Cost-Effective and High Purity Valuable Metals Extraction from Water Leaching Solid Residues Obtained as a By-Product from Processing the Egyptian Boiler Ash

The water leaching solid residues (WLSR) obtained from salt-roasting Egyptian boiler ash are considered an essential secondary resource for (13%) nickel and (5.6%) zinc extraction. Hence, the current study aims for the cost-effective and high purity Ni, Zn, Fe and Mg metal ion extraction from (WLSR) using a sulfuric acid leaching process. The factors affecting the percentage recovery of Ni, Zn, Fe and Mg from WLSR, including leaching temperature, time, acid concentration and solid/liquid ratio, have been investigated. The obtained leaching solutions were analyzed chemically using ICP, and the different precipitates were analyzed mineralogically using XRD and EDX analysis and chemically using XRF. The maximum percentage recovery of Ni, Zn, Fe and Mg was 95.02%, 90.13%, 66.29% and 75.73%, which was obtained under the optimum leaching conditions of 8% H2SO4 concentration and 1/15 solid/liquid ratio at 85 ◦C for 240 min. The effect of pH, Fe2O3 dosage as nucleating agent and the precipitation duration on iron removal and Ni and Zn loss have been thoroughly studied. It has been found that >95% of the contained iron impurity can be removed, while nickel and zinc losses are around 4.2% and 3.8%, respectively. Additionally, a pH of 6 and 0.45 mol/L concentration of H2C2O4 was utilized to precipitate Mg as MgC2O4·2H2O, demonstrating that the precipitation efficiency of Mg reaches 96.9%. Nickel and zinc precipitation efficiency was 92.25% and 85.51%, respectively, by raising the solution pH to approximately 9.