Abstract
The isothermal phase diagram of SiO2-CaO-Al2O3 slag system was calculated by FactSage6.4. By fixing the agent MgO content at 8wt% and controlling Al2O3 content lower than 35wt%, a reasonable liquidus temperature and mineralogical phase of the glass slag were obtained. The effects of temperature, binary basicity wCaO/wSiO2 and Al2O3 content on viscosity of the feasible SiO2-CaO-Al2O3-MgO slag were investigated by the rotating spindle method and simulating calculation. Results show that with increasing the temperature, the slag viscosity decreases, Al2O3 content increases from 15wt% to 35wt% and binary basicity wCaO/wSiO2 increases from 0.3 to 1.0 according to the univariate investigation. It is known from the smelting experiment using iron as collector that the recovery rate of palladium increases with increasing the mass fraction of waste catalyst in material system, and it increases first and then decreases with continuously increasing the basicity and temperature. With the waste Pd/Al2O3 catalyst used in this study and using the optimized slag ingredients of about 30wt% Al2O3, 8wt% MgO and binary basicity wCaO/wSiO2=0.5, the recovery rate of palladium reaches 99% and the residual palladium in glass tailing is less than 4.50 g/t.
Science Press
The catalytic activity of platinum group metals (PGMs) revolutionizes the chemical processes, which is contributed to their widest application in preparation of catalys
Recovery of PGMs from solid wastes such as electronic waste, anode slime, and waste catalysts involves various metallurgical and chemical methods. Hydrometallurgical method is an achievable and widely acceptable technology in the past years, which have been conducted for the recovery of PGMs from solid waste by leaching PGMs with hydrochloric acid and oxidants system or cyanide solution
Pyrometallurgical process is the primary and effective approach to recover PGMs from solid waste, especially widely used in treatment of waste catalyst for its unique advantages such as simple operation and flow process, and enormous potential for large-scale industrial production. Many famous enterprises such as Umicore, Badische Anilinund-Soda-Fabrik, and Johnson Matthey around the world have extensively applied pyrometallurgical process to recovery PGM
Generally, physicochemical properties of melted slag are important impact factors on metallurgical proces
In this work, a typical and practical SiO2-CaO-Al2O3-MgO glass slag system was proposed, specifically for the recovery of palladium from waste Pd/Al2O3 catalyst by smelting-collection process, and the viscosity of the feasible SiO2-CaO-Al2O3-MgO slag was investigated using both the rotating spindle method and simulating calculation. Then, the optimum technology parameters were obtained by the practical smelting experiment using iron as collector. The alloy product and glass slag in this study were tested by XRD, XRF, SEM and ICP (inductively coupled plasma) method. This work provides a novel and significant foundation for efficient recovery of palladium from waste Pd/Al2O3 catalyst.
The waste catalyst in cylindrical particles used in this study was obtained from catalytic hydrogenation reaction in chemical industry, and supplied by a catalyst recovery company in Jiangsu province, China. Before use, the harmful volatile and moisture were completely removed by high-temperature roasting process. The main chemical composition of the waste Pd/Al2O3 catalyst was tested by EDTA, XRF and ICP. The mass percent of alumina and silica was 99.22wt% and 0.42wt%, respectively, and the content of palladium was 1595.3 g/t. So, the melting point of the waste catalyst will be very close to 2327 K, which is difficult for conventional smelting process. Slagging is an effective solution to achieve the conventional smelting process and the slag system of SiO2-CaO-Al2O3-MgO was chosen due to its applicable properties. The waste catalyst was crushed into powder to increase its specific surface area which is beneficial to the mixture and smelting processes subsequently. The fluxes such as SiO2, CaO and MgO, Al2O3 and metallic iron collector powder were analytically pure and dried at the temperature of 423 K for 24 h before use to make sure the complete removal of moisture. In order to meet the high temperature and reduce the impact of impurities, high-purity graphite material was used for preparation of smelting vessel.
Firstly, the isothermal phase diagram of SiO2-CaO-Al2O3 basic slag system was calculated by FactSage6.4 for selecting a reasonable composition. Then, the fluxes, Al2O3, iron collector and waste catalyst were accurately weighed according to the experiment scheme. These above weighed material in groups were fully mixed and sealed for subsequent experiments. The viscosity of slag with various compositions (MgO 8wt%, Al2O3 15wt%~35wt% and binary basicity wCaO/wSiO2 0.3~1.0) and temperature (1673~1973 K) were measured by the rotating spindle method and calculated by FactSage6.4. Lastly, the smelting experiment was carried out by resistance furnace with molybdenum disilicide heating unit. The effects of binary basicity and smelting temperature on recovery rate of palladium were evaluated. The mass of waste catalyst involved in each static smelting experiment was 200 g, and the mass ratio of iron collector to waste catalyst was 0.2, i.e. 40 g, and after these materials were fully mixed with fluxes, they were held in the furnace with argon atmosphere for 1 h. After the smelting process, the crucible was removed from the furnace and the melted material was allowed to completely solidify by air-cooling. Later, the hot and solid products were removed for further water quenching process, and then the ferroalloy was separated from slag, cleaned, and weighed for subsequent assays. The specific diagram of flow sheet in this work is shown in

Fig.1 Flow sheet of the developed process
The content of palladium in glass slag and ferroalloy in smelting process were analyzed by ICP method, and the recovery rate of palladium was defined as:
RPd=AP/(AP+SP)×100% | (1) |
where RPd is the recovery rate of palladium, AP is the mass (g) of palladium concentrated into the ferroalloy phase, SP is the mass (g) of palladium remained in the glass slag phase.
X-ray diffraction (XRD, PANalytical X'pert PRO diffract-meter, 2θ=5°~90°, Cu Kα radiation) of the cooled glass slag and ferroalloy powders was conducted to detect the characteristic of phase. The detailed compositions of waste catalyst and glass slag were measured with X-ray fluorescence (XRF, ZSX Primus II, Rigaku Corporation, Japan). The SEM (SEM-EDS, SU800) was employed to obtain microscopic images and EDS patterns of the alloy.
The system of SiO2-CaO-Al2O3-MgO is selected as target slag due to its wide use in pyrometallurgy and glass manufacturing field

Fig.2 Liquidus isotherms diagram of SiO2-CaO-Al2O3 ternary system
MgO acts as basic oxide and oxygen supplier which breaks the discrete silica network and renders the slag more fluid. So, liquidus temperature of the slag system decreases with increasing MgO content in a certain range

Fig.3 Change of liquid region with MgO content in SiO2-Al2O3-CaO-MgO ternary system under 1500 °C/1.01×1
The viscosity and liquidus temperature of slag system are important factors in the smelting process, which are usually determined by the composition or basicit

Fig.4 Viscosity of quaternary slag system with different binary basicity C/S and Al2O3 content at 1823 K
Based on the above results, the effect of binary basicity C/S on recovery rate of palladium was evaluated by smelting experiment at 1823 K, and the corresponding results are shown in
vT=(ρm-ρs)dmg/(18μ) | (2) |
where vT is the terminal velocity of the settling metal droplet, dm is the diameter of the metal droplet, ρm is the density of metal droplet, ρs is the density of molten slag, μ is molten slag viscosity and g is gravity.
The separation velocity between metallic particle and slag is inversely proportional to slag viscosity according to
The temperature is an important factor on physicochemical properties of molten slag system, which affects the smelting process directl

Fig.5 Temperature dependence of slag viscosity under different Al2O3 contents at C/S=0.5
In order to obtain an effective recovery of palladium, as well as to achieve an energy efficient process, the smelting temperature should be investigated and optimized by the experiment. In this work, the temperature range of 1673~1923 K was used in optimization experiments according to the liquidus isotherms diagram of slag system and empirical temperature from Ref.[

Fig.6 Influence of smelting temperature on recovery rate of palladium at C/S=0.5
It is observed that the recovery rate of palladium increases significantly with the increase of smelting temperature from 1673 K to 1823 K. This may be due to the fact that the high smelting temperature is conductive to the silicate network to be broken, resulting in the depolymerization of complex units in the molten slag. Therefore, it is consistent with the results in
Based on above analysis, the optimal smelting process was conducted under the following conditions: the mass fractions of waste catalyst and MgO in the initial material are 30wt% and 8wt%, respectively, the C/S is 0.5, and the smelting tem-perature and time are 1823 K and 1 h, respectively. Then, the produced glass slag and ferroalloy were analyzed by a variety of analysis techniques such as XRF, ICP, XRD, and SEM-EDS. The detailed characteristics of glass slag and ferroalloy were obtained, and the palladium recovery efficiency was evaluated.

Fig.7 XRD patterns of the ferroalloy (a) and glass slag (b) from pilot-scale experiment
The corresponding details of chemical composition for the ferroalloy and glass slag from three repeated experiments are listed in
A stable and reasonable glass slag was produced in this study, which is environmentally friendl

Fig.8 Macroscopic feature of glass slag

Fig.9 SEM images (a, b) and EDS results (c) of the ferroalloy from optimal smelting experiment
corresponding mass fractions are 96.09wt%, 1.05wt%, 0.96wt%, 0.83wt%, 0.31wt% and 0.76wt%, respectively, generally in agreement with the results listed in
1) Smelting-collection technology can be used to recover palladium from waste catalyst. A critical and reasonable composition of SiO2-CaO-Al2O3-MgO quaternary glass slag is proposed for the novel process. The effects of binary basicity C/S, smelting temperature, as well as viscosity of molten slag on recovery palladium are evaluated.
2) The optimal viscosity of the slag system for palladium recovery is about 0.6 Pa·s at the smelting temperature 1823 K, the corresponding mass fractions of SiO2, CaO, and MgO in the quaternary slag system are about 41.3wt%, 20.7wt%, and 8.0wt%, respectively, the binary basicity C/S ratio is 0.5, and the added waste Pd/Al2O3 catalyst in mixture is 30.0wt%. The slag from the smelting experiment is amorphous and has apparent macroscopic features of glass. The residual palladium content in the glass slag is very low and all the detected values are less than 4.50 g/t.
3) The collected palladium in ferroalloy is about 0.80wt% which is around 5 times larger than that in the waste catalyst and thousands of times larger than that in glass slag. So, with the waste Pd/Al2O3 catalyst used in this study and the optimal process conditions, the recovery rate of palladium can reach 99%. The concerned silicon content in the ferroalloy is less than 1.0wt%, which is efficiently controlled by the present novel process and benefits to the subsequent refining process.
4) The glass slag properties can obviously influence the melt fluidity and even the palladium recovery. Due to the strong effect of cavitation impinging stream on fluidity, its potential application in increasing melt fluidity to further improve metal recovery rate and efficiency will be carried out in the subsequent exploration experiment.
References
Dong Haigang, Zhao Jiachun, Chen Jialin et al. International Journal of Mineral Processing[J], 2015, 145: 108 [Baidu Scholar]
Jin Yonglee, Raju B, Kumar B N et al. Separation and Purification Technology[J], 2010, 73(2): 213 [Baidu Scholar]
Barakat M A, Mahmoud M H H, Mahrous Y S. Applied Catalysis A: General[J], 2006, 301(2): 182 [Baidu Scholar]
Paiva A P, Ortet O, Carvalho G I et al. Hydrometallurgy[J], 2017, 171: 394 [Baidu Scholar]
Steinlechner S, Antrekowitsch J. JOM[J], 2015, 67(2): 406 [Baidu Scholar]
Zhang Ruoran, Chen Qishen, Liu Quanyi et al. Resources Science[J], 2015, 37(5): 1018 [Baidu Scholar]
Zhang Mei. Mineral Exploration[J], 2010, 1(2): 114 [Baidu Scholar]
Liu Shijie. Metallurgy of Platinum Group Metals[M].Changsha: Central South University Press, 2013: 539 (in Chinese) [Baidu Scholar]
Chen Jining, Xu Shaoshi, Guo Shengkun. Shanghai Building Materials[J], 2016(4): 1 (in Chinese) [Baidu Scholar]
Rapaport D. Hydrocarb Process[J], 2000, 79(7): 49 [Baidu Scholar]
Nogueira C A, Paiva A P, Oliveira P C et al. Journal of Hazardous Materials[J], 2014, 278: 82 [Baidu Scholar]
Trinh H B, Lee J, Srivastava R R et al. Journal of Hazardous Materials[J], 2019, 379: 120 772 [Baidu Scholar]
Zhang Fuyuan, Lu Sujun. Rare Metal Materials and Engineering[J], 2021, 50(9): 3388 [Baidu Scholar]
Chen Shuai, Shen Shaobo, Cheng Yao et al. Hydrometallurgy[J], 2014, 144: 69 [Baidu Scholar]
Hasani M, Khodadadi A, Koleini S M J et al. Journal of Physics: Conference Series. IOP Publishing[C]. 2017, 786(1): 12 042 [Baidu Scholar]
Wan Jing, Yu Jianmin, Qian Lin et al. Precious Metals[J], 2012, 33: 28 [Baidu Scholar]
Baghalha M, Gh H K, Mortaheb H R. Hydrometallurgy[J], 2009, 95(3-4): 247 [Baidu Scholar]
Huang Kun. Thesis for Doctorate[D]. Kunming: Kunming University of Science and Technology, 2005 (in Chinese) [Baidu Scholar]
Li Jun, Liang Chun, Ma Chun. Journal of Material Cycles and Waste Management[J], 2015, 17(3): 529 [Baidu Scholar]
Alekseeva T Y, Karpov Y A, Dal'nova O A et al. Inorganic Materials[J], 2018, 54(14): 1421 [Baidu Scholar]
Peng Zhiwei, Li Zhizhong, Lin Xiaolong et al. JOM[J], 2017, 69(9): 1553 [Baidu Scholar]
Compernolle S, Wambeke D, De Raedt I et al. Journal of Analytical Atomic Spectrometry[J], 2011, 26(8): 1679 [Baidu Scholar]
Kolliopoulos G, Balomenos E, Giannopoulou I et al. Open Access Lib[J], 2014, 1: 1 [Baidu Scholar]
Fornalczyk A, Saternus M. Metalurgija[J], 2013, 52(2): 219 [Baidu Scholar]
Fornalczyk A, Saternus M. Acta Metallurgica Sinica (English Letters)[J], 2013, 26(3): 247 [Baidu Scholar]
Benson M, Bennett C R, Harry J E et al. Resources, Conservation and Recycling[J], 2000, 31(1): 1 [Baidu Scholar]
He Xiaotang, Li Yong, Wu Xiaolong et al. Precious Metals[J], 2016, 37(1): 1 [Baidu Scholar]
Kim B S, Lee J, Seo S P et al. JOM[J], 2004, 56(12): 55 [Baidu Scholar]
Kim B S, Lee J C, Jeong J et al. JOM[J], 2013, 54(6): 1045 [Baidu Scholar]
Shen Xiang, Chen Min, Wang Nan et al. ISIJ International[J], 2019, 59(1): 9 [Baidu Scholar]
Li Wei, Cao Xu, Jiang Tian et al. ISIJ International[J], 2016, [Baidu Scholar]
56(2): 205 [Baidu Scholar]
Kou Mingyin, Wu Shengli, Ma Xiaodong et al. Metallurgical and Materials Transactions B[J], 2016, 47(2): 1093 [Baidu Scholar]
Chen Han, Mao Chen, Zhang Weidong et al. Metallurgical and Materials Transactions B[J], 2016, 47(5): 2861 [Baidu Scholar]
Kang Xinting, Tang Huiping, Zhang Jian et al. Rare Metal Materials and Engineering[J], 2006(S2): 442 (in Chinese) [Baidu Scholar]
Cao Longhu, Liu Chengjun, Zhao Qing et al. Journal of Iron and Steel Research International[J], 2017, 24(3): 258 [Baidu Scholar]
Mombelli D, Mapelli C, Barella S et al. Process Safety and Environmental Protection[J], 2016, 102: 810 [Baidu Scholar]
He Feng, Fang Yu, Xie Junlin et al. Materials & Design[J], 2012, 42: 198 [Baidu Scholar]
Veit U, Rüssel C. Journal of Materials Science[J], 2017, 52(13): 8280 [Baidu Scholar]
Yang Shumin, Zhang Wei. Bulletin of the Chinese Ceramic Society[J], 2015, 34: 487 [Baidu Scholar]
Wang Yawen, Gui Yongliang, Song Chunyan et al. Multipurpose Utilization of Mineral Resources[J], 2018, 210(2): 1 [Baidu Scholar]
Chen Kun. Thesis for Master[D]. Wuhan: Wuhan University of Science and Technology, 2015 (in Chinese) [Baidu Scholar]
Talapaneni T, Yedla N, Sarkar S et al. Metallurgical Research & Technology[J], 2016, 113(5): 501 [Baidu Scholar]
Nakamoto M, Miyabayashi Y, Holappa L et al. ISIJ International[J], 2007, 47(10): 1409 [Baidu Scholar]
Tang Xulong, Zhang Zuotai, Guo Min et al. Journal of Iron and Steel Research International[J], 2011, 18(2): 1 [Baidu Scholar]
Szekely J. Fluid Flow Phenomena in Metals Processing[M]. New York: Academic Press, 1979 [Baidu Scholar]
Hu B. Thesis for Master[D]. Chongqing: Chongqing University, 2007 (in Chinese) [Baidu Scholar]
Gao Yunming, Wang Shaobo, Yang Yingbin et al. Journal [Baidu Scholar]
of Wuhan University of Science and Technology[J], 2013, 36(3): 161 (in Chinese) [Baidu Scholar]
Nakamura S, Iwasawa K, Morita K et al. Metallurgical and Materials Transactions B[J], 1998, 29(2): 411 [Baidu Scholar]
Hunter P B. Fuel and Energy Abstracts[J], 1998, 39(1): 54 [Baidu Scholar]
Zhou Limin, Dong Haigang, Zhao Jiachun et al. Precious Metals[J], 2015, 36(1): 17 [Baidu Scholar]
Ding Yunji. Thesis for Doctorate[D]. Beijing: University of Science and Technology Beijing, 2019 (in Chinese) [Baidu Scholar]
Li Ming, Liang Yahong, Su Juan et al. Metall Eng[J], 2017, [Baidu Scholar]
4(4): 244 [Baidu Scholar]
Mugoni C, Montorsi M, Siligardi C et al. Ceramics International[J], 2015, 41(3): 3400 [Baidu Scholar]