USH1852H - Waste treatment of metal plating solutions - Google Patents

Waste treatment of metal plating solutions Download PDF

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Publication number
USH1852H
USH1852H US08/985,822 US98582297A USH1852H US H1852 H USH1852 H US H1852H US 98582297 A US98582297 A US 98582297A US H1852 H USH1852 H US H1852H
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Prior art keywords
solution
metal
precipitate
dissolved
waste
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Abandoned
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US08/985,822
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English (en)
Inventor
Celia L. Alexander
Anthony M. Mariniello
Brian A. McBride
Michael M. Cook
David A. Dunn
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Morton International LLC
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Morton International LLC
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Priority to US08/985,822 priority Critical patent/USH1852H/en
Priority to CA002251480A priority patent/CA2251480A1/en
Priority to EP98309898A priority patent/EP0922678A1/de
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Publication of USH1852H publication Critical patent/USH1852H/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F9/00—Multistage treatment of water, waste water or sewage
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/70—Treatment of water, waste water, or sewage by reduction
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00—Nature of the contaminant
    • C02F2101/10—Inorganic compounds
    • C02F2101/20—Heavy metals or heavy metal compounds

Definitions

  • This invention relates to a process for the waste treatment of metal-bearing solutions to substantially eliminate the dissolved metal content in such solutions prior to discharge to the environment and, more particularly, to a process for the waste treatment of spent metal plating solutions which will enable such solutions to be discharged as non-toxic waste directly to a municipal wastewater treatment plant.
  • Solutions capable of plating metals onto substrates are widely used in industry.
  • the most commonly used metal plating solutions include electrolytic and electroless solutions.
  • Electroless nickel plating solutions have come into widespread usage in the manufacture of computer memory discs.
  • Such solutions generally contain a nickel metal salt, such as the sulfate, acetate, carbonate or chloride salt, for the source of dissolved metal plating ions, a reducing agent, such as sodium hydrosulfite, sodium hypophosphite, sodium borohydride, boranes or hyrdazines, to reduce the metal ions to metallic form, a complexing or chelating agent, such as monocarboxylic acids, dicarboxylic acids, hydroxycarboxylic acids, amino acids, and alkanolamines, to maintain the metal ions in solution and prevent premature precipitation, and a pH adjuster to maintain the solution pH typically within an acidic range of 4-5. Accelerators, stabilizers, buffers, and wetting agents may also be included in the electroless nickel solutions.
  • electroless nickel solutions only have a limited useful life and eventually become depleted or spent.
  • concentration is reduced of both the complexed metal in solution (by plate-out onto the substrate) and the reducing agent (by consumption according to the chemical reaction controlling plating) to where the plating rate of the electroless bath is slowed sufficiently to become unsatisfactory, and the bath has to be discarded.
  • a number of wastewater treatment processes have been proposed to reduce the metal content in spent electroless solutions to low levels prior to discharge.
  • many users of electroless baths simply dosed their wastes with caustic soda to precipitate the bulk of the heavy metal contaminant as insoluble hydrous oxides (metal hydroxides), whereupon the hydrous oxide sludge was pressed into a filter cake, drummed, and disposed.
  • This method of metal removal was known to produce a very large quantity of metal-bearing sludge, all of which needed to be disposed of in approved hazardous landfills.
  • Sludge disposal is very expensive, environmentally detrimental, wasteful of natural resources, and involves compliance with local, state and federal regulations.
  • the sludge producer assumes perpetual liability for the sludge deposited in the landfill site which is undesirable.
  • Another problem with this treatment method is that it is inefficient and generally did not work well due to the high chelant levels in the spent solutions.
  • Another waste treatment method previously used for spent electroless solutions was to simply electrolessly plate out the metal by dosing the solution at slightly alkaline pH with reducing agents.
  • the reducing agents typically used to convert the dissolved metal salt into insoluble metal precipitate include sodium borohydride, sodium hydrosulfite, sodium hypophosphite, boranes and hydrazines.
  • An advantage of this method is that the metal-bearing sludge produced contains high levels of elemental metal which can be reclaimed by smelting and sold at a profit. Therefore, hazardous waste disposal of the sludge is no longer required. Plainly, this method is economical, environmentally friendly, and conserves natural resources.
  • One drawback, however, is that the soluble nickel content in the treated electroless nickel baths can only be partially reduced. Generally, the nickel content can only be lowered to about 3-70 parts per million (ppm) which no longer meets the discharge limits in most jurisdictions.
  • Still another prior waste treatment method known for reducing the dissolved metal content of spent electroless baths to acceptable discharge levels involves organosulfur precipitation of the metal by dosing the spent solution at a pH of 5-8 with water-soluble sodium dithiocarbamate (DTC) precipitating agents, such as sodium dimethyldithiocarbamate (DTC-Na).
  • DTC water-soluble sodium dithiocarbamate
  • DTC-Na sodium dimethyldithiocarbamate
  • the dissolved metal salt complexes with the soluble dithiocarbamate salts to form insoluble metal dithiocarbamate precipitates.
  • the metal dithiocarbamate particles are generally very fine and not conducive to settling, and typically require the aid of coagulants and flocculants to form larger, faster settling flocs which are more capable of removal by filtration.
  • the dithiocarbamate method effectively removes the heavy metal content in spent electroless baths to non-detectable levels, but undesirably produces huge quantities of heavy metal-bearing carbamate sludge which create potentially dangerous hydrolytic loading on the typical liquid-solid system. Furthermore, these sludges must be classified as hazardous waste and disposed of predominantly in approved hazardous landfills. Here again, sludge disposal is very expensive, environmentally detrimental, and wasteful of natural resources.
  • Yet another object of this invention is to provide a waste treatment process which conserves natural resources by generating, for the most part, a sludge containing high levels of solid metal compounds, including elemental metal ore, which can be recovered and reclaimed, rather than disposed of as a hazardous waste.
  • Still another object of this invention is to provide a waste treatment process which reduces the dissolved metal content down to the low parts per million and, in most cases, down to fractional parts per million.
  • Yet another object of this invention is to provide a waste treatment process which can treat multiple metal-bearing wastewater streams, which previously required separate treatments.
  • Yet another object of this invention is to provide an apparatus suitable for use in performing such a waste treatment process.
  • a process for the waste treatment of metal-bearing wastewater solutions containing dissolved chelated or non-chelated metals, particularly electroless nickel plating solutions, whereby the treated solution can be discharged directly to a municipal wastewater treatment plant or to the environment.
  • the process comprises the sequential steps of chemical reduction, followed by organosulfur precipitation, with an intermediate filtration step and pH adjustment interposed there between.
  • the first step comprises borohydride reduction and the second step comprises dithiocarbamate precipitation.
  • the heavy metal content in the precipitated matter produced in the first stage of this process can ultimately be recovered as metal, essentially eliminating the need for large volumes of hazardous waste disposal.
  • FIG. 1 represents a flow chart showing the currently preferred process and apparatus for waste treatment of spent electroless nickel solutions in accordance with this invention.
  • This invention provides a sequential, two-step, simple, efficient, economical, and environmentally favorable, waste treatment process for metal-bearing wastewater solutions, particularly spent electroless nickel plating solutions, which can lower the dissolved metal content in such solutions to acceptable levels, generally on the order of about ca. ⁇ 3 ppm and preferably ca. ⁇ 0.5 ppm, so that the solutions can be discharged directly into a wastewater treatment plant stream or a natural stream.
  • the metal-bearing solutions to be waste treated may come form a variety of sources such as metal process streams from mining and metallurgical operations, electrolytic and electroless metal plating baths, other metal recovery operations, such as ion exchange, and chemical manufacture, and the like.
  • Metal-bearing solutions containing heavy metals, such as nickel, copper, cobalt, silver, gold, lead, mercury, platinum, and any other metals reduced or precipitated by alkali metal borohydrides may be treated according to this invention. Such metals can be found throughout the transition metals, lanthanides, actinides, and post-transition metals.
  • metal-bearing solutions that contain heavy metals, such as zinc, which are not reduced by alkali metal borohydrides but can be precipitated by alkali thiocarbamates may also be treated according to this invention.
  • the invention is particularly effective in treating metal-bearing waste solutions containing dissolved nickel.
  • the following description of this invention will be directed to the treatment of discarded or spent electroless nickel plating solutions.
  • Spent electroless nickel solutions to be treated usually contain substantial quantities of dissolved nickel.
  • the dissolved nickel content can vary within very wide limits dependent upon the source of the specific solution treated.
  • the nickel content of a conventional spent electroless nickel solution to be treated in accordance with this invention usually varies between about 4,000-6,000 ppm (4-6 grams/liter). Consequently, a successful waste treatment process permitting direct disposal of the solution to the environment should comprise lowering the dissolved metal content in the solution to non-toxic discharge levels generally on the order of ca. ⁇ 3 ppm Ni, and preferably ca. ⁇ 0.5 ppm.
  • the waste treatment process of this invention is amenable to batchwise or continuous processing, although batchwise processing is presently preferred.
  • the first step in the waste treatment of the spent electroless nickel plating solution is removal of the dissolved metal from solution by chemical reduction, particularly borohydride or borohydride catalyzed reduction.
  • the spent electroless solution to be waste treated is first contacted with a reducing agent for a sufficient time to cause the dissolved metal salt to undergo chemical reduction, resulting in the precipitation of metal compounds out of the solution.
  • a preferred method for accomplishing this is by the addition of an alkali or alkaline earth metal borohydride, preferably sodium borohydride from an economic standpoint, to the spent electroless nickel solution.
  • the sodium borohydride is usually added as an aqueous solution of sodium borohydride and sodium hydroxide (for hydrolytic stability of the borohydride ion and reduction of hydrogen gas evolution).
  • An example of a suitable hydrolytically stabilized borohydride reduction solution is sold under the trademark VenMet® by Morton International, Inc. of Chicago, Ill.
  • the amount of sodium borohydride solution used will vary depending upon the particular system for which treatment is desired and will mainly be influenced by the metal content of the waste solution and the presence of other ligands and chelant molecules.
  • sodium borohydride vis-a-vis the dissolved metal content
  • the sodium borohydride solution is added in a sufficient amount to provide at least about 4 to 15 times the amount of sodium borohydride required to reduce the waste metal in the spent electroless nickel solution.
  • less than stoichiometric levels of borohydride can be employed as the borohydride reduced nickel often catalyzes additional hypophosphite reduction of the chelated nickel ions in solution.
  • Adjustment of the pH of the electroless nickel solution before the addition of sodium borohydride is generally desired to maximize the rate of sodium borohydride reduction.
  • the borohydride reduction can be carried out in a pH range of between about 4 and 11 and preferably in a range of between 7 and 11.
  • the pH adjustment is typically accomplished with the addition of sufficient quantities of alkaline agents, such as sodium hydroxide, calcium hydroxide, magnesium hydroxide, and lime, or mixtures thereof, to the electroless nickel solution before the addition of the sodium borohydride solution. Normally between about 200 and 2,000 ppm of lime is employed and then final pH adjustment is made to the solution.
  • oxidizer scavenging agents such as sodium bisulfite, sodium metabisulfite, and sodium sulfite, or mixtures thereof, to the reaction mixture in order to minimize consumption of the sodium borohydride prior to metal reduction.
  • This material is typically added to the spent solution at a low solution pH of about 4-5 prior to final pH adjustment. Normally between about 200 and 2,000 ppm of bisulfite is employed in this first treatment stage.
  • the treated solution is allowed to settle and the nickel-bearing precipitate which results from such treatment is separated from the treated electroless solution by conventional solid-liquid separation techniques, such as decantation or filtration.
  • solid-liquid separation techniques such as decantation or filtration.
  • the precipitate is allowed to settle and is then withdrawn from the bottom of the reaction vessel as a sludge.
  • the sludge is then passed through a filter press to separate the precipitate as a filter cake from the treated liquid.
  • the filter cake which contains high levels of metallic nickel compounds is desirably transported to a smelting operation to recover elemental nickel which can be reused in various chemical processes, instead of being disposed as hazardous waste in a landfill.
  • the dissolved nickel content in the essentially precipitate-free treated solution following borohydride reduction is typically between about ca. 3-70 ppm.
  • the second step in the sequential treatment process of this invention is the removal of substantially all of the remaining dissolved metal content from the treated solution by organosulfur precipitation, particularly thiocarbamate precipitation.
  • organosulfur precipitation particularly thiocarbamate precipitation.
  • the solution prior to this treatment stage is essentially free of precipitated matter generated from the first treatment stage. This prevents the reduction precipitate from interfering with the subsequent thiocarbamate precipitation, and allows for direct contact between the precipitating agent and the remaining nickel in the treated solution. Furthermore, cross-contamination of precipitates is eliminated, which preserves the high purity of the reduction precipitate.
  • the treated electroless solution is contacted with an organosulfur precipitating agent, such as a thiocarbamate, for a sufficient time to form an insoluble metal organosulfur precipitate.
  • organosulfur precipitating agent such as a thiocarbamate
  • a convenient method for accomplishing this is by the addition of a water-soluble alkali and alkaline earth metal polythiocarbamate to the treated electroless nickel solution.
  • particularly useful water-soluble alkali metal polythiocarbamates include sodium dimethyldithiocarbamate, sodium diethydithiocarbamate, sodium trithiocarbamate, and the like.
  • the alkali metal dialkyldithiocarbamates are most desirable, particularly sodium dimethyldithiocarbamate. Specific examples of sodium dimethyldithiocarbamates are those sold under the trademark Metal PlexTM 143 by Morton International, Inc. of Chicago, Ill.
  • the sodium thiocarbamate vis-a-vis the metal content
  • the sodium thiocarbamate is used in an amount sufficient to provide at least about 20 times the amount required to precipitate the waste metal as insoluble nickel thiocarbamate complexes.
  • Adjustment of the solution pH before precipitation is effected is generally desired.
  • the pH of the electroless solution is typically lowered to between about 5-8 prior to the addition of the thiocarbamate precipitating agent with appropriate pH adjusters, such as nitric acid, sulfuric acid, acetic acid, or hydrochloric acid.
  • appropriate pH adjusters such as nitric acid, sulfuric acid, acetic acid, or hydrochloric acid.
  • Suitable flocculation agents useful herein include anionic polymers, such as anionic polyacrylamides.
  • anionic polymers such as anionic polyacrylamides.
  • An example of a flocculation agent based on an anionic polyacrylamide is sold under the trademark MetaFlocTM 495 by Morton International, Inc. of Chicago, Ill.
  • Suitable coagulation agents include cationic polymers, such as cationic polyquarternary amines and cationic polyacrylamides.
  • a coagulation agent based on cationic polyquarternary amine is sold under the trademark MetaFlocTM 137 by Morton International, Inc. of Chicago, Ill. It is generally desirable to first add from about 50 to 300 ppm of the cationic polymer to the reaction mixture to coagulate the precipitated particulates, followed by the addition of from about 1 to 10 ppm of the anionic polymer to bridge the coagulated particulates together to form larger, faster settling flocs. Usually, it is also desirable to add between about 400 and 2,400 ppm of dry diatomaceous earth to the reaction mix. The diatomite acts as a filtering aid by further building-up the size of the particulates.
  • the treated solution is allowed to settle and the nickel-bearing precipitate which results from the second stage of the treatment is separated from the electroless solution by conventional solid-liquid separation techniques, such as decantation or filtration.
  • the precipitated floc is allowed to settle and is then withdrawn from the bottom of the reaction vessel as a sludge.
  • the sludge is then transported to a filter press to separate the precipitate as a filter cake from the treated liquid.
  • the filter cake containing the insoluble nickel thiocarbamate complex can either be mixed with the sludge produced from the first step and smelted together, or discarded separately as hazardous waste in a landfill.
  • the two-step treated liquid can then be pumped directly to a municipal wastewater treatment facility or a natural stream. It is usually desirable to filter the treated liquid prior to discharge, since residual particulates may be present in the liquid extracted from the filter press.
  • the nickel content in the electroless nickel solution following thiocarbamate precipitation and prior to discharge is typically about ca. ⁇ 3 ppm Ni and more typically about ca. ⁇ 0.5 ppm.
  • the inventors have also surprisingly found that incorporation of other metal removal process waste streams, such as zincate waste (a zinc caustic solution) and ion exchange regenerate waste (a nickel acidic solution), into the spent electroless nickel feed solutions can be accomplished without adversely affecting the final nickel levels.
  • metal removal process waste streams such as zincate waste (a zinc caustic solution) and ion exchange regenerate waste (a nickel acidic solution)
  • zincate waste a zinc caustic solution
  • ion exchange regenerate waste a nickel acidic solution
  • a waste electroless nickel solution 10 along with optional zincate waste solution 12 and optional ion exchange regenerate waste solution 14, is fed at room temperature to a first reaction vessel 16 equipped with a stirrer 18.
  • a first reaction vessel 16 equipped with a stirrer 18.
  • sodium metabisulfite 20 and lime 22 to facilitate reduction and filtration are added and the pH of the solution is then raised to the 7-11 range with the addition of sodium hydroxide 24.
  • excess stabilized sodium borohydride reduction solution 26 (VenMet® solution) is added. Agitation is continued until substantial completion of the borohydride reduction reaction.
  • the borohydride reduction reaction can be represented by the following equation:
  • X the anion (chloride, sulfate, carbonate, acetate).
  • agitation is discontinued and the solid precipitate is allowed to settle as a slurry or sludge 28.
  • the sludge 28 can be drawn off the bottom of the reaction vessel 16 and fed to a filter press 30 where the treated liquid is separated from the solid precipitate.
  • the filter cake 32 which contains high concentrations of solid nickel compounds is drummed and set aside for subsequent nickel recovery by a smelting operation (not shown).
  • the treated liquid 34 containing substantially reduced levels of nickel and being essentially free of solids is then fed at room temperature to a second reaction vessel 36 equipped with a stirrer 38.
  • nitric acid 40 which may be drawn from a spent acid stream, is added to lower the pH of the solution to within the range of 5-8.
  • excess sodium dimethyldithiocarbamate 42 (Metal PlexTM 143) is added. Agitation is continued until substantial completion of the organosulfur precipitation reaction.
  • the organosulfur precipitation reaction is represented by the following equation:
  • a coagulant 44 (MetaFlocTM 137) is added and mixed until sufficient coagulation, then a flocculant 46 (MetaFlocTM 495) is added and mixed until sufficient flocculation, and lastly sufficient dry diatomaceous earth 48 is added and mixed until the desired build-up of the precipitate is complete.
  • the agitation is then discontinued and the solid organosulfur precipitate is allowed to settle as a slurry or sludge 50.
  • the sludge 50 can then be drawn off the bottom of the reaction vessel and fed to a filter press 52 where the treated liquid is separated from the solid precipitate.
  • the filter cake 54 containing essentially all remaining nickel is minimal and can be combined with the filter cake 32 that resulted from the borohydride treatment.
  • the treated liquid 56 is then fed through a filter 58 (0.2 micron filter) to ensure removal of any residual solid particulates from the solution. Also, as shown in FIG. 1, at start-up the treated liquid 56 may be returned back to the second reaction vessel 36 instead of being initially passed through the filter 58 to prevent unwanted clogging of the filter.
  • the filtered liquid 60 can then be safely discharged directly into a wastewater treatment plant stream or a natural stream (not shown).
  • 500 mL of spent electroless nickel solution was placed in a beaker with a magnetic stir bug. 250 ppm Na 2 S 2 O 5 was added to the electroless nickel solution. The pH of the solution was then raised from pH 5 to 10.5 with 500 ppm of lime and 50% NaOH solution. 6 mL of VenMet® reduction solution (12 mL/L) was placed in a small beaker and diluted approximately 2:1 with water. The diluted VenMet® solution was poured directly into the pH adjusted electroless nickel solution. The small beaker was rinsed once with water and the rinse was also poured into the electroless nickel solution. Using moderate agitation the solution was mixed for 4 hours.
  • the electroless nickel solution was removed from agitation and filtered through a #4 Whatman® filter paper to remove the solids.
  • the pH of the solution was then lowered to pH 7 with 35% nitric acid solution.
  • 4 mL of Metal PlexTM 143 (20 mL/L) was added to the reduced and filtered solution. This was allowed to mix for 1 hour using moderate agitation.
  • 100 ppm of MetaFlocTM 137 was added to the solution and allowed to mix for 10 minutes.
  • 2 ppm of MetaFlocTM 495 was added and allowed to mix for 10 minutes.
  • 2 mL (dry) diatomaceous earth (10 mL/L) was added and allowed to mix for 10 minutes.
  • the treated solution was then filtered through a 0.2 ⁇ m syringe filter for analysis.
  • the final nickel content in the treated solution was ca. ⁇ 0.1 ppm.
  • the pH of the solution was then lowered to pH 8 with 35% nitric acid solution.
  • 10 mL of Metal PlexTM 143 50 mL/L was added to the reduced and filtered solution and allowed to mix for 1 hour using moderate agitation. After the 1 hour 100 ppm of MetaFlocTM 137 was added to the solution and mixed for 10 minutes. Then 2 ppm of MetaFlocTM 495 was added and mixed for 10 minutes. Lastly, 2 mL (dry) diatomaceous earth (10 mL/L) was added and mixed for 10 minutes. The treated solution was then filtered through a 0.2 ⁇ m syringe filter for analysis. The final nickel content in the treated solution was ca. ⁇ 0.1 ppm and the final zinc content in solution was ca. 0.16 ppm.

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  • Life Sciences & Earth Sciences (AREA)
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US08/985,822 1997-12-05 1997-12-05 Waste treatment of metal plating solutions Abandoned USH1852H (en)

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Application Number Priority Date Filing Date Title
US08/985,822 USH1852H (en) 1997-12-05 1997-12-05 Waste treatment of metal plating solutions
CA002251480A CA2251480A1 (en) 1997-12-05 1998-10-26 Waste treatment of metal plating solutions
EP98309898A EP0922678A1 (de) 1997-12-05 1998-12-03 Behandlung vom Metallplattierungsabwasser

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US08/985,822 USH1852H (en) 1997-12-05 1997-12-05 Waste treatment of metal plating solutions

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US6352675B1 (en) * 1999-06-07 2002-03-05 Nalco Chemical Company Process for removing heavy metals from a caustic fluid stream
US20030085177A1 (en) * 2001-11-06 2003-05-08 Dubin Valery M. Method of treating an electroless plating waste
US6797195B1 (en) * 1995-05-19 2004-09-28 Lawrence Kreisler Method for recovering and separating metals from waste streams
US20050178048A1 (en) * 2001-11-13 2005-08-18 Lumsden Charles A. Aqueous borohydride compositions
US7601264B2 (en) 2006-10-04 2009-10-13 Applied Materials, Inc. Method for treatment of plating solutions
US7833583B2 (en) 2007-03-27 2010-11-16 Trevor Pearson Method of recycling electroless nickel waste
US20160060133A1 (en) * 2014-08-27 2016-03-03 Baker Hughes Incorporated Removal of metals and cations thereof from water-based fluids
CN113549990A (zh) * 2021-06-11 2021-10-26 洛阳吉瓦新材料科技有限公司 一种电镀金刚石线锯上砂镀液的处理方法
CN115837141A (zh) * 2022-11-05 2023-03-24 云南大地丰源环保有限公司 一种废弃硼氢化钾或硼氢化钠的处理方法

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EP2585185A4 (de) * 2010-06-23 2013-10-30 Veolia Water Solutions & Tech Verfahren zur reduzierung der sulfatkonzentration in einem abwasserstrom
CN104355457B (zh) * 2014-11-23 2016-03-16 云南驰宏锌锗股份有限公司 一种将污酸中汞富集分离的方法

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