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.

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  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

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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

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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

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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.

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                                       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

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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

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V
    United States
    Environmental Protection
    Agency
Center for Environmental Research
Information
Cincinnati OH 45268
     BULK RATE
POSTAGE & FEES PAID
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  PERMIT No. G-35
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             OG00329    PS
                                             *SIMCT

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