Synergistic promotion of particulate matter reduction and production performance via adjusting electrochemical reactions in the zinc electrolysis industry

Highlights

● Electrolytic PM can be reduced by controlling operation parameters.

● The optimization conditions exist, reducing PM without deteriorating PC and CE_Zn.

● Abatement essence is to inhibit gas evolution reactions.

Abstract

Heavy particulate matter (PM) pollution and high energy consumption are the bottlenecks of hydrometallurgy, especially in the electrolysis process. Therefore, an urgent need is to explore PM reduction methods with production performance co-benefits. This study presents three PM reduction methods based on controlling operating parameters, i.e., lowering electrolyte temperature, H₂SO₄ concentration, and current density of the cathode. The optimized conditions were also investigated using the response surface methodology to balance the PM reduction effect and Zn production. The results showed that lowering electrolyte temperature is the most efficient, with an 89.0% reduction in the PM generation flux (GF_PM). Reducing H₂SO₄ concentration led to the minimum side effects on the current efficiency of Zn deposition (CE_Zn) or power consumption (PC). With the premise of non-deteriorating CE_Zn and PC, GF_PM can be reduced by 86.3% at the optimal condition (electrolyte temperature = 295 K, H₂SO₄ = 110 g/L, current density = 373 A/m²). In addition, the reduction mechanism was elucidated by comprehensively analyzing bubble characteristics, electrochemical reactions, and surface tension. Results showed that lower electrolyte temperature inhibited the oxygen evolution reaction (OER) and compressed gas volume. Lower H₂SO₄ concentration inhibited the hydrogen evolution reaction (HER) and reduced electrolyte surface tension. Lower current density inhibited both OER and HER by decreasing the reaction current. The inhibited gas evolutions reduced the microbubbles’ number and size, thereby reducing GF_PM. These results may provide energy-efficient PM reduction methods and theoretical hints of exploring cleaner PM reduction approaches for industrial electrolysis.

Graphical abstract

Keywords

Zinc electrolysis / Particulate matter / Energy consumption / Operating parameters / Bubble characteristic / Electrochemical reaction

References

[1] Al Shakarji R , He Y , Gregory S . (2011a). The sizing of oxygen bubbles in copper electrowinning. Hydrometallurgy, 109(1): 168–174

[2] Al Shakarji R, He Y, Gregory S (2011b). Statistical analysis of the effect of operating parameters on acid mist generation in copper electrowinning. Hydrometallurgy, 106(1–2): 113–118

[3] Al Shakarji R, He Y, Gregory S (2013). Performance evaluation of acid mist reduction techniques in copper electrowinning. Hydrometallurgy, 131–132: 76–80

[4] Berny A , Popinet S , Seon T , Deike L . (2021). Statistics of jet drop production. Geophysical Research Letters, 48(10): e2021GL092919

[5] Bouakaz A , Versluis M , De Jong N . (2005). High-speed optical observations of contrast agent destruction. Ultrasound in Medicine & Biology, 31(3): 391–399

[6] Cai Z , Wang J , Lu Z , Zhan R , Ou Y , Wang L , Dahbi M , Alami J , Lu J , Amine K . . (2022). Ultrafast metal electrodeposition revealed by in situ optical imaging and theoretical modeling towards fast-charging Zn battery chemistry. Angewandte Chemie International Edition, 61(14): e202116560

[7] Deike L , Reichl B G , Paulot F . (2022). A mechanistic sea spray generation function based on the sea state and the physics of bubble bursting. AGU Advances, 3(6): 14942

[8] Dhak D, Mahon M, Asselin E, Alfantazi A (2011). The effects of mixtures of acid mist suppression reagents on zinc electrowinning from spent electrolyte solutions. Hydrometallurgy, 108(1–2): 1–10

[9] Dusen J V , Smith J W . (1989). Comparison of the effectiveness of bubble coalescence and foamed surfactant in controlling the acid mist formed by electrowinning cells. American Industrial Hygiene Association Journal, 50(5): 252–256

[10] Dwivedi K A , Huang S J , Wang C T . (2022). Integration of various technology-based approaches for enhancing the performance of microbial fuel cell technology: a review. Chemosphere, 287: 132248

[11] Ghabache E , Seon T . (2016). Size of the top jet drop produced by bubble bursting. Physical Review Fluids, 1(5): 051901

[12] He H , Yu Q , Lai C , Zhang C , Liu M , Huang B , Pu H , Pan X . (2021). The treatment of black-odorous water using tower bipolar electro-flocculation including the removal of phosphorus, turbidity, sulfion, and oxygen enrichment. Frontiers of Environmental Science & Engineering, 15(2): 18

[13] He Y , Cui Y , Shang W , Zhao Z , Tan P . (2022). Insight into the bubble-induced over potential towards high-rate charging of Zn-air batteries. Chemical Engineering Journal, 448: 137782

[14] Ji S L , Weon B M , Su J P , Je J H , Fezzaa K , Lee W K . (2011). Size limits the formation of liquid jets during bubble bursting. Nature Communications, 2(1): 367

[15] Kargl-Simard C , Huang J H , Alfantazi A M . (2003). Electrical conductivity and density of CoSO₄/H₂SO₄ solutions in the range of modern cobalt electrowinning electrolytes. Minerals Engineering, 16(6): 529–535

[16] Ke W R , Kuo Y M , Lin C W , Huang S H , Chen C C . (2017). Characterization of aerosol emissions from single bubble bursting. Journal of Aerosol Science, 109: 1–12

[17] Lasia A . (2019). Mechanism and kinetics of the hydrogen evolution reaction. International Journal of Hydrogen Energy, 44(36): 19484–19518

[18] Luo J , Jiao P , Duan N , Xu F , Jiang L . (2018). Flow field characterization in the vicinity of vertical plane electrodes in a bench-scale zinc electrowinning cell. Hydrometallurgy, 181: 103–112

[19] Ma Z , Duan L , Jiang J , Deng J , Xu F , Jiang L , Li J , Wang G , Huang X , Ye W , Wen Y , Zhang G , Duan N . (2020a). Characteristics and threats of particulate matter from zinc electrolysis manufacturing facilities. Journal of Cleaner Production, 259: 120874

[20] Ma Z , Jiang J , Duan L , Li Z , Deng J , Li J , Zhang R , Zhou C , Xu F , Jiang L , Duan N . (2020b). Ultrasonication to reduce particulate matter generated from bursting bubbles: a case study on zinc electrolysis. Journal of Cleaner Production, 272: 122697

[21] Maslova M V , Ivanenko V I , Yanicheva N Y , Mudruk N V . (2020). Comparison of the sorption kinetics of lead(II) and zinc(II) on titanium phosphate ion-exchanger. International Journal of Molecular Sciences, 21(2): 447

[22] Mason T J , Lorimer J P , Saleem S , Paniwnyk L . (2001). Controlling emissions from electroplating by the application of ultrasound. Environmental Science & Technology, 35(16): 3375–3377

[23] Mcginnity J J , Nicol M J . (2014). Sulfuric acid mist: generation, suppression, health aspects, and analysis. Mineral Processing and Extractive Metallurgy Review, 35(3): 149–192

[24] Mokarram M , Pourghasemi H R , Zhang H . (2020). Predicting non-carcinogenic hazard quotients of heavy metals in pepper (Capsicum annum L.) utilizing electromagnetic waves. Frontiers of Environmental Science & Engineering, 14(6): 114

[25] Papachgristodoulou A , Foulkes F R , Smith J W . (1985). Bubble characteristics and aerosol formation in electrowinning cells. Journal of Applied Electrochemistry, 15(4): 581–590

[26] Qu C, Li K, Xie Z, Yang S, Zhao J, Sun D, Sun Y (2022). Stacking polymer microspheres matrix: a facile, practical, and energy-saving strategy for suppression of acid mist. Environmental Technology, 44: 18, 2693–2701

[27] Shaw L , Shaw D , Hardisty M , Britz-Mckibbin P , Verma D K . (2020). Relationships between inhalable and total hexavalent chromium exposures in steel passivation, welding and electroplating operations of Ontario. International Journal of Hygiene and Environmental Health, 230: 113601

[28] Sorour N , Zhang W , Ghali E , Houlachi G . (2017). A review of organic additives in zinc electrodeposition process (performance and evaluation). Hydrometallurgy, 171: 320–332

[29] Theerthagiri J , Madhavan J , Lee S J , Choi M Y , Ashokkumar M , Pollet B G . (2020). Sonoelectrochemistry for energy and environmental applications. Ultrasonics Sonochemistry, 63: 104960

[30] Wang X , Deane G B , Moore K A , Ryder O S , Stokes M D , Beall C M , Collins D B , Santander M V , Burrows S M , Sultana C M , Prather K A . (2017). The role of jet and film drops in controlling the mixing state of submicron sea spray aerosol particles. Proceedings of the National Academy of Sciences of the United States of America, 114(27): 6978–6983

[31] Wu X , Liu Z , Liu X . (2014). The effects of additives on the electrowinning of zinc from sulphate solutions with high fluoride concentration. Hydrometallurgy, 141: 31–35

[32] Xu K , Lu J , Tegladza I D , Xu Q , Yang Z , Lv G . (2020a). Combined metal/air fuel cell and electrocoagulation process: energy generation, flocs production and pollutant removal. Chemosphere, 255: 126925

[33] Xu X , Li D , Chen L , Liu M , Jia J J H . (2020b). Improve the energy efficiency: effects of additives on longtime zinc electrowinning. Hydrometallurgy, 193: 105326

[34] Xue T , Xu L , Wang Q . (2019). Measurement of seawater surface tension coefficient based on bubble rising behavior. Measurement, 138: 332–340

[35] Zeng M , Li Y . (2015). Recent advances in heterogeneous electrocatalysts for the hydrogen evolution reaction. Journal of Materials Chemistry. A, Materials for Energy and Sustainability, 3(29): 14942–14962

[36] Zhang C , Duan N , Jiang L , Xu F . (2018). The impact mechanism of Mn²⁺ ions on oxygen evolution reaction in zinc sulfate electrolyte. Journal of Electroanalytical Chemistry (Lausanne, Switzerland), 811: 53–61

Acknowledgements

This research was financially supported by the National Natural Science Foundation of China (No. 22106081), the Natural Science of Foundation of Shandong Province, China (No. ZR202103040646), the special fund of State Key Joint Laboratory of Environment Simulation and Pollution Control (China) (No. 20K09ESPCT), the Major Basic Research Projects of Natural Science Foundation of Shandong Province (China) (No. ZR2020KE025), the Fundamental Research Funds for the Central Universities (China) (No. 22120220166).

Conflict of Interest

The authors Fuyuan Xu and Ning Duan are Editorial Board Members of Frontiers of Environmental Science & Engineering. The authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.

Electronic Supplementary Material

Supplementary material is available in the online version of this article at https://doi.org/10.1007/s11783-024-1762-0 and is accessible for authorized users.

Open Access

This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made. The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

RIGHTS & PERMISSIONS

2024 The Author(s) . This article is published with open access at link.springer.com and journal.hep.com.cn