Resource Recovery and Recycling from Waste Metal Dust

Preface
Contents
Part I: Resource Recovery and Recycling from Waste Metal Dust
	Chapter 1: Resource Recovery and Recycling from Waste Metal Dust (I): Waste Iron Dust and Waste Aluminum Dust
		1.1 Waste Metal Dusts
		1.2 Types of Waste Metal Dusts
			1.2.1 Waste Iron Dust
				1.2.1.1 Generation
				1.2.1.2 Description of WID
					Particle Size Distribution of WID
					Chemical Composition of Typical WID
					Mineralogy of WID
					Morphology of WID
				1.2.1.3 Stabilization/Solidification for Recirculation or Disposal of WID
				1.2.1.4 Resource Recovery and Recycling from WID
					The Recovery of Metals from WID
					Conversion of WSD into Value-Added Product
			1.2.2 Waste Aluminum Dust
				1.2.2.1 Generation
				1.2.2.2 Description of WAD
					Particle Size Distribution of WAD
					Chemical Composition of Typical WAD
					Mineralogy of WAD
					Morphology of WAD
				1.2.2.3 Recirculation of WAD
				1.2.2.4 Resource Recovery and Recycling from WAD
		1.3 Conclusions
		References
	Chapter 2: Resource Recovery and Recycling from Waste Metal Dust (II): Waste Copper Dust
		2.1 Introduction
		2.2 Waste Copper Dust
			2.2.1 Generation
			2.2.2 Description of WCD
				2.2.2.1 Particle Size Distribution of WCD
				2.2.2.2 Chemical Composition of Typical WSD
				2.2.2.3 Mineralogy of WCD
				2.2.2.4 Morphology of WCD
			2.2.3 Recirculation of WCD
			2.2.4 Resource Recovery and Recycling from WCD
				2.2.4.1 The Recovery of Metals from WCD
					The Use of Hydrometallurgical Techniques
					The Use of Bio-Hydrometallurgy Techniques
					The Use of Pyrometallurgical–Hydrometallurgical Techniques
					The Use of Physical Separation Techniques
					Stabilization/Solidification
					Conversion of WCD into Value-Added Product
		2.3 Conclusions
		References
Part II: Pre-treatment of Waste Copper Dust
	Chapter 3: Pre-treatment of Waste Copper Dust (I): Potential of Oxidative Roasting–Density Separation–Sulphuric Acid Leaching Technology for Copper Recovery
		3.1 Introduction
		3.2 Experimental Method
			3.2.1 Material
			3.2.2 Methods
				3.2.2.1 Pre-Treatment Methods
					Oxidative Roasting
					Density Separation Method
		3.3 Results and Discussion
			3.3.1 Effect of Pre-Treatments on Mineralogy of WCD
				3.3.1.1 Oxidative Roasting
				3.3.1.2 Density Separation
				3.3.1.3 Effect of Pre-Treatment on Classification of WCD
				3.3.1.4 Effect of Pre-Treatment on Micro-Porosities
				3.3.1.5 Effect of Pre-Treatment on Surface Area, Pore Volume, and Pore Diameter of CSD
		3.4 Conclusions
		References
	Chapter 4: Pre-treatment of Waste Copper Dust (II): Optimum Predictive Models and Experimental Data Error Margin
		4.1 Introduction
		4.2 Experimental Method
			4.2.1 Materials
				4.2.1.1 Waste Metal Dust (WMD)
				4.2.1.2 Methods
					Design of Experiment (DOE)
					Modelling
		4.3 Results and Discussion
			4.3.1 Model Development for Outputs from OR and DS
				4.3.1.1 Different Experimental Conditions and Constraints for OR
					Categorizing Constraint Models for OR
				4.3.1.2 Different Experimental Conditions and Constraints for DS
					Categorizing Constraint Models for DS
				4.3.1.3 Data Error Margin for OR
		4.4 Conclusions
		References
Part III: Extraction of Copper Oxide
	Chapter 5: Extraction of Copper Oxide (I): Purified CuSO4 Solution
		5.1 Introduction
		5.2 Materials and Methods
			5.2.1 Material
			5.2.2 Methods
				5.2.2.1 Sampling Using Rotary Splitter
				5.2.2.2 Sampling Using the Coning and Quartering Method
				5.2.2.3 Particle Size Distribution (PSD) of As-Received WCD
				5.2.2.4 Calculations for Preparing Sulfuric Acid Solution
				5.2.2.5 Leaching Parameters
				5.2.2.6 Experimental Procedures for Sulfuric Acid Leaching
					Experimental Procedure for Leaching of WCD Using Hotplate with Stirrer
					Experimental Procedures for Leaching of WCD Using a Laboratory Oven
				5.2.2.7 Sample Filtration
				5.2.2.8 Proposed Process Flow Diagram
		5.3 Results and Discussion
			5.3.1 Visual Observation of As-Received WCD
			5.3.2 Digital Hotplate Leaching Process of WCD
			5.3.3 Visual Analysis of Residue After Leaching Process
			5.3.4 Visual Analysis Digital Hotplate Leachate
			5.3.5 Visual Analysis on Oven Leachate
			5.3.6 Results on Mass Balance: Digital Hotplate
				5.3.6.1 Test 1 Hotplate Leaching Results for 2 M H2SO4
				5.3.6.2 Test 2 Hotplate Leaching Results for 2 M H2SO4
				5.3.6.3 Test 1 Hotplate Leaching Results for 4 M H2SO4
				5.3.6.4 Test 2 Hotplate Leaching Results for 4 M H2SO4
				5.3.6.5 Test 1 Hotplate Leaching Results for 6 M H2SO4
				5.3.6.6 Test 2 Hotplate Leaching Results for 6 M H2SO4
			5.3.7 Results on Mass Balance: Oven
				5.3.7.1 Test 1 Oven Leaching Results for 2 M H2SO4
				5.3.7.2 Test 2 Oven Leaching Results for 2 M H2SO4
				5.3.7.3 Test 1 Oven Leaching Results for 4 M H2SO4
				5.3.7.4 Test 2 Oven Leaching Results for 4 M H2SO4
				5.3.7.5 Test 1 Oven Leaching Results for 6 M H2SO4
				5.3.7.6 Test 2 Oven Leaching Results for 6 M H2SO4
				5.3.7.7 Test 1 Oven Leaching Results for 8 M H2SO4
				5.3.7.8 Test 2 Oven Leaching Results for 8 M H2SO4
				5.3.7.9 Test 1 Oven Leaching Results for 10 M H2SO4
				5.3.7.10 Test 2 Oven Leaching Results for 10 M H2SO4
			5.3.8 Graphical Leaching Results for Digital Hotplate
				5.3.8.1 Digital Hotplate Leaching for 2 M H2SO4 Test Work
				5.3.8.2 Digital Hotplate Leaching for 4 M H2SO4 Test Work
				5.3.8.3 Digital Hotplate Leaching for 6 M H2SO4 Test Work
				5.3.8.4 Oven Leaching for 2 M H2SO4 Test Work
				5.3.8.5 Results for Oven Leaching of 4 M H2SO4
				5.3.8.6 Results for Oven Leaching of 6 M H2SO4
				5.3.8.7 Results for Oven Leaching of 8 M H2SO4
				5.3.8.8 Results for Oven Leaching of 10 M H2SO4
			5.3.9 Production of Purified Pregnant Leach Solution from Leachate
		5.4 Conclusion
		References
	Chapter 6: Extraction of Copper Oxide (II): Copper Oxide Nanoparticles
		6.1 Introduction
		6.2 Experimental Method
			6.2.1 Material
				6.2.1.1 Waste Metal Dust
			6.2.2 Methods
				6.2.2.1 Production of Pregnant Leach Solution (PPLS)
				6.2.2.2 Design of Experiment and Procedure for Production of Copper Precursor
				6.2.2.3 Design of Experiment and Procedure for Production of CuO-NPs from Copper Precursor
		6.3 Results and Discussion
			6.3.1 Mineralogy of Copper Precursor
				6.3.1.1 Mineralogy of Copper Precursor Produced Under TC 25 °C/340 rpm
				6.3.1.2 Mineralogy of Copper Precursor Produced Under TC 25 °C/740 rpm
				6.3.1.3 Mineralogy of Copper Precursor Produced Under TC 25 °C/1480 rpm
				6.3.1.4 Mineralogy of Copper Precursor Produced Under TC 55 °C/340 rpm
				6.3.1.5 Mineralogy of Copper Precursor Produced Under TC 55 °C/740 rpm
				6.3.1.6 Mineralogy of Copper Precursor Produced Under TC 55 °C/1480 rpm
				6.3.1.7 Mineralogy of Copper Precursor Produced Under TC 85 °C/340 rpm
				6.3.1.8 Mineralogy of Copper Precursor Produced Under TC 85 °C/740 rpm
				6.3.1.9 Mineralogy of Copper Precursor Produced Under TC 85 °C/1480 rpm
				6.3.1.10 Optimum TC for Production of Copper Precursor
			6.3.2 Mineralogy of Copper Oxide Nanoparticles
				6.3.2.1 Mineralogy of CuO-NPs Produced under 650 °C/1 h
				6.3.2.2 Mineralogy of CuO-NPs Produced under 650 °C/2 h
				6.3.2.3 Mineralogy of CuO-NPs Produced under 650 °C/3 h
				6.3.2.4 Mineralogy of CuO-NPs Produced Under 750 °C/1 h
				6.3.2.5 Mineralogy of CuO-NPs Produced Under 750 °C/2 h
				6.3.2.6 Mineralogy of CuO-NPs Produced Under 750 °C/3 h
				6.3.2.7 Mineralogy of CuO-NPs Produced Under 850 °C/1 h
				6.3.2.8 Mineralogy of CuO-NPs Produced Under 850 °C/2 h
				6.3.2.9 Mineralogy of CuO-NPs Produced Under 850 °C/3 h
				6.3.2.10 Optimum TC for Production of CuO-NPs
			6.3.3 Characterization of CuO-NPs
				6.3.3.1 SEM
				6.3.3.2 TEM
		6.4 Conclusions
		References
Part IV: Thermal and Mechanical Properties
	Chapter 7: Thermal and Mechanical Properties (I): Optimum Predictive Thermal Conduction Model Development for Epoxy-Filled Copper Oxide Nanoparticles Composite Coatings on Spent Nuclear Fuel Steel Casks
		7.1 Introduction
		7.2 Problem Statement
		7.3 Research Objectives
			7.3.1 Main Objective
			7.3.2 Sub-Objectives
		7.4 Research Hypotheses
		7.5 Significance of Study
		7.6 Literature Review
			7.6.1 Background and Literature Survey
				7.6.1.1 Background
					Transportation of SNF
					Types of Casks for Transportation of SNF
					Steel
					Surface Coatings
					Epoxy Coatings
			7.6.2 Literature Survey
				7.6.2.1 Introduction
					Intrinsically Thermally Conductive Epoxy (ITCE) Coatings
					Filled-Type Thermally Conductive Epoxy (FTCE) Composites Coatings
				7.6.2.2 Review of Publications on Anticorrosion Properties and Interfacial Thermal Resistance of Epoxy Composite Coatings
					Anticorrosion Property of Epoxy Composites Coatings
					Interfacial Thermal Resistance of Epoxy Composite Coatings
				7.6.2.3 Review of Publications on Neutron Shielding, Anticorrosion Properties and interfacial Thermal Resistance of CuO-NPs-Epoxy Composite Coatings
					Neutron Shielding Capacity of Epoxy-CuO-NPs Coatings
					Thermal Conductivity of Epoxy-CuO-NPs Coatings
					Anticorrosion and Mechanical Properties of Epoxy-CuO-NPs Coatings
				7.6.2.4 Thermal Conduction Models and Inner Mechanisms of Thermally Conductive Epoxy Composite
		7.7 Methodology
			7.7.1 Materials and Methods
				7.7.1.1 Materials
					WCD
					Epoxy-Resin
					Steel
				7.7.1.2 Methods
					Density Separation of WCD
					Design of Experiment and Procedure for Production of Copper Precursor from Concentrates
					Design of Experiment and Procedure for Production of CuO-NPs from Copper Precursor
					Preparation and Polymerization of Hybrid Nanocomposite Coatings by Electron Beam Radiation
					Development of Predictive Models
					Experimental Validation and Simulation
					Characterization of the Developed Epoxy-CuO-NPs Composite Coatings
					Measurement of the Basic Properties of the Developed Epoxy-CuO-NPs Composite Coatings
					Corrosion Tests
					Weight Loss Measurements
					Thermal Conductivity Measurements
		7.8 Contribution to Knowledge
		7.9 Ethical Considerations
		7.10 Dissemination
		7.11 Budget and Time Frame
			7.11.1 Budget
			7.11.2 Time Frame
		References
	Chapter 8: Thermal and Mechanical Properties (II): Spark Plasma Sintered Ti–6Al–4V Alloy Reinforced with Mullite-Rich Tailings for Production of Energy Efficient Brake Rotor
		8.1 Introduction
		8.2 Problem Statement
		8.3 Research Objectives
			8.3.1 Main Objective
			8.3.2 Sub-Objectives
		8.4 Research Hypotheses
		8.5 Significance of Study
		8.6 Literature Review
			8.6.1 Introduction
			8.6.2 Theoretical Background
				8.6.2.1 Titanium and Ti–6Al–4V Alloy
				8.6.2.2 Mullite
				8.6.2.3 Design of Brake Rotors
			8.6.3 Review: Use of TI–6Al–4V Alloy to Design Brake Rotors
				8.6.3.1 Problem Definition and Solution Formulation of Ti–6Al–4V Alloy for Design of Vehicle Brake Rotors
					Problem Definition
					Solution Formulation
				8.6.3.2 Additive Manufacturing of Ti–6Al–4V Alloy and Effect on Its Wear and Thermal Conductivity Properties as Material for Design of Brake Rotors
					Microstructural Modification of Ti–6Al–4V Alloy
					Coating of Ti–6Al–4V Alloy
					Reinforcement
					Secondary Resource of Mullite as Reinforcement to Ti–6Al–4V Alloy
					Manufacturing Method
		8.7 Methodology
			8.7.1 Materials
				8.7.1.1 Matrix Material
				8.7.1.2 Reinforcement Materials
				8.7.1.3 Equipment and Tools
				8.7.1.4 Methods
					Powder Weighing
					Powder Mixing
					Density Measurement
					Process Optimization
					Spark Plasma Sintering
					Development of Predictive Models
					Experimental Validation and Simulation
					Characterization and Tribological Measurement
		8.8 Contribution to Knowledge
		8.9 Ethical Considerations
		8.10 Dissemination
		8.11 Budget and Time Frame
			8.11.1 Budget
			8.11.2 Time Frame (Table 8.9)
		References
Part V: Other Engineering Applications
	Chapter 9: Wave Energy Converter Design: Seawater Integrity and Durability of Epoxy Resin-Filled Corrosive Microorganism Surface-Modified Waste Copper Dust
		9.1 Introduction
		9.2 Problem Statement
		9.3 Research Objectives
			9.3.1 Main Objective
			9.3.2 Sub-Objectives
				9.3.2.1 To Determine the Following Mechanical Properties of Unmodified Epoxy Resin
				9.3.2.2 To Optimize the Following Mechanical Properties of Epoxy Resin-Filled Synthetic Copper Powder Without Surface Modification
				9.3.2.3 To Optimize the Following Mechanical Properties of Epoxy Resin-Filled Synthetic Copper Powder with Surface Modification
				9.3.2.4 To Optimize the Following Mechanical Properties of Epoxy Resin-Filled Synthetic Aluminum Powder Without Surface Modification
				9.3.2.5 To Optimize the Following Mechanical Properties of Epoxy Rresin-Filled Synthetic Aluminum Powder with Surface Modification
				9.3.2.6 To Optimize the Following Mechanical Properties of Epoxy Resin-Filled WCD Without Surface Modification
				9.3.2.7 To Optimize the Following Mechanical Properties of Epoxy Resin-Filled WCD with Surface Modification
				9.3.2.8 To Determine the Effect of Seawater Aging on Tensile Strength and Fatigue Strength of the Following Composites Chosen at Optimum Test Conditions
				9.3.2.9 Development of Optimum Predictive Models for the Different Epoxy Resin Composites and the Experimental Validation of Optimum Predictive Models
		9.4 Research Hypotheses
		9.5 Significance of Study
		9.6 Background and Literature Survey
			9.6.1 Background
				9.6.1.1 Physicochemistry
				9.6.1.2 Adhesion
					Mechanical Adhesion
					Proper Adhesion
				9.6.1.3 Adhesive
					Phenolic
					Acrylic
					Cyanoacrylate
					Urethane
					Epoxy Resins
			9.6.2 Literature Survey
				9.6.2.1 Modification of Epoxy Resin with Fiber Reinforcement
					Effect of External Pressure (i.e., Cyclic Loads) on Epoxy Resin-Bonded Polymer Composite Performance
					Effect of Internal Pressure (i.e., Water) on Epoxy Resin-Bonded Polymer Composite Performance
					Combined Effect of External and Internal Pressures on Epoxy Resin-Bonded Polymer Composite Performance
				9.6.2.2 Modification of Epoxy Resin with Powder Fillers
					Epoxy Composite
					Powder Fillers
				9.6.2.3 Physical Parameters of Powder Fillers
					Specific Surface
					Shape
				9.6.2.4 Surface Modification Methods
					Acidic or Basic Solutions
					Coupling Agents
					Microorganisms
		9.7 Methodology
			9.7.1 Materials and Methods
				9.7.1.1 Materials
					Unmodified Epoxy Resin
					Curing Agent
					Filler
					Surface Modifying Agent
				9.7.1.2 Methods
					Preparation of Unmodified and Modified Epoxy Resin
					Optimization of Mechanical Properties of Adhesive with Filler
					MATLAB Code Used for Model Development
					Experimental Validation and Simulation
					Shape, Dimension, and Fabrication of the Unmodified and Modified Samples
					Combined Cyclic Loading and Seawater Aging
					Microstructural Analysis of Deformed Samples
		9.8 Contribution to Knowledge
		9.9 Ethical Considerations
		9.10 Dissemination
		9.11 Budget (Table 9.13)
		9.12 Time Frame (Table 9.14)
		References
	Chapter 10: Aircraft Engine Fan Blade Design: Impact Tolerance Prediction of Partially Filled 3D Printed Aluminum, Titanium, and PEEK-Filled Waste Metal Dusts
		10.1 Introduction
		10.2 The Problem Statement
		10.3 Research Hypotheses
		10.4 Research Objectives
			10.4.1 Main Objectives
			10.4.2 Sub-Objectives
		10.5 The Assumptions
		10.6 The Project Deliverables
		10.7 Importance of Study
			10.7.1 Benefits to the Academia, Research, and Development
			10.7.2 Benefits to the Industry
			10.7.3 Benefits to South Africa
		10.8 Overview of the Study
		10.9 Literature Review
			10.9.1 Introduction
			10.9.2 Review of Publications: Present and Past
				10.9.2.1 Review of Articles on the Impact of Infill Density on the Mechanical Characteristics of 3D Printed Components
				10.9.2.2 A Review of Publications on Selective Laser Melted Aluminum Alloys for Development of Aerospace Components
				10.9.2.3 An Analysis of Articles on the Use of Selective Laser Melting to Create PEEK for Aerospace Components
				10.9.2.4 A Review of Works on Selective Laser Melting of Ti–6Al–4V for Use in Aerospace Parts
		10.10 Research Methodology
			10.10.1 Material Study and Selection
				10.10.1.1 Material Study
				10.10.1.2 Material Selection
					Unmixed Material
					Composite Materials
			10.10.2 Methods
				10.10.2.1 Scaling and Similitude of Turbine Blade
				10.10.2.2 Optimization in the Abaqus Environment Using TOSCA
				10.10.2.3 Impact Analysis in Abaqus Based on Tosca’s Optimal Solutions
				10.10.2.4 3D Printing of the Turbine Blade
				10.10.2.5 Experimental Validation
				10.10.2.6 Measurements and Microstructural Analysis of Damaged Samples
					Scanning Electron Microscopy (SEM)
					Electron Backscatter Diffraction (EBSD)
					X-Ray Diffraction (XRD)
		10.11 Project Plan and Financial Budget
			10.11.1 Project Plan
			10.11.2 Financial Budget
		References
Part VI: Preparation and Characterization of Hydrotalcite-Derived Material from Mullite-Rich Tailings
	Chapter 11: Preparation and Characterization of Hydrotalcite-Derived Material from Mullite-Rich Tailings (I): Transesterification of Used Cooking Oil to Biodiesel
		11.1 Introduction
		11.2 Problem Statement
		11.3 Research Objectives
			11.3.1 Main Objective
			11.3.2 Sub-objectives
		11.4 Research Hypotheses
		11.5 Significance of Study
		11.6 Literature Review
			11.6.1 Introduction
			11.6.2 Biodiesel Production in South Africa
			11.6.3 Manufacturing Cost of Biodiesel in South Africa
			11.6.4 The Choice of Feedstock and Its Impact on Biodiesel Production
			11.6.5 Soybean in South Africa
			11.6.6 Waste from Soybean Production
			11.6.7 Proactive Measures for South Africa’s Biodiesel Industry
			11.6.8 Transesterification of WCO to Biodiesel
			11.6.9 Production of Hydrotalcite from Natural Resources
				11.6.9.1 Natural Dolomite
				11.6.9.2 Bittern
				11.6.9.3 Blast Furnace Steel Slag
				11.6.9.4 Aluminum Slag
				11.6.9.5 Oil Shale Ash
				11.6.9.6 Coal Fly Ash
				11.6.9.7 Mullite-Rich Tailings from Density-Separated Waste Copper Dust (WCD)
		11.7 Methodology
			11.7.1 Introduction
				11.7.1.1 Materials
					Waste Cooking Oil
					Waste Metal Dusts
				11.7.1.2 Methods
					Preparation of WCO Feedstock for Transesterification
					Density Separation of WCD
					Optimization of Hydrotalcite Production from MRT
					Optimization of Catalytic Activity
					Characterization of Biodiesel
			11.7.2 Contribution to Knowledge
			11.7.3 Ethical Considerations
			11.7.4 Dissemination
			11.7.5 Budget (Table 11.12)
			11.7.6 Time Frame (Table 11.13)
		References
	Chapter 12: Preparation and Characterization of Hydrotalcite-Derived Material from Mullite-Rich Tailings (II): CO2 Capture from Coal-Fired Thermal Power Plants
		12.1 Introduction
		12.2 Problem Statement
			12.2.1 Economic Problems
			12.2.2 Environmental Problems
			12.2.3 Social Problems
		12.3 Research Objectives
			12.3.1 Main Objective
			12.3.2 Sub-Objectives
		12.4 Research Hypotheses
		12.5 Significance of Study
		12.6 Literature Review
			12.6.1 Introduction
			12.6.2 Review: Past and Current Publications
				12.6.2.1 A Review of Works on the Definition of Problems and Formulation of Solutions
					Problem definition
					Solution Formulation
				12.6.2.2 Review of Publications on Technological Routes for CO2 Capture
					Absorption Technology
					Membrane Separation Technology
					Cryogenic Separation Technology
					Adsorption Technology
				12.6.2.3 Review of Papers on Various Fly Ash-Based Sorbent Types That Have Been Prepared and Characterized
					Potassium-Based Sorbents
					Activated Carbon
					Sodium Silicate Sorbents
					Mesoporous Silica Materials
				12.6.2.4 CO2 Aluminosilicate Sorbents
					Zeolites
					Hydrotalcites (HT)
				12.6.2.5 Preparation and Characterization of Hydrotalcite-Derived Material from Various Feedstocks
					Natural Dolomite
					Bittern
					Blast Furnace Steel Slag
					Aluminum Slag
					Oil Shale Ash
					Coal Fly Ash
					Mullite-Rich Tailings
		12.7 Methodology
			12.7.1 Materials and Methods
				12.7.1.1 Materials Description and Preparation
				12.7.1.2 Methods and Processes
					Density Separation of WCD
					Synthesis of Hydrotalcite HTMRT
					Characterization and Measurement
					CO2 Sorption on Synthesized HTMRT
		12.8 Contribution to Knowledge
		12.9 Ethical Considerations
		12.10 Dissemination
		12.11 Budget (Table 12.6)
		12.12 Time Frame (Table 12.7)
		References
Index