3 form, with a theoretical alumi- num content of 34.6%, used in Equation 1 to describe the chemistry of the acidic extraction. Sulfuric acid was added to dewatered cakes, in accordance with Equation 1, at the rate of 1.89 g H2S04/g ------- fixed solids or 5.44 g H2SO.i/g Al. Acid doses were also expressed as a percen- tage of the stoichiometric acid dose based on sludge aluminum content (e.g., the addition of 5.44 g H2S04/g Al to a sludge cake would represent a stoichi- ometric dose of 100%). Filtrate aluminum data in Figure 4 indicate the results of a typical acidic extraction. In general, with an initial 1- hr period, the aluminum contained in the sludge cakes was extracted to near completion and approached the concen- tration of commercial-strength liquid 40 80 120 Time, min. 160 200 240 Figure 1. Cumulative filtrate volume for high-pressure (14 to 15 bar} dewatenng of CN sludges. 1.00 I I I ' ' ' ' I ' ' ' ' Run Number • 24 • 25 » 26 X 27 O 28 •* 29 000 0.000 -*. —"V*. . . . . X. : I . I ._ f , 0050 0.100 Volume, mm3 0.150 0.200 Figure 2. Filtration rate for high pressure dewatenng of CN sludges and projection of ultimate filtrate volume produced. alum (i.e., 8% as AI203). Because of the robust exothermic nature of the reaction during the initial period, the controlled reaction temperature had only a minimal effect on the rate of the reaction, as measured after a 0.5-hr extraction period. Data in Table 6 indicate that 89% to 109% of the aluminum placed in the reactors was accounted for in the studies conducted. In addition, the data indicate that, for all but the ER cakes, 93% to 100% of the aluminum was extracted and appeared in the soluble form as alum- inum sulfate. Those instances in which the percentage extracted was low (i.e., 93%) were attributable to extractions in which acid addition was less than the stoichiometric amount. For ER cakes, the level of aluminum extracted ranged from 69% to 85%. In some extractions of these cakes, dilution water (required because of the high solids content of these sludges) was withheld until later portions of the extraction. This produced an elevated acid strength in the initial extraction phase, and a higher level of aluminum extraction (i.e., 81% to 85%), as com- pared to those in which the additional water was added prior to acid addition and lower portions were extracted (i.e., 68% to 69%). The trace metal content of liquid alum produced with CN-2, SN-1, and ER-1, sludge cakes compared favorably with commercial products. Data in Table 7 indicated that concentrations of cad- mium, chromium, iron, silver, and zinc in alum produced from aluminum- anodizing cakes compared favorably with those contained in commercial alum products obtained from, and used at, two large municipal water treatment plants. The concentrations of lead were moder- ately higher than those in the commercial products. Concentrations of nickel and tin in alum produced from a conventional sludge (CN-2) were significantly higher than those in the commercial products. This was attributed to the nickel and tin used in the two-step anodizing process atthe plant. Nickel and tin concentrations in the alum produced from SN and ER cakes were well below the concentra- tions contained in the commercial prod- ucts. Therefore, with the exception of nickel and tin originating from a two-step anodizing system, the levels of trace metals contained in the alum produced from aluminum-anodizing sludges were similar to those contained in commercial ------- Table 3. Predicted Cake Solids Concentrations for Filter-Press Dewatering of CN Suspensions from Plant A Range of Suspended Solids 9/L Predicated Cake Solids Concentration (CJULT, % 9, % High pressure (14 to 15 bar) 21-73* Low pressure (6 to 7 bar) 17-61 + 27-29 22-25 25-26 21-23 "Results for a total of 15 runs. ^Results for a total of 13 runs. Table 4. Predicted Cake Solids Concentration for High-Pressure Filter-Press Dewatering of Blends of SN and CN Suspension SN Suspension in Blend of SN-1 and CN-2 Suspensions % (by volume) 0 5 15 30 100 Suspended Solids 9/L 38 47 60 78 180 Predicted Cake Solids Concentration CC^ULT, % 29 33 37 39 51 (C>Joa, % 27 31 34 37 49 I 80 60 40 20 • 172 Filter O Squeeze • 175 Filter [D Squeeze V 176 Filter A Squeeze X 179 Filter f(. Squeeze 0 40 80 120 Time. min. Figure 3. Cumulative filtrate volume for filter and squeeze portions of diaphragm filter press dewatering of CN sludges. alum, indicating the potential utility of the alum for use in coagulation of drinking waters. However, since less than 10% of commercial alum is actually used in the treatment of drinking water, it is apparent that the alum products produced from aluminum-anodizing sludges can be marketed for non- potable-water uses in industry. Conclusions Research was conducted on filter- press dewatering followed by reclama- tion of three types of aluminum- anodizing sludges as commercial- strength liquid alum. Numerous conclu- sions were drawn from the study. Pressure filtration studies were con- ducted with two pilot-scale, fixed- volume, recessed-chamber filter presses at low (6 to 7 bar) and high (14 to 15 bar) pressures. The solids content of dewatered sludge cakes at the ultimate completion of a filter press run were projected from filtration rate data. CN suspensions had ultimate cake solids contents of 22% to 25% and 27% to 29%, respectively, at low (6 to 7 bar) and high (14 to 15 bar) pressures for suspensions with suspended solids concentrations of 17to73g/L SN suspensions could be effectively dewat;red separately and resulted in major improvements in the dewatering of CN suspensions when blended with them. At low and high pressures, ulti- mate cake solids contents of 49% and 51%, respectively, were achieved with SN suspensions. Blends of SN suspen- sions at 5% to 30% volumetric ratios with CN suspensions resulted in ultimate solids contents of 33% to 39% with high- pressure filtration and 31% to 37% with low-pressure filtration. A diaphragm press was used effec- tively to dewater aluminum anodizing suspensions. CN suspensions had final cake solids contents of 25% to 31 %, while 5% to 30% volumetric blends of SN suspensions with CN suspensions had solids contents of 31 % to 43%. Commercial-strength solutions of liquid alum can be effectively and rapidly produced with the addition of sulfuric acid. Addition of stoichiometric quanti- ties of acid, based on sludge aluminum content resulted in virtually complete extraction within 30 to 60 min. CN sludge cakes with solids contents of 17% to 18% were extracted to produce liquid alum with concentrations of 7.4% to 8.8% as AI2O3. A total of 93% to 97% of the aluminum was extracted. ------- C/V Dewatered Sludge Cake Stoichiometric Run Temp Acid Dosage 2-1 90°C 100% 2-2 50° C 100% 0 2 4 6 8 Time, hr Figure 4. Filtrate aluminum concentration for sulfuric acid extraction of sludge cake CN- 2. Table 5. Characteristics of Aluminum-Anodizing Sludge Cakes Used in Acidic Extraction Studies Cake Solids Sludge Cake Total. % Fixed. % Aluminum Content g/IOOg fixed solids Conventional Neutralization C/V-7 CN-2 Segregated Neutralization S/V-7 Etch Recovery ER-1 18.1 17.4 368 91 6 133 13.9 29.9 66.4 35.6 39.2 31.0 43.6 SN sludge cakes with solids contents of 36.8% were extracted to produce liquid alum with concentrations of 8.1% to 9.0% as AI203. An ER sludge with a solids content of 91.6% produced a liquid alum with a concentration of 8.3% to 9.2% AI2Oa. Acid addition resulted in extrac- tion of 69% to 85% of the aluminum. Addition of SN or ER solids to CN solids increased the aluminum content of the blended sludge and could be effectively extracted to easily produce commercial- strength liquid alum. The cadmium, chromium, and iron concentrations of liquid alum produced from CN sludges were less than those of commercial alum products, while lead, silver, and zinc concentrations were slightly above those for commercial alum products. The concentrations of nickel and tin were sixfold to seventeenfold higher than those in commercial alum. The high nickel and tin concentrations were attributed to dragout from the two- step anodizing process and to the use of nickel in seal tanks. Segregation of these wastes from plant wastewaters may be needed to eliminate them from the sludges produced for extraction and reclamation. The full report was submitted in fulfillment of CR110290-01-0 by Georgia Institute of Technology under the spon- sorship of the U.S. Environmental Pro- tection Agency. Blended Cakes CN-2 & S/V-/ CN-2 & ER-1 25.2 30.2 21.4 22.5 34.6 41.3 ------- Table 6. Material Balance on Aluminum and Alum Product Quality for Acidic Extraction of Sludge Cakes Alum Product Reactor Material AI extracted into Balance-Aluminum soluble form Concentration Sludge Cake %AI recovered % of total Al %asAI203 Conventional Neutralization CN-1 104 93-97 7.4-8.0 CN-2 99 97 8.1-8.8 Segregated Neutralization SN-1 100-105 99-100 8.1-9.0 Etch Recovery ER-1 Blends CN-2 & SN-1 CN-2 & ER-1 89-109 99 102 69-85 99 82 8.3-9.2 8.2 8.8 Table 7. Metal Content of Liquid-Alum Samples. Produced from CN-2, SN-1. and ER-1 Sludge Cakes, and Two Commercial Alum Products Concentration, mg/L Sludge-Cake Alum Commercial Alum Metal Cadmium, Cd Chromium, Cr Iron. Fe Lead, Pb Nickel. Ni Silver, Ag Tin, Sn Zinc, An CN-2 0.4 30.0 60.0 20 752 0.7 914 12 SN-1 0.3 4.4 18.3 19 8 0.2 28 6 ER-1 0.3 3.7 21.0 26 7 0.08 17 7 Plant 1 0.03 78 1845 6.6 44 0.25 155 8.5 Plant 2 0.3 0.9 2080 4.1 44 0.2 — 8.5 F. MichaelSaunders is with Georgia Institute of Technology, Atlanta, GA 30332. Thomas J. Powers is the EPA Project Officer (see below). The complete report, entitled "Reclamation of Aluminum Finishing Sludges," (Order No. PB 88-133 566/AS; Cost: $19.95, subject to change) will be available only from: National Technical Information Service 5285 Port Royal Road Springfield. VA 22161 Telephone: 703-487-4650 The EPA Project Officer can be contacted at: Water Engineering Research Laboratory U.S. Environmental Protection Agency Cincinnati, OH 45268 ------- V United States Environmental Protection Agency Center for Environmental Research Information Cincinnati OH 45268 BULK RATE POSTAGE & FEES PAID EPA PERMIT No. G-35 Official Business Penalty for Private Use S300 EPA/600/S2-87/103 OG00329 PS *SIMCT ------- |