Zero-waste recycling method for textile dyeing sludge by magnetizing roasting–magnetic separation process and ceramic filter preparation

Abstract

We developed an environmental recycling process for textile dyeing sludge that involved a magnetizing roasting–magnetic separation process followed by the preparation of a ceramic filter. The optimal parameters for the magnetizing roasting process included blending the textile dyeing sludge with 5.0% content of coal and roasting at 800 °C for 45 min. The main iron-bearing mineral (Fe2O3) was converted to Fe3O4. The roasted ore was beneficiated by low-intensity magnetic separation (0.15 T strength of the magnetic field). A concentrate with 57.85% iron grade and 68.11% iron recovery was obtained. A ceramic filter material produced from the tailings of the magnetic separation process met the national standard requirements for water treatment applications. These results offered an effective approach to solve an environmental problem associated with textile dyeing sludge waste products.

This is a preview of subscription content, log in to check access.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

References

  1. Chen QS, Zhang QL, Fourie A, Xin C (2017) Utilization of phosphogypsum and phosphate tailings for cemented paste backfill. J J Environ Manage 201(10):2026. https://doi.org/10.1016/j.jenvman.2017.06.027

    CAS  Article  Google Scholar 

  2. Chun TJ, Zhu DQ, Pan J (2015) Simultaneously roasting and magnetic separation to treat low grade siderite and hematite ore. J Mineral Process Extr Metall Rev 4:223–226. https://doi.org/10.1080/08827508.2014.928620

    CAS  Article  Google Scholar 

  3. Detcheva AK, Mitsiev SE, Vassileva PS, Jordanov JH, Karadjov MG, Ivanova E (2015) Total reflection X-ray fluorescence analysis of fly ash from Bulgarian coal-fired power plants. J Chem Papers 69(5):650–654. https://doi.org/10.1515/chempap-2015-0071

    CAS  Article  Google Scholar 

  4. Djafer A, Djafer L, Maimoun B, Iddou A, Mostefai SK, Ayral A (2017) Reuse of waste activated sludge for textile dyeing wastewater treatment by biosorption: performance optimization and comparison. J Water Environ J 1:105–112. https://doi.org/10.1111/wej.12218

    CAS  Article  Google Scholar 

  5. Fan XH, Deng Q, Gan M, Wang HB (2015) Effect of biochar as reductant on magnetizing-roasting behavior of pyrite cinder. J Iron Steel Res Int 5:371–376. https://doi.org/10.1016/S1006-706X(15)30014-5

    Article  Google Scholar 

  6. Gayana BC, Chandar KR (2018) Sustainable use of mine waste and tailings with suitable admixture as aggregates in concrete pavement. J Adv Concrete Constr 3:222–240. https://doi.org/10.12989/acc.2018.6.3.221

    Article  Google Scholar 

  7. Ghosh A, Dastidar MG, Sreekrishnan TR (2017) Bioremediation of chromium complex dyes and treatment of sludge generated during the process. J Int Biodeterior Biodegrad 119:448–460. https://doi.org/10.1016/j.ibiod.2016.08.013

    CAS  Article  Google Scholar 

  8. Haddad M, Abid S, Hamdi M, Bouallagui H (2018) Reduction of adsorbed dyes content in the discharged sludge coming from an industrial textile wastewater treatment plant using aerobic activated sludge process. J Environ Manag 223:936–946. https://doi.org/10.1016/j.Jenvman.2018.07.009

    CAS  Article  Google Scholar 

  9. Huang J, Huang GH, An CJ, He Y, Yao Y, Zhang P, Shen J (2018) Performance of ceramic disk filter coated with nano ZnO for removing Escherichia coli from water in small rural and remote communities of developing regions. J Environ Pollut 238:52–62. https://doi.org/10.1016/j.envpol.2018.03.008

    CAS  Article  Google Scholar 

  10. Khorram AG, Fallah N (2018) Treatment of textile dyeing factory wastewater by electrocoagulation with low sludge settling time: optimization of operating parameters by RSM. J Environ Chem Eng 6:635–642. https://doi.org/10.1016/j.jece.2017.12.054

    CAS  Article  Google Scholar 

  11. Li C, Sun HH, Bai J (2010) Innovative methodology for comprehensive utilization of iron ore tailings Part 1: the recovery of iron from iron ore tailing using magnetic separation after magnetizing roasting. J Hazard Mater 2:71–77. https://doi.org/10.1016/j.jhazmat.2009.09.018

    CAS  Article  Google Scholar 

  12. Li Y, Cao W, Gong LL, Zhang RF, Cheng XD (2016) Effect of starch on sintering behavior for fabricating porous cordierite ceramic. J High Temp Mater Processes 9:955–961. https://doi.org/10.1515/htmp-2015-0074

    CAS  Article  Google Scholar 

  13. Liu JY, Zhuo ZX, Xie WM, Kuo JH, Lu XW, Buyukada M, Evrendilek F (2018) Interaction effects of chlorine and phosphorus on thermochemical behaviors of heavy metals during incineration of sulfur-rich textile dyeing sludge. Chem Eng J 351:897–911. https://doi.org/10.1016/j.cej.2018.06.158

    CAS  Article  Google Scholar 

  14. Man KX, Zhu Q, Guo Z, Xing ZP (2018a) Fe-Ti/Fe (II)-loading on ceramic filter materials for residual chlorine removal from drinking water. J Chemosphere 200:405–411. https://doi.org/10.1016/j.chemosphere.2018.02.156

    CAS  Article  Google Scholar 

  15. Man XY, Ning XA, Zou HY, Liang JY, Sun J, Lu XW, Sun JK (2018b) Removal of polycyclic aromatic hydrocarbons (PAHs) from textile dyeing sludge by ultrasound combined zero-valent iron/EDTA/Air system. J Chemosphere 191:839–847. https://doi.org/10.1016/j.chemosphere.2017.10.043

    CAS  Article  Google Scholar 

  16. Manjarrez L, Zhang LY (2018) Utilization of copper mine tailings as road base construction material through geopolymerization. J Mater Civil Eng 9:33–39. https://doi.org/10.1061/(ASCE)MT.1943-5533.0002397

    Article  Google Scholar 

  17. Mosier-boss PA, Sorensen KC, George RD, SimsO'braztsova PCA (2017) SERS substrates fabricated using ceramic filters for the detection of bacteria: eliminating the citrate interference. J Spectrochim Acta Part A Mol Biomol Spectr 180:161–167. https://doi.org/10.1016/j.saa.2017.03.021

    CAS  Article  Google Scholar 

  18. Niu XF, Liu XS, Huang X, Huang K, Ma YQ, Huang F, Lv FR (2016) On the structure and some properties of LaCo Co-substituted NiZn ferrites prepared using the standard ceramic technique. J High Temp Mater Processes 4:417–423. https://doi.org/10.1515/htmp-2014-0221

    CAS  Article  Google Scholar 

  19. Oh S, Shin WS (2017) Applicability of solidified/stabilized dye sludge char as a landfill cover material. KSCE J Civ Eng 7:2573–2583. https://doi.org/10.1515/htmp-2014-0221

    CAS  Article  Google Scholar 

  20. Puttaiah Shivaraju H, Egumbo H, Madhusudan P, Anil Kumar KM, Midhun G (2018) Preparation of affordable and multifunctional clay-based ceramic filter matrix for treatment of drinking water. J Environ Technol 2:1–11. https://doi.org/10.1080/09593330.2018.1430853

    CAS  Article  Google Scholar 

  21. Samouhos M, Taxiarchou M, Pilatos G, Tsakiridis PE, Devlin E, Pissas M (2017) Controlled reduction of red mud by H2 followed by magnetic separation. J Miner Eng 105:36–42. https://doi.org/10.1016/j.mineng.2017.01.004

    CAS  Article  Google Scholar 

  22. Sarvajitha M, Reddya KK, Nancharaiaha YV (2018) Textile dye biodecolourization and ammonium removal over nitrite in aerobic granular sludge sequencing batch reactors. J Hazard Mater 342:536–543. https://doi.org/10.1016/j.jhazmat.2017.08.064

    CAS  Article  Google Scholar 

  23. Shazim AM, Israr W, Muhammad KK, Muhammad AT, Madina B (2018) Environmentally friendly utilization of wheat straw ash in cement-based composites. J Sustain 10:1322–1323. https://doi.org/10.3390/su10051322

    CAS  Article  Google Scholar 

  24. Shafiquzzaman MD, Al-Mahmud A, Alsaleem SS, Haider H (2018) Application of a low cost ceramic filter for recycling sand filter backwash water. J Water 10:1–14. https://doi.org/10.3390/w10020150

    CAS  Article  Google Scholar 

  25. Su ZJ, Zhang YB, Chen J (2016) Selective separation and recovery of iron and tin from high calcium type tin and iron-bearing tailings using magnetizing roasting followed by magnetic separation. J Separat Sci Technol 11:1900–1912. https://doi.org/10.1080/01496395.2016.1178292

    CAS  Article  Google Scholar 

  26. Tung TX, Xu D, Zhang Y, Zhou QH, Wu ZB (2018) Effective removal of humic acid using strontium-doped TiO2 coated on porous ceramic filter media in water resource. Polish J Environm Stud 6:2765–2774. https://doi.org/10.15244/pjoes/81063

    CAS  Article  Google Scholar 

  27. Wang ML, Mao MM, Zhang M, Wen GD, Yang Q, Su BG, Ren QL (2019) Highly efficient treatment of textile dyeing sludge by CO2 thermal plasma gasification. J Waste Manag 90:29–36. https://doi.org/10.1016/j.wasman.2019.04.025

    CAS  Article  Google Scholar 

  28. Wong S, Yac'cob NAN, Ngadi N, Hassan O, Inuwa IM (2018) From pollutant to solution of wastewater pollution: Synthesis of activated carbon from textile sludge for dye adsorption. J Chin J Chem Eng 26:870–878. https://doi.org/10.1016/j.cjche.2017.07.015

    CAS  Article  Google Scholar 

  29. Wu YS, Yang X, Li LS, Wang YZ, Li MC (2019) Kinetics of extracting alumina by leaching coal fly ash with ammonium hydrogen sulfate solution. J Chem Papers 73(9):2289–2295. https://doi.org/10.1007/s11696-019-00779-w

    CAS  Article  Google Scholar 

  30. Xie C, Liu JY, Buyukada M, Evrendilek F, Samaksaman U, Kuo JH, Ozyurt O (2019) Parametric assessment of stochastic variability in co-combustion of textile dyeing sludge and shaddock peel. J Waste Manag 96:128–135. https://doi.org/10.1016/j.wasman.2019.07.010

    CAS  Article  Google Scholar 

  31. Zeng J, Chen S, Wan K, Li JM, Hu D, Zhang SH, Yu X (2018) Study of biological up-flow roughing filters designed for drinking water pretreatment in rural areas: using ceramic media as filter material. J Environ Technol 9:1–10. https://doi.org/10.1080/09593330.2018.1530304

    CAS  Article  Google Scholar 

  32. Zhang K, Chen XL, Guo WC, Luo HJ, Gong ZJ, Li BW, Wu WF (2017) Effects of biomass reducing agent on magnetic properties and phase transformation of Baotou low-grade limonite during magnetizing roasting. J Plos One 10:2–17. https://doi.org/10.1371/journal.pone.0186274

    CAS  Article  Google Scholar 

  33. Zhang HD, Gao ZP, Liu Y, Ran CM, Mao X, Kang QH, Ao WY, Fu J, Li J, Liu GQ, Dai JJ (2018) Microwave-assisted pyrolysis of textile dyeing sludge migration and distribution of heavy metals. J Hazard Mater 355:128–133. https://doi.org/10.1016/j.jhazmat.2018.04.080

    CAS  Article  PubMed  Google Scholar 

Download references

Acknowledgements

The authors wish to express their thanks to the National key research and development plan of China (No. 2017YFC0210302) for the financial support of this research.

Author information

Affiliations

Authors

Corresponding author

Correspondence to Jinchao Wei.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Zhao, Q., Wei, J. Zero-waste recycling method for textile dyeing sludge by magnetizing roasting–magnetic separation process and ceramic filter preparation. Chem. Pap. (2020). https://doi.org/10.1007/s11696-020-01249-4

Download citation

Keywords

  • Textile dyeing sludge
  • Magnetizing roasting
  • Ceramic filter
  • Environment