Systems and methods for processing ash

Patent metadata

Field	Value
Publication number	US-2023330724-A1
Application number	US-202118017114-A
Country	US
Kind code	A1
Filing date	Jul 21, 2021
Priority date	Jul 21, 2020
Publication date	Oct 19, 2023
Grant date	—

Abstract

Disclosed herein are systems and methods for processing ash. For example, in certain embodiments, the method comprises dissolving at least a portion of ash in acid. In some embodiments, the acid is produced in a reactor. In some embodiments, dissolving at least a portion of ash in acid produces refined silica (SiO 2 ) (e.g., amorphous silica, substantially pure silica, and/or a substantial amount of silica). According to certain embodiments, the ash can be further processed (e.g., using electro winning, pH-based precipitation, and/or electrorefining) to obtain other components instead of or in addition to refined silica.

First claim

What is claimed is:

1 . A method, comprising dissolving at least a portion of ash in acid to produce refined silica with a purity of greater than or equal to 60 wt. %.

2 . The method of claim 1 , wherein the refined silica has a purity of greater than or equal to 80 wt. %.

3 . The method of any preceding claim, wherein the refined silica has a purity of greater than or equal to 90 wt. %.

4 . The method of any preceding claim, wherein the refined silica has a purity of less than or equal to 99.9 wt. %.

5 . The method of any preceding claim, wherein the refined silica comprises less than or equal to 2 wt. % toxic impurities.

6 . The method of claim 5 , wherein the toxic impurities comprise mercury, lead, cadmium, chromium, and/or arsenic.

7 . The method of any preceding claim, wherein the dissolving at least a portion of ash in acid produces greater than or equal to 10 kg of refined silica.

8 . The method of any preceding claim, wherein the dissolving at least a portion of ash in acid produces less than or equal to 1,000,000 kg of refined silica.

9 . The method of any preceding claim, wherein the refined silica comprises greater than or equal to 10 wt. % amorphous silica.

10 . The method of any preceding claim, wherein the refined silica comprises less than or equal to 95 wt. % amorphous silica.

11 . The method of any preceding claim, wherein the refined silica comprises greater than or equal to 40 wt. % amorphous silica.

12 . The method of any preceding claim, wherein the refined silica comprises greater than or equal to 80 wt. % amorphous silica.

13 . The method of any preceding claim, wherein the method further comprises disposing the refined silica in a landfill; using the refined silica as a component in cement, concrete, and/or construction materials; using the refined silica to make glass; and/or using the refined silica as a dessicant, thickener, and/or additive in rubber and/or plastics.

14 . The method of any preceding claim, wherein the dissolving at least a portion of ash in acid produces the refined silica and an acid leachate, and wherein the method further comprises at least partially separating the refined silica from the acid leachate.

15 . The method of claim 14 , wherein the method further comprises electrowinning the acid leachate to produce one or more electroplated metals.

16 . The method of claim 15 , wherein the one or more electroplated metals comprises a metal that was present in an amount of less than or equal to 10 wt. % of the ash.

17 . The method of any one of claims 15 - 16 , wherein the one or more electroplated metals comprises a metal that was present in an amount of less than or equal 1 wt. % of the ash.

18 . The method of any one of claims 15 - 17 , wherein the one or more electroplated metals comprises a metal that was present in an amount of greater than or equal to 1 part per billion (ppb) of the ash.

19 . The method of any one of claims 15 - 18 , wherein the one or more electroplated metals comprises Mn, Zn, Cr, Fe, Cd, Co, Ni, Pb, Cu, Bi, As, Ag, and/or Hg.

20 . The method of any one of claims 15 - 19 , wherein the electrowinning the acid leachate produces at least two electroplated metals, and wherein the method further comprises electrorefining the at least two electroplated metals to at least partially separate at least one electroplated metal from the other.

21 . The method of any one of claims 15 - 20 , wherein the electrowinning and/or electrorefining comprises the use of porous electrodes.

22 . The method of any one of claims 15 - 21 , wherein the electrowinning and/or electrorefining comprises the use of a flow-by apparatus.

23 . The method of any one of claims 15 - 21 , wherein the electrowinning and/or electrorefining comprises the use of a flow-through apparatus.

24 . The method of any one of claims 15 - 23 , wherein the electrowinning the acid leachate further produces an aqueous solution, and wherein the method further comprises adding a base to the aqueous solution to precipitate one or more metal hydroxides.

25 . The method of claim 24 , wherein the one or more metal hydroxides comprises calcium hydroxide, magnesium hydroxide, strontium hydroxide, barium hydroxide, manganese hydroxide, iron oxide, cobalt hydroxide, nickel hydroxide, zinc hydroxide, zirconium hydroxide, cerium hydroxide, vanadium hydroxide, neodymium hydroxide, dysprosium hydroxide, cadmium hydroxide, lead hydroxide, silicon hydroxide, and/or aluminum hydroxide.

26 . The method of any preceding claim, wherein the method further comprises adding a base to the refined silica to form a basic solution and a solid, at least partially separating the solid from the basic solution to form a separated basic solution, adding an acid to the separated basic solution to form an acidic solution, and electrowinning the acidic solution to produce one or more electroplated noble metals.

27 . The method of claim 26 , wherein the one or more electroplated noble metals comprises gold, silver, platinum, palladium, rhodium, and/or iridium.

28 . The method of any one of claims 26 - 27 , wherein the electrowinning the acidic solution produces at least two electroplated noble metals, and wherein the method further comprises electrorefining the at least two electroplated noble metals to separate at least one electroplated noble metal from the other.

29 . The method of any one of claims 24 - 28 , wherein the base is produced in a reactor.

30 . The method of any preceding claim, wherein the acid is produced in a reactor.

Assignees

• Massachusetts Inst Technology
• Univ Carnegie Mellon

Inventors

• Chiang Yet-Ming
• Ellis Leah
• Coppieters 'T Wallant Sophie C
• Zhang Sonia
• Viswanathan Venkatasubramanian
• Olivetti Elsa A
• Wang Michael Joseph

Classifications

• C25C1/22

  of metals not provided for in groups C25C1/02 - C25C1/20 · CPC title

• C25C1/18

  of lead · CPC title

• C25C1/16

  of zinc, cadmium or mercury · CPC title

• C25C1/12

  of copper · CPC title

• C25C1/10

  of chromium or manganese · CPC title