Philosophiae Doctor - PhD / Coal fly ash has been studied extensively to understand the environmental impacts associated with its disposal, management and reuse. Although several beneficiation processes have been proposed, there has been little or no emphasis on the environmental safety of such processes, products and wastes. Elemental analysis has revealed that toxic elements and radionuclides are present in coal fly ash. Rare earth elements (REE) such as La, Ce and Y are also present in significant amounts in coal fly ash. The aims of this study were to determine the total elemental composition of coal fly ash using different analytical techniques; to validate the application potentials of fly ash beneficiation processes in terms of their environmental safety; and to valorise coal fly ash with a view of recovering REE either by concentrating or leaching the REE in the coal fly ash, products or waste from the beneficiation processes. The beneficiation processes studied were treatment of acid mine drainage (AMD) with fly ash; and the synthesis of geopolymer from fly ash. The fresh fly ash sample used in this study was collected directly from the hoppers at Matla power station and the AMD sample was collected from Carletonville goldmine. A total of 54 major, trace and REE were accurately determined in the ash using different analytical techniques. It was shown that the elemental content of Matla fly ash was of the same order as the SRM NIST coal fly ash 1633b. The comparative study of the four analytical techniques established that ENAA can accurately determine the major, minor and trace elements; that XRF is best suited for the determination of the major and minor elements, whilst the LA ICP-MS is reliable for trace elements determination. The solid residue (AMD/FA) resulting from the AMD interaction with fly ash was characterized with fly ash and the results compared. The results revealed that the amounts of La (141.09 ± 3.85 mg/kg), Ce (27.45 ± 2.04 mg/kg), and Nd (63.73 ± 0.05 mg/kg) in AMD/FA residue was considerably higher than their average abundance in the earth crust that varies from 66 mg/kg in Ce and 40 mg/kg in Nd to 35 mg/kg in La. The results also showed that the AMD/FA residue contained As (11.39 ± 1.21 mg/kg), Cd (3.77 ± 0.02 mg/kg), Cr (72.43 ± 1.27 mg/kg), Hg (10.50 ± 0.85 mg/kg), Ni (124.15 ± 1.6 mg/kg) and Pb (22.46 ± 1.43 mg/kg) which are potentially harmful if leached in to the environment in excessive amounts.

Thesis (PhD)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: Sulphuric acid/oxygen pressure leaching is typically employed on Base Metal Refineries (BMRs) to selectively dissolve base metals from platinum group metal (PGM) bearing nickelcopper matte. Optimal operation of this processing step requires an understanding of the system chemistry and the effects of process variables on base metal and PGM leaching behaviour. This project aimed to aid in the development of an improved understanding of the high pressure leaching system. The effects of temperature, pressure, acid concentration, and solid to liquid ratio on the leaching behaviour were determined experimentally using a two litre autoclave. For conditions comparable to that typically used at the Western Platinum Ltd. BMR, changes in the acid concentration had the largest effect on the copper leaching behaviour. Increasing the initial acid concentration from 140 g H2SO4/ℓ to 165 g H2SO4/ℓ resulted in the copper dissolution decreasing from 88.7% to 75.3% on average for the experiments performed at different temperatures (116°C, 130°C) and pressures (7 bar, 9 bar), and with different solids contents (80 g/ℓ, 130 g/ℓ). In the case of the other precious metals (OPMs), temperature was determined to be the process variable with the largest effect on the leaching kinetics. The average percentage rhodium dissolution achieved after seven hours of leaching at different conditions (pressure, acid concentration, and solids content were varied) increased from 58.3% at 116°C to 83.6% at 130°C. Similar effects were observed for ruthenium (96.2% dissolution at 130°C; 79.4% dissolution at 116°C) and iridium (81.8% dissolution at 130°C; 46.9% dissolution at 116°C). The rate of copper leaching was found to be limited by the rate of oxygen transfer from the gaseous phase to the liquid phase, while the remainder of the reactions were chemical reaction limited. The extent of OPM leaching was found to be dependent on the rate and extent of copper leaching. A set of 21 chemical reactions was proposed to describe the leaching behaviour, and the shape factors and reaction rate constants were determined by the method of least squares to minimise the error between the predicted concentrations and the experimental data. Apart from direct base metal leaching reactions, six cationic exchange reactions contribute to the leaching of copper sulphides and nickel sulphides by precipitation of OPM oxides. Three leaching reactions for each of the OPMs (one for sulphide phases, one for metallic phases, and one for oxide phases) resulted in satisfactory modelling of the system behaviour. Activation energies of -26.2 kJ/mol and -5.9 kJ/mol were calculated for the digenite acid leaching reaction and the covellite direct oxidation reaction, respectively, which confirmed that the rates of these reactions were mass transfer limited. The activation energies for the remainder of the base metal leaching reactions exceeded 30 kJ/mol. The activation energies of the reactions accounting for rhodium sulphide leaching, rhodium leaching, and rhodium oxide leaching, were calculated to be 64.2 kJ/mol, 138.5 kJ/mol, and 116.2 kJ/mol, respectively. Similar activation energies were calculated for the respective Ru and Ir leaching reactions. The rate of OPM sulphide leaching was typically an order of magnitude and three orders of magnitude larger than the rate of OPM leaching reactions and OPM oxide leaching reactions, respectively. The autoclave at the Western Platinum Ltd. BMR was modelled assuming a monosized distribution of the feed and approximating the autoclave as four ideal continuously stirred tank reactors. The steady state solution employed the sequential modular approach in MATLAB, while the dynamic simulation involved solving a set of 217 differential equations derived from mass and energy balances simultaneously in MATLAB. The model was used successfully to evaluate the effects that changes in the leaching temperature, leaching pressure, acid feed rate, and solids feed rate have on the extent of base metal and OPM leaching in the autoclave. The optimum operating conditions depend on the flow rates and compositions of the feed streams. A feed stream containing 10.3 wt% solids (825 kg solids/h) and an acid addition rate of 28.6 kg/h were considered as typical operating conditions for model-based analysis. More than 95% copper dissolution and no OPM dissolution were predicted when performing the pressure leaching at a pressure of 8 bar and a temperature of approximately 123°C. Decreasing the pressure resulted in lower copper dissolution when OPM leaching started to occur. Increasing the temperature resulted in reduced copper leaching, while decreasing the temperature resulted in a longer OPM leaching period and hence higher OPM dissolution. Model-based analysis furthermore showed that the relative amounts and relative leaching rates of digenite and covellite significantly influence the percentage copper dissolution achieved when noticeable OPM leaching start to occur. / AFRIKAANSE OPSOMMING: Swawelsuur/suurstof hoë druk loging word tipies op Basis Metaal Raffinaderye (BMRe) gebruik om basis metale selektief op te los vanuit platinum groep metaal (PGM) bevattende nikkel-koper mat. Optimale bedryf van hierdie prosesstap vereis ʼn begrip van die sisteem se chemie en die effekte wat proses veranderlikes op die logingsgedrag van basis metale en PGMe het. Hierdie projek het ten doel gehad om ʼn beter begrip van die hoë druk loging sisteem te ontwikkel. Die effekte van temperatuur, druk, suur konsentrasie, en vastestof tot vloeistof verhouding op die logingsgedrag is eksperimenteel met behulp van ʼn twee liter outoklaaf bepaal. Vir toestande vergelykbaar met dié wat tipies by die Western Platinum Bpk. BMR gebruik word, het veranderinge in die suurkonsentrasie die grootste effek op die logingsgedrag van koper gehad. Verhoging van die aanvanklike suurkonsentrasie van 140 g H2SO4/ℓ na 165 g H2SO4/ℓ het tot gevolg gehad dat die gemiddelde koper oplossing afgeneem het van 88.7% na 75.3% vir die eksperimente wat by verskillende temperature (116°C, 130°C) en drukke (7 bar, 9 bar), en met verskillende vastestof inhoud (80 g/ℓ, 130 g/ℓ), uitgevoer is. In die geval van die ander edelmetale (AEM) is bevind dat die temperatuur die prosesveranderlike met die grootste effek op die logingskinetika is. Die gemiddelde persentasie rodium oplossing wat na sewe ure se loging by verskillende toestande (druk, suurkonsentrasie, en vastestof inhoud is varieer) behaal is, het toegeneem van 58.3% by 116°C na 83.6% by 130°C. Soortgelyke effekte is waargeneem vir rutenium (96.2% oplossing by 130°C; 79.4% oplossing by 116°C) en iridium (81.8% oplossing by 130°C; 46.9% oplossing by 116°C). Dit is bevind dat die tempo van koper loging beperk is deur die tempo van suurstof oordrag vanaf die gas na die vloeistoffase, terwyl chemiese reaksies beperkend was vir die res van die reaksies. Die mate van AEM loging was afhanklik van die tempo en mate van koper loging. ʼn Stel van 21 reaksies is voorgestel om die logingsgedrag te beskryf, en die vorm faktore en reaksie tempo konstantes is bepaal deur middel van die metode van kleinste kwadrate om die fout tussen die voorspelde konsentrasies en die eksperimentele data te minimeer. Afgesien van die direkte basis metaal logingsreaksies het ses kationiese uitruilingsreaksies bygedra tot die loging van kopersulfiede en nikkelsulfiede deur presipitasie van AEM oksiede. Drie logingsreaksies vir elk van die AEMe (een vir die sulfied fase, een vir die metaal fase, en een vir die oksied fase) het bevredigende modellering van die sisteem se gedrag tot gevolg gehad. Aktiveringsenergieë van -26.2 kJ/mol en -5.9 kJ/mol is bereken vir die Cu1.8S suur logingsreaksie en die CuS direkte oksidasie reaksie, onderskeidelik, wat bevestig het dat die tempo’s van hierdie reaksies deur massa oordrag beperk is. Die aktiveringsenergieë vir die res van die basis metaal logingsreaksies het 30 kJ/mol oorskry. Die aktiveringsenergieë vir die reaksies wat die rodiumsulfied loging, rodium loging, en rodiumoksied loging beskryf is as 64.2 kJ/mol, 138.5 kJ/mol, en 116.2 kJ/mol, onderskeidelik, bereken. Soortgelyke aktiveringsenergieë is bereken vir die onderskeie Ru en Ir logingsreaksies. Die tempo van AEM sulfied loging was tipies ʼn ordegrootte en drie ordegroottes groter as die tempo van AEM logingsreaksie en AEM oksied logingsreaksies, onderskeidelik. Die outoklaaf by die Western Platinum Bpk. BMR is gemodelleer deur ʼn enkelgrootte verspreiding vir die voer te aanvaar en die outoklaaf as vier ideale kontinu geroerde tenk reaktore te benader. Die oplossing vir gestadige toestande het die sekwensiële modulêre benadering toegepas in MATLAB, terwyl die dinamiese simulasie die gelyktydige oplos van 217 differensiale vergelykings, wat vanaf massa- en energiebalanse afgelei is, in MATLAB behels het. Die model is suksesvol gebruik om die effekte wat veranderinge in die logingstemperatuur, logingsdruk, suur voertempo, en vastestof voertempo op die mate van basis metaal en AEM loging in die outoklaaf het, te bepaal. Die optimale bedryfstoestande is afhanklik van die vloeitempo’s en samestellings van die voerstrome. ʼn Voerstroom wat 10.3 massa% vastestof (825 kg vastestof per uur) bevat en ʼn suur voertempo van 28.6 kg/h is as tipiese bedryfstoestande beskou vir model-gebaseerde analises. Meer as 95% koper oplossing sonder enige AEM oplossing is voorspel wanneer die loging by ʼn druk van 8 bar en ʼn temperatuur van ongeveer 123°C uitgevoer word. ʼn Vermindering van die druk het tot gevolg gehad dat laer koper loging behaal is toe AEM loging begin plaasvind het. ʼn Verhoging in die temperatuur het laer koper loging tot gevolg gehad, terwyl laer temperature ʼn langer AEM logingsperiode en gevolglik hoër AEM loging tot gevolg het. Model-gebaseerde analises het verder getoon dat die relatiewe hoeveelhede en relatiewe tempo’s van loging van Cu1.8S en CuS ʼn beduidende invloed het op die persentasie koper wat geloog is wanneer beduidende AEM loging begin plaasvind.

>Magister Scientiae - MSc / Fly ash is the major waste material produced by power plants in the combustion of coal to generate electricity. The main constituents of fly ash are Si, Al, Fe and Ca with smaller amount of S, Mn, Na, K, and traces of many other elements such as Co, Cd, As, Se, Zn, Mo, Pb, B, Cu and Ni. Fly ash is usually disposed either by dry or wet disposal methods. These disposal methods have raised major environmental concerns due to the potential leaching of chemical species from the ash heap by ingress of rainfall and brine used to transport the fly ash to the dam. This study focuses on the changes in chemical composition, morphology and mineral phases due to weathering, of coal fly ash co-disposed with brine over 20 years at Sasol Secunda ash dump in Mpumalanga Province, South Africa. The design and operation of the Secunda ash dump presupposes that the ash dump may act as a sink for the salts which originated from chemicals used for normal operation in the plants. The majority of these salts come from the brines generated during desalination and raw water regeneration. The aim of this study is to ascertain if the ash dump could serve as a sustainable salt sink.Samples were drawn along the depth of two drilled cores (S1 and S3) from the weathered Secunda ash dump and analysed in conjunction with the fresh (unweathered) Secunda fly ash taken from the fly ash hoppers for comparative analysis. Scanning electron microscopy (SEM), X-ray diffractive (XRD) and X-ray fluorescence (XRF) spectrometry were employed to obtain a detailed morphological, mineralogical and bulk chemical composition of all the samples. Pore water analysis was used to determine the pH, EC and moisture content of fly ash samples. A five step sequential chemical extraction procedure was used to establish the geochemical association of particular elements with various mineral phases. The total acid digestion test was also used to determine the total elemental compositions of the Secunda fly ash samples. The SEM results showed that the fly ashes consist of irregular and numerous spherically shaped particles. Changes (encrustations, etchings and corrosion) in the morphologies of the weathered ash particles were also observed. The XRD results revealed quartz, mullite, lime and calcite as the major mineral phases. Other minerals identified in very minor quantities in the drilled Secunda ash core that were dried prior to analysis were halite, kaolinite, nitratine, bassanite, microline. and hydrophitte. These phases may have formed during sample handling. XRF investigation revealed that the major oxides present in the dumped ash samples were SiO₂, A₂2O₃, CaO, Fe₂O₃, MgO, Na₂O, TiO₂ and the minor elements present were K₂O, P₂O₅, SO₃ and MnO. The sum of the mean values of the % composition of SiO₂, Al₂O₃, and Fe₂O₃ was 70.19 %, and 72.94 % for the two drilled ash core samples (S1 and S3) respectively, and 78.67 % for the fresh ash which shows the significant alteration of the Si, Al and Fe content in the ash matrix over time. The fly ash is classified as Class F using the ASTM C 618 standards. The loss on ignition (LOI) which is an indication of unburned carbon or organic content was 4.78 %, 13.45 % and 8.32 % for the fresh ash, drilled ash cores S1 and S3 respectively. The high LOI values for the drilled ash cores could indicate high hydrocarbon content in the ash dump because of co-disposal practises where hydrocarbon waste are included in the brine stream for disposal on the ash. While the ash samples from the surface appeared dry, moisture content (MC) analysis showed that there is considerable water entrained in the fly ash dump. The fresh ash MC was 1.8 % while core S1 ranged from 41.4 – 73.2 %; core S3 ranged from 21.7 – 76.4 %. The variations in the MC values can be attributed to uneven flow paths due to inconsistent placement conditions or variations in ambient weather conditions during placement. The fresh fly ash (n=3) had a pH of 12.38±0.15, EC value of 4.98±0.03 mS/cm and TDS value of 2.68±0.03 g/L, the pH of the drilled ash core S1 (n=35) was 10.04 ±0.50, the EC value was 1.08±0.14 mS/cm and the TDS value was 0.64 ±0.08 g/L. Core S3 (n=66) had pH of 11.04±0.09; EC was 0.99 ±0.03 and TDS was 0.57 ± 0.01. The changes in pH values can be attributed to the dissolution and flushing out from the dump basic alkaline oxides like CaO and MgO These variations in pH values shows that the fly ash is acidifying over time and metal mobility can be expected under these conditions. The large decrease of EC in the drilled ash cores S1 and S3 compared to the fresh ash indicated a major loss of ionic species over time in the ash dump. The sequential extraction scheme revealed that the elements Al, Si, Ca, Mg, Ba, Sr, Fe, Mn, Na, K, As, Pb, Cr, Mo, Cu, Ni and Zn are present in Secunda fresh and weathered fly ash and are partitioned between the water soluble, exchangeable, carbonate, iron and manganese, and residual fractions of the coal fly ash. It also showed that the trace elements As, Pb, Cr, Mo, Cu, Ni and Zn do not show permanent association with particular mineral phases as a continuous partitioning between different mineral phases was observed in the weathered drilled core. Generally, all the elements had the highest concentration in the residual fraction. But it was evident that the labile phase (water soluble, exchangeable and carbonate fractions) had fairly high concentrations of Si (± 6.5 %), Al (± 6.5 %), Ca (±10 %), Mg (± 5.5 %), Ba (± 7.5 %),Sr (± 7.5 %), Na (± 12 %) and K (± 12 %) for the Secunda drilled ash core (S1 and S3) and fresh fly ash samples. This indicates that these species can leach easily upon water ingress and could pose a danger to the environment. Na and K had the highest concentrations leached out in the labile phase in all the ash samples. The amount of Na leached out of the drilled Secunda ash core in the labile phase was 13.21 % of 18584.26 mg/kg in the five geochemical phases of core S1; and 9.59 % of 11600.17 mg/kg in the five geochemical phases of core S3 while the fresh Secunda fly ash leached out 11.28 % of 16306.30 mg/kg of Na in the five geochemical phases. This study provided significant insight into the pore water chemistry, morphology, mineralogy and chemical composition and the elemental distribution pattern of the major and trace elements in the Secunda fly ash and weathered drilled Secunda ashm core S1 and S3. Though results from XRF analysis and the sequential extraction scheme shows that Na, K, S, Ca and Mg were slightly captured from the co-disposed brine by the Secunda fly ash, these species were however released in the labile phase. Hence there was no significant retention of these species in the ash dump. The amount of these species retained in the weathered ash were (0.26 % and 0.55 %) for Na, (0.02 % and 0.34 %) for K, (0.08 % and 0.06 %) for S, (0.94 % and 0.01 %) for Ca and (0.37 % and 0.96 %) for Mg in drilled ash cores S1 and S3 respectively. This poor retention of Na K, S, Ca and Mg which are major components of Sasol Secunda brine in the drilled ash cores S1 and S3 clearly shows the unsustainability of the Secunda fly ash dump as a salt sink.

Mineralogical and geochemical characteristics of metallurgical wastes from the Cu-Co smelters situated in the Zambian Copperbelt have been investigated. A number of instrumental analytical methods (XRD, SEM/EDS, EPMA, TEM/EDS) has been used to identify primary and secondary phases in smelter slags and dusts. A set of leaching experiments (CEN/TS 14997 pH-static test, EN 12457 batch test) in combination with geochemical modelling has been performed, with the emphasis on the leaching behaviour of potential contaminants and their release as a function of the pH. The effect of sample preparation on metal leachability from slag was also evaluated, considering the grain size reduction required by the standardised leaching protocols. Environmental and health risk assessments of the dust samples have been performed. It was shown that the main carriers of metals in the studied slags were Cu sulphides (bornite, digenite, chalcocite), Co sulphides (cobaltpentlandite), Co-bearing intermetallic phases and alloys. Copper and cobalt were detected in major silicates and spinels, substituting for Fe or Mg in their structures, and in glass. The presence of secondary metal-bearing phases observed on the slag surfaces indicated the reactivity of the slags on contact with water/atmosphere. It was reported that in...