Total recycling of all valuable metals such as PGMs, Ce, Al and Mg from the spent automobile catalysts has been explored. The alkali roasting was performed under NaOH, 0.5-3.0 g; temperature, 300-800 °C; and time, 10-60 min. The phase transformation from cordierite to the soluble products (NaAlO2, Na2MgSiO4) was influenced by the temperature, following the diffusion-controlled model (Ea(roasting), 6.4 kJ/mol). XRD analysis of the roasted mass revealed that the refractory phases of cordierite and γ-alumina could be eliminated at ≥600 °C at sample-to-NaOH mass ratio, 1:1. The leaching of the roasted mass followed an intermediate-controlled mechanism for aluminum leaching with (Ea(Al-leaching) value of 20.3 kJ/mol), while it was diffusion-controlled for magnesium leaching (Ea(Mg-leaching), 8.9 kJ/mol). At the optimum leaching condition (1.0 M H2SO4, 90 °C, 60 min, yielding >95% aluminum and magnesium), a significant amount of PGMs was also leached. Thereafter, the cementation process was investigated with Al0-powder that could precipitate >99% PGMs within 15 min at 90 °C. The yielded concentrate of PGMs and CeO2 was subsequently leached in 6.0 M HCl with 2.0 M NaClO3 that dissolved >97% PGMs, leaving the residue as the CeO2 concentrate. Individual metals can be recovered by following established separation and purification techniques.
Keywords: Automobile catalyst; Cerium oxide; Cordierite; Platinum group metals; Recycling.
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