US20120273431A1 - Zero valent iron/iron oxide mineral/ferrous iron composite for treatment of a contaminate fluid - Google Patents

Zero valent iron/iron oxide mineral/ferrous iron composite for treatment of a contaminate fluid Download PDF

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US20120273431A1
US20120273431A1 US13/509,963 US201013509963A US2012273431A1 US 20120273431 A1 US20120273431 A1 US 20120273431A1 US 201013509963 A US201013509963 A US 201013509963A US 2012273431 A1 US2012273431 A1 US 2012273431A1
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iron
treatment system
reactive
zone
wastewater
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Yongheng Huang
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Texas A&M University System
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    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/70Treatment of water, waste water, or sewage by reduction
    • C02F1/705Reduction by metals
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/02Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
    • B01J20/0203Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising compounds of metals not provided for in B01J20/04
    • B01J20/0225Compounds of Fe, Ru, Os, Co, Rh, Ir, Ni, Pd, Pt
    • B01J20/0229Compounds of Fe
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/02Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
    • B01J20/06Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising oxides or hydroxides of metals not provided for in group B01J20/04
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30Processes for preparing, regenerating, or reactivating
    • B01J20/3085Chemical treatments not covered by groups B01J20/3007 - B01J20/3078
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/72Treatment of water, waste water, or sewage by oxidation
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/001Processes for the treatment of water whereby the filtration technique is of importance
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/28Treatment of water, waste water, or sewage by sorption
    • C02F1/281Treatment of water, waste water, or sewage by sorption using inorganic sorbents
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/66Treatment of water, waste water, or sewage by neutralisation; pH adjustment
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/72Treatment of water, waste water, or sewage by oxidation
    • C02F1/74Treatment of water, waste water, or sewage by oxidation with air
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/103Arsenic compounds
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/106Selenium compounds
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/108Boron compounds
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/12Halogens or halogen-containing compounds
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/16Nitrogen compounds, e.g. ammonia
    • C02F2101/163Nitrates
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/20Heavy metals or heavy metal compounds
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/20Heavy metals or heavy metal compounds
    • C02F2101/203Iron or iron compound
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/10Inorganic compounds
    • C02F2101/20Heavy metals or heavy metal compounds
    • C02F2101/22Chromium or chromium compounds, e.g. chromates
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00Nature of the contaminant
    • C02F2101/30Organic compounds
    • C02F2101/36Organic compounds containing halogen
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/06Contaminated groundwater or leachate
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/18Nature of the water, waste water, sewage or sludge to be treated from the purification of gaseous effluents
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/34Nature of the water, waste water, sewage or sludge to be treated from industrial activities not provided for in groups C02F2103/12 - C02F2103/32
    • C02F2103/36Nature of the water, waste water, sewage or sludge to be treated from industrial activities not provided for in groups C02F2103/12 - C02F2103/32 from the manufacture of organic compounds
    • C02F2103/365Nature of the water, waste water, sewage or sludge to be treated from industrial activities not provided for in groups C02F2103/12 - C02F2103/32 from the manufacture of organic compounds from petrochemical industry (e.g. refineries)
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W10/00Technologies for wastewater treatment
    • Y02W10/30Wastewater or sewage treatment systems using renewable energies
    • Y02W10/37Wastewater or sewage treatment systems using renewable energies using solar energy

Definitions

  • Wastewater treatment is one of the most important and challenging environmental problems associated with coal-based power generation.
  • wet scrubbers to clean flue gas is becoming more popular worldwide in the electrical power industry. In the coming years, hundreds of wet scrubbers will be installed in the US alone. While wet scrubbers can greatly reduce air pollution, toxic metals in the resulting wastewater present a major environmental problem. The industry prepares to invest billions of dollars in the next decade to meet more the ever more stringent environmental regulations; unfortunately, a cost-effective and reliable technology capable of treating such complicated wastewater is still not available.
  • compositions of FGD wastewaters vary greatly, depending not only on the types of coal and limestone used but also on the types of scrubber and processes used. Pretreatment method and management practices also affect wastewater characteristics. According to a recent survey by EPR1 (2006), untreated raw FGD wastewater could have TSS in ⁇ 10,000 mg/L but after settlement, it falls to ⁇ 10 mg/L; the pH typically falls in 5.8-7.3; sulfate is in the range of 1,000-6,000 mg/L; nitrate-N at level of 50 mg/L is not uncommon; chloride, alkalinity and acidity vary from hundreds to thousands ppm; selenium exists in various forms, ranging from dozens of ppb to over 5 ppm, among which, selenate could account for about half of total Se; arsenic ranges from a few ppb to hundreds of ppb; mercury ranges from below 1 ppb to dozens of ppb; and boron can be as high as hundreds of ppm.
  • Se selanate-Se
  • Se is a naturally occurring chemical element in rocks, soils and natural waters.
  • Se is an essential micronutrient for plants and animals, it can be toxic at elevated levels and some of Se species may be carcinogenic.
  • the hexavalent selenium is stable in oxic environments and exists as the selenate (SeO 4 2 ⁇ ) anion, which is weakly sorbed by mineral materials and generally soluble.
  • Tetravalent Se is the stable valence state under mildly reducing or anoxic condition (0.26 V ⁇ Eh ⁇ 0.55 V at pH 7).
  • a biological treatment system ABMet
  • ABMet A biological treatment system, ABMet, has been patented and is being marketed by GE Water.
  • the present inventor has developed a chemical treatment process that can cost-effectively treat all major pollutants in the flue gas desulfurization (FGD) wastewater in a single process.
  • FGD flue gas desulfurization
  • the present inventor developed a fluidized reacting system using a hybrid reactive solid/secondary reagent reactor that can cost-effectively remove many toxic metals from wastewater.
  • the system and process are effective to treat an aqueous suspension.
  • the system uses a reactive solid and a secondary reagent as reactive agents to rapidly reduce selenate to become insoluble selenium species, which are then adsorbed or precipitated along with various of other toxic metals (such as As and Hg, if present) in wastewater onto the iron oxide sludge.
  • the system is particularly effective for removing selenate-Se.
  • the present process is effective for removing almost all concern toxic metals in an aqueous suspension; in addition, it can remove oxyanion pollutants and metalloids. More particularly, contaminants removable by the present system and process are: most toxic metals such as arsenic, mercury, selenium, cobalt, lead, cadmium, chromium, silver, zinc, nickel, molybdenum, and the like; metalloid pollutants such as boron and the like; many oxyanion pollutants, such as nitrate, bromate, iodate, and periodate, and the like; and the like.
  • the present system and process use common, non-toxic, and inexpensive chemicals.
  • the present chemical treatment system costs much less to construct and operate than biological treatment systems, which tend to be more complex.
  • the present system and process are versatile and flexible.
  • the present system and process are more robust and manageable than a biological process when exposed to toxic chemicals or any disturbances and changes in wastewater quality and quantity.
  • FIG. 1 is a schematic illustrating a single-stage fluidized bed reactor
  • FIG. 2 is a flow chart illustrating a three-stage reaction system
  • FIG. 3 is a schematic illustrating a single-stage fluidized bed ZVI/FeOx/Fe(II);
  • FIGS. 4A , 4 B are pictures illustrating a bench scale single-stage reactor
  • FIGS. 5A , 5 B are pictures illustrating an alternative bench scale single-stage reactor
  • FIGS. 6A. 6B , 6 C are pictures illustrating a bench scale three-stage ZVI/FeOx/Fe(II) fluidized-bed reactor system.
  • FIG. 7 shows three panels of pictures illustrating settling of a mixture of Fe 0 and magnetite powder rich of surface bound Fe(II); pictures taken after settling for 1 min (left panel), 3 min (middle), and 6 min (right).
  • the present inventors have discovered a novel system for treating wastewater. Experiments have demonstrated the system operable for removal of selenium present as selenate.
  • a reactor system includes zero valent iron.
  • ferrous iron is added to a reactor system.
  • the present inventor believes that ferrous iron acts as a passivation reversal agent for zero valent iron.
  • the mechanism is complex. While not wishing to be limited by theory, the present inventor believes that passivation is partially caused by corrosion of iron in a water environment.
  • the present inventor believes that ferrous iron acts to cause conversion of iron corrosion product on the surface of the zero valent iron to magnetite.
  • a sufficient amount of magnetite is produced so as to optimize removal of toxic materials by a reaction system including zero valent iron.
  • the process produces removable solids.
  • the removable solids contain toxic material encapsulated in magnetite.
  • the encapsulated toxic material is solid.
  • the process uses a highly reactive mixture of zerovalent iron (Fe 0 ), iron oxide minerals (FeOx), and ferrous iron (Fe II ) to react with, absorb, and precipitate various toxic metals and metalloids from wastewater, forming chemically inert and well crystallized magnetite (Fe 3 O 4 ) particles that can be separated from water and disposed with encapsulated pollutants.
  • Fe 0 zerovalent iron
  • FeOx iron oxide minerals
  • Fe II ferrous iron
  • the reactive zone is maintained near neutral pH.
  • the present inventor believes that boron in the wastewater further contributes to passivation and that ferrous iron removes boron form the zero valent iron.
  • wastewater is illustrative of an aqueous suspension.
  • the present inventor contemplates treating oil refinery waste. Further, the present inventor contemplates treating wetlands.
  • selenium is illustrative of a toxic material.
  • Other common toxic materials are contemplated.
  • the present inventor contemplates removing arsenic, mercury, cobalt, lead, cadmium, chromium, silver, zinc, nickel, molybdenum, and the like; metalloid pollutants such as boron and the like; many oxyanion pollutants, such as nitrate, bromate, iodate, and periodate, and the like; and the like.
  • ferrous iron is illustrative of a secondary reagent.
  • the secondary reagent is desirable adapted to act as a passivation reversal agent.
  • Passivation is generally the process of rendering an active material, for example zero valent zinc, inactive.
  • Aluminum ion, Al 3+ may substitute for (e.g. added as aluminum sulfate) for ferrous iron.
  • iron is illustrative of a reactive solid. The present inventor believes that iron is particularly practical. However, the present inventor contemplates other treatment materials.
  • the treatment material is zinc.
  • a reactive system may include the treatment material in zero valent form.
  • the reactive system further includes a passivation reversal agent suitable for the zero valent form as may be advantageous.
  • a reactor includes an internal settling zone in communication with a reactive zone.
  • the reactor is illustrated in schematic in FIG. 1 .
  • the internal settling zone uses gravitational forces to separate solids from liquids. According to some embodiments, mostly liquids remain in the settling zone.
  • the internal settling zone is towards the top of the reactor ( FIG. 1 ).
  • communication with the reactive zone is via an inlet at the bottom of the internal settling zone.
  • effluent is removed from the top region of the internal settling zone.
  • the effluent is very clear. Magnetite is known to be black. Settling observed in an experiment over time is illustrated in FIG. 3 of the document “pilot test scale plan” appended hereto, which shows clearer separation of black material and clear fluid over time. The present inventor believes that settling for a separating method is particularly efficient. However, other suitable separating methods are contemplated.
  • a reactive zone includes a central conduit.
  • the central conduit improves mixing.
  • the central conduit promotes convective motion.
  • the reactor system operates as a fluidized bed that employs a motorized stirrer in conjunction with a central flow conduit to create a circular flow within the reactor and provide an adequate mixing between reactive solids and wastewater.
  • An internal settling zone was created to allow solid-liquid separation and return of the solid into the fluidized zone.
  • FIG. 1 is a schematic illustrating an embodiment of the system and process.
  • a single-stage fluidized-bed system includes a fluidized reactive zone, an internal solid/liquid separating zone, an aerating basin, a final settling basin, and an optional sand filtration bed.
  • the fluidized zone is the main reactive space where reactive solid, in the form of particles, is completely mixed with wastewater and secondary reagent and where various physical-chemical processes responsible for toxic metal removal occur.
  • the internal settling zone is to allow particles to separate from water and be retained in the fluidized zone.
  • an internal settling zone with a short hydraulic retention time is sufficient for complete solid/liquid separation. This eliminates the need of a large external clarifier and a sludge recycling system.
  • the aeration basin has two purposes: (1) to eliminate residual secondary reagent in the effluent from fluidized zone; and (2) to increase dissolved oxygen level.
  • effluent from fluidized reactive zone will always contain certain amount of secondary reagent. Oxidation of secondary reagent will consume alkalinity and therefore will lower the pH.
  • the aeration basin should maintain a pH of above 7.0. Chemicals such as Ca(OH) 2 , NaOH and Na 2 CO 3 could be used for pH control.
  • the final settling tank is to remove flocculent formed in the aeration basin.
  • the floc (fluffy) settled to the bottom can be returned to the fluidized zone and transformed by secondary reagent into dense particulate matter.
  • a sand filtration bed may be used to further polish the treated water before discharge.
  • the post-FBR (fluidized bed reactor) stages may not be needed under certain operation conditions.
  • each stage maintain its own reactive solid. That is, the solids are separated in each stage.
  • each stage may have its own internal solid-liquid separation structure.
  • the post FBR treatments may not be needed.
  • a multi-stage system is more complex and may result in a higher initial construction cost
  • a multi-stage fluidized-bed reactor system has several major advantages.
  • a multi-stage system can achieve higher removal efficiency than a single-stage system under comparable conditions.
  • the FGD wastewater may contain certain chemicals (i.e., phosphate) that may be detrimental to the high reactivity of the reactive solids.
  • a multi-stage system can intercept and transform these harmful chemicals in the first stage and thus reducing the exposure of the subsequent stages to the negative impact of these chemicals. As such, a multi-stage configuration is more stable and robust.
  • a multi-stage configuration facilitates the control of nitrate reduction, for example in an iron-based system.
  • stage 1 can remove virtually all dissolved oxygen; as a result, the subsequent stages can be operated under rigorous anaerobic environment.
  • a multi-stage system allows flexible control of different chemical conditions in each individual reacting basin.
  • the chemical conditions in each reactive basin can be controlled by adjusting the pumping rate of supplemental chemicals and turning aeration on or off.
  • a multi-stage system can be operated in a mode of multiple feeding points. Each stage may be operated under different pH and dissolved oxygen condition.
  • a multi-stage system will lower chemical consumption.
  • secondary reagent in the reactor are desirably maintained at a relatively high concentration in order to maintain high reactivity of reactive solids.
  • the residual secondary reagent in the effluent will be high.
  • residual secondary reagent from stage 1 can still be used in stage 2.
  • secondary reagent can be added in a way that conforms to its actual consumption rate in each stage. As a result, it is possible to control residual secondary reagent in the effluent in the final stage to be much lower than the one in a single stage system.
  • the reactive solid includes zero valent iron (ZVI) and iron oxide mineral (FeOx), and the secondary reagent is Fe 2+ .
  • ZVI zero valent iron
  • FeOx iron oxide mineral
  • a single-stage fluidized-bed ZVI/FeOx/Fe(II) system includes a fluidized reactive zone, an internal solid/liquid separating zone, an aerating basin, a final settling basin, and an optional sand filtration bed.
  • the fluidized zone is the main reactive space where ZVI and FeOx reactive solids are completely mixed with wastewater and dissolved Fe 2+ and where various physical-chemical processes responsible for toxic metal removal occur.
  • the internal settling zone is to allow ZVI and FeOx to separate from water and be retained in the fluidized zone. Because of high density of fully or partially crystallized FeOx particles, an internal settling zone with a short hydraulic retention time would be suffice for complete solid/liquid separation. This eliminates the need of a large external clarifier and a sludge recycling system.
  • the aeration basin has two purposes: (1) to eliminate residual dissolved Fe 2+ in the effluent from fluidized zone; and (2) to increase dissolved oxygen level.
  • effluent from fluidized reactive zone will always contain certain amount of dissolved Fe 2+ . Oxidation of Fe 2+ will consume alkalinity and therefore will lower the pH.
  • the aeration basin should maintain a pH of above 7.0. Chemicals such as Ca(OH) 2 , NaOH and Na 2 CO 3 could be used for pH control.
  • the final settling tank is to remove iron oxide flocculent formed in the aeration basin.
  • the ferric oxide floc (fluffy) settled to the bottom can be returned to the fluidized zone and transformed by Fe 2+ into dense particulate matter.
  • a sand filtration bed may be used to further polish the treated water before discharge.
  • the reactive solid may initially be zero valent iron, with the iron oxide mineral formed in situ.
  • the iron oxide mineral may coat the zero valent iron.
  • the system can be operated under various controlled conditions as needed.
  • an iron-based technique employs a mixture of zerovalent iron (ZVI or Fe 0 ) and iron oxide minerals (FeOx), and Fe(II) species to react with, adsorb, precipitate, and remove various toxic metals, metalloids and other pollutants from the contaminated wastewater.
  • an iron-based physical-chemical treatment process that employs a hybrid Zerovalent Iron/FeOx/Fe(II) Reactor to treat toxic metal-contaminated wastewater.
  • the present system and process involve a hybrid Zerovalent Iron/FeOx/Fe(II) reactor for removing toxic metals in wastewater.
  • the process employs a fluidized bed system and use a reactive mixture of Fe 0 , Fe (II) and FeOx to absorb, precipitate, and react with various toxic metals, metalloids and other pollutants for wastewater decontamination.
  • toxic metals are encapsulated within iron oxide crystalline (mainly magnetite powder) that are chemically inert and physically dense for easier solid-liquid separation and final disposal.
  • the present inventor believes that the following are contributing mechanisms for the present iron based system and process: a) using the reducing power of Fe 0 and Fe(II) to reduce various contaminants in oxidized forms to become insoluble or non-toxic species; b) using high adsorption capacity of iron oxide surface for metals to remove various dissolved toxic metal species from wastewater; and c) promoting mineralization of iron oxides and growth of certain iron oxide crystalline so that surface-adsorbed or precipitated toxic metals and other pollutants could be incorporated into iron oxide crystalline structure and remain encapsulated in a stabilized form for final disposal.
  • the present system and process are a result of laboratory research conducted by the present inventor to develop a cost-effective method for removing toxic metals in the flue gas desulfurization wastewater generated from wet scrubbers of coal-fired steam electric power plants.
  • this chemical reactive system is suitable for general application of removing a wide spectrum of toxic metals in industrial wastewater, tail water of mining operations, and contaminated groundwater.
  • a single stage may achieve 90% selenate removal within 4 hr reaction time.
  • a three-stage system in comparison, may achieve a 96% removal rate.
  • Reactor#1 has an internal settling zone (the compartment on the left side) in which it allows reactive solid to separate from the water and be retained within the fluidized zone.
  • Reactor#2 (not shown) is identical to Reactor#1.
  • Reactor#1 and #2 both had an operating capacity of 7.2 L and had an internal settling zone (0.5 L) within the reactors ( FIGS. 4A and 4B ).
  • Reactor#3 is an integral system that has an internal settling zone (far left), an aeration basin (near left), and a second settling basin (right) within the reactor.
  • Reactor#3 had an operating capacity of 10 L. It had a built-in aeration basin (0.6 L) and a built-in final settling basin ( FIGS. 5A and 5B ).
  • Peristaltic pumps Masterflex pumps, Cole-Parmer, Illinois
  • a small aquarium air pump (purchased from Wal-Mart) as used to provide aeration.
  • a motorized stirrer (max. 27 watt, adjustable rpm 100-2000, three-blade propeller stirrer) was used to provided mixing condition.
  • Zerovalent iron powder used in the tests was obtained from Hepure Technology Inc., including I-1200+ and HCl5 (see Batch Test results for more details).
  • Other reagents used in the operation include HCl, FeCl 2 , and NaOH.
  • a magnetite coating on a ZVI particle is helpful to the success of the system.
  • Appropriate aqueous chemical conditions must be maintained for the purpose. Iron corrosion could produce various iron oxides under different chemical conditions.
  • Our batch and continuous flow reactor tests show that in order to generate magnetite from iron corrosion reaction, three conditions must be met: a pH of 6.5 to 7.5; adequate dissolved Fe 2+ that can form s.b.Fe(II); and appropriate species and concentration of oxidants.
  • Oxidants can be certain oxyanions such as selenate, nitrate, nitrite, iodate (IO 3 ⁇ ) and periodate (IO 4 ⁇ ) in the wastewater.
  • Oxidation of ZVI by these oxidants tends to form ferric oxides (most likely lepidocrocite, ⁇ -FeOOH).
  • the small quantity of ferric oxides can be transformed to magnetite in the presence of surface-adsorbed Fe(II).
  • Dissolved oxygen can also serve as an oxidant to generate magnetite (Huang et al. 2006).
  • Low-intensity aeration in the early stage could accelerate the magnetite-coating process.
  • High-intensity aeration should be avoided because it could form large quantity of ferric oxides even in the presence of dissolved Fe 2+ and moreover, it will waste ZVI.
  • Our experiences from live successful start-ups using simulated FGD wastewater indicates that in general the system will take about one to two weeks for the fresh ZVI to mature; over time, the system will gradually improve before reaching a state of high performance.
  • Nitrate would be completely reduced and in the presence of adequate dissolved Fe 2+ , a high quality (better crystallized and less amorphous, containing less ferric oxides or ferrous hydroxides) magnetite coating can be formed on ZVI particles.
  • start-up with nitrate solution would take only two days.
  • a general start up procedure and exemplary controlled parameters are:
  • Routine operations and maintenances include one or more of:
  • a pre-settling basin may be needed to reduce TSS in wastewater before entering the system. This can avoid accumulation of inert TSS in the fluidized reactive zone that might dilute the effective ZVI/FeOx solid concentration.
  • the concentration of total solid in the fluidized zone could be maintained between 80 and 120 g/L.
  • ZVI/FeOx reactive solids are considered mature when the surface of ZVI grains is covered with well crystallized magnetite (dark black color after dry) and a significant presence of discrete magnetite crystalline (may be aggregated into a larger particle due to its strong magnetic property). Unlike typical ZVI powder, matured ZVI/FeOx reactive solids will not cement easily when settled at the bottle. Therefore, the reactor could be stopped for weeks with no risk of iron powder cementation. That is, the reactor can be stopped and restarted very flexibly without a need to vacate the ZVI/FeOx mixture from the reactor.
  • Nitrate solution was also found to be very effective in rejuvenating a fouled system in which the system was accidentally acidified (pH dropped to below 4.0) for a few hours, which might permanently damage iron oxide reactivity and resulted in extremely poor performance even after returning to normal operation conditions.
  • Reactor#1, #2, and #3 was combined in sequence to form a three-stage FBRs treatment system.
  • This system was a 24-liter three-stage ZVI/FeOx/Fe(II) fluidized-bed reactor system. Initial testing on the three-stage system is described in Appendix A and Appendix D.
  • the success of the laboratory-scale prototype has paved the road for constructing a pilot-scale system and conducting extended field demonstrations to further evaluate, develop and refine the technology.
  • the present inventor contemplates a pilot-scale treatment system based on a proved laboratory-scale prototype and conduct long-term field tests to further develop the technique and finalize its design for commercialization.
  • the pilot scale test may involve one or more steps, such as: design and construct a pilot treatment system based on the laboratory prototype; conduct on-site long-term demonstrations in conjunction with further laboratory mechanistic study; collaborated closely with industry and other stakeholders to further refine the system to meet the industrial needs and environmental goals. Contemplated pilot scale tests are further described in Appendix D.
  • the present inventor contemplates an integral treatment system that can treat FGD wastewater at a flow rate of 2 to 5 gallon per minute, which represents about 1% of wastewater expected from a 1,000 megawatt power plant.
  • the pilot system may be mounted on a trailer that is adapted to be hauled to different test sites.
  • the present inventor estimates that for treating a 500 gpm FGD waste stream from a 1,000 megawatt, a iron-based system will consume per year: 200 to 400 ton of iron chemical (est. bulk price: $1,000 to $2,000/ton); 200 to 400 tons of concentrated HCl; 50-200 kilowatt electric power consumption. Further, the present inventor estimates that for treating a 500 gpm FGD waste stream from a 1,000 megawatt, a iron-based system will generate per year: 300 to 800 tons of iron oxide (weight in dry mass; laden with toxic metals), to be disposed as a hazardous waste.

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