The raw material required for the hybrid thorium recovery process is the remains and ends of the welding electrodes at high temperatures. These materials can be selectively collected on construction sites or industrial production halls and undergo membrane electrolysis followed by nanofiltration, when thorium is recovered as thorium dioxide and tungsten as a tungstate solution.
3.3.2. Membrane electrolysis of welding electrodes
In order to avoid the loss of thorium as thorium dioxide of nanometric dimensions from the membrane electrolysis process, this was coupled with the nanofiltration of both the solution from the cathode space and the solution in the anode space (
Figure 13).
The probable reactions in the anodic space (1–4) and cathodic space (5,6) follow:
However, the choice of the potential of the working electrode (anode) as well as the pH in the anodic space largely determine the speciation of each component element of the welding electrodes considered in this study: tungsten, thorium and aluminum (
Table 2 and
Figure 14). Thus, superimposing the Pourbaix diagrams [
61,
62,
63] of the three elements (
Figure 14) it is possible to specify, at constant potential, the chemical species for each pH in the anodic space (
Table 2).
At the potential of 20.0 V and pH=0 in the anodic space, and pH=13 in the cathodic space, following electrolysis, tungsten will be found in the form of tungstic acid WO
3·H
2O(s), thorium as Th
4+(aq) and aluminum as Al
3+(aq) (
Figure 14). The two cations, Th
4+ and Al
3+, will migrate to the cathode, and the tungstic acid will remain in the anodic space. Tungsten in the anode space will be recovered by nanofiltration through the module attached to this space. Thorium will be immobilized as a solid in cathode space in the form of thorium dioxide (ThO
2), and the aluminum ion will pass into sodium aluminate (AlO
2⁻), soluble. By nanofiltration [
64,
65,
66] of the solution from the cathode space through the module attached to this space, thorium dioxide will be retained on the membrane (concentrate) and aluminate ion as permeate.
At the same potential value of the anodic space, but at pH between 1 and 3.5, the chemical species of the three elements will be: tungsten as WO3 H2O(s), thorium as ThO2(s), and aluminum as Al3+(aq). In this case, the solution in the anodic space is nanofiltered after treatment with ammonia solution, when ammonium tungstate will pass into the permeate, and thorium dioxide remains on the membrane, in concentrate. The solution in the cathode space will contain sodium aluminate, which, being in solution, does not require nanofiltration. However, for the safety of the hybrid process, the solution from the cathode space also undergoes nanofiltration, when we will find sodium aluminate in the permeate, and any other solid impurity is retained on the membrane.
If the anode has a potential of 20.0 V and the pH in anodic space stays between 3.5 and 6, the chemical species obtained for the three elements are: tungsten as WO3·H2O(s), thorium as ThO2(s), and aluminum as Al(OH)3 (s). In this case, the solutions from the anodic and cathodic spaces obtained after electrolysis are mixed together and subjected to nanofiltration, when thorium dioxide is retained in the concentrate, and the tungstate and aluminate ions are found in the permeate. To separate the two anions, the pH is adjusted to 5 when the aluminum hydroxide precipitates, which is retained by nanofiltration in the second module of the installation.
If the anode has a potential of 20.0 V, and the pH in the anodic space is kept between 6 and 12, then the chemical species obtained for the three elements are: tungsten as WO42⁻(aq), thorium as ThO2(s), and aluminum as Al(OH)3(s).
In this case, the nanofiltration of the anodic space takes place in two stages:
the first stage at the pH (6–12) from this space when a permeate, containing the soluble tungstate ion, and a concentrate containing thorium dioxide and aluminum hydroxide, are obtained;
the second stage when the concentrate is mixed with the pH 13 solution from the cathodic space, when the aluminum is solubilized as aluminate, passing into the permeate, and thorium dioxide remains in the concentrate.
If the anode has a potential of 20.0 V, and the pH in the anodic space is above 12, then the chemical species obtained for the three elements are: tungsten as WO42⁻(aq), thorium as ThO2(s) and aluminum as AlO2⁻(aq).
In this case the nanofiltration of anodic space takes place in two stages:
the first stage at the pH in this space (above 12), when a permeate containing soluble tungstate and aluminate ions is obtained, and a concentrate containing thorium dioxide and aluminum hydroxide;
the second stage when the permeate is brought to a pH between 6 and 9, when the aluminum precipitates as hydroxide and is separated from the tungstate ion by nanofiltration, in the second module.
Tungsten recovery after electrolysis means nanofiltration of the solution in order to purify it, because it is obtained as tungstate either by neutralizing tungstic acid or directly, at a pH higher than 6.
The recovery of thorium requires additional attention, firstly because thorium is a radioactive element, and secondly because being obtained as a thorium dioxide dispersion, it will have to be nanofiltered under optimal conditions so as not to be lost in the permeate.
The results obtained during the nanofiltration of nanodispersions, containing thorium dioxide, depending on the pH and at 8 bar working pressure, show flows between 8.5 and 14 L/m
2·h and a removal of thorium reaching below 1 ppm in the permeate, at pH higher than 4, with a determination error of ±0.1 ppm (
Figure 15). This concentration of thorium is below the natural background in various locations in the world, especially those where rare earths are also found [
67,
68,
69,
70,
71,
72,
73].
The higher concentration of thorium in the permeate at pH below 3 is due to the existence of thorium dioxide in dispersion and as Th4+ ion, which is partially retained by the C–PHF–M membrane, which is in cationic form (+H3N–R). At pH above 3, the concentration of thorium in the permeate drops sharply to 0.1 ppm, which shows that thorium is found almost entirely as thorium dioxide ThO2, and any thorium ions are retained by the membrane in cationic form.
What is interesting is the evolution of the permeate concentration during nanofiltration depending on the morphological nature of thorium dioxide (
Figure 14). Thus, over the entire pH range, the concentration of thorium in the permeate for thorium dioxide obtained from electrolysis (
Figure 15 – green circles) is lower than that of the same element precipitated from Th(NO
3)
4 solution (
Figure 15 – blue squares).
There can be two reasons for this behavior:
The first argument would probably have a greater influence on the thorium concentration in the permeate. Thus, the thorium dioxide obtained by the precipitation of Th(NO
3)
4 in amorphous form (
Figure 16a) is retained to a lesser extent on the membrane, than the crystalline form of thorium dioxide released from the interstices of the tungsten wires (plates), through electrolysis of the welding electrode (
Figure 16b,
Figure 11c,d).
The permeate flow performances of nanofiltration of thorium dioxide nanodispersions, from the complex system obtained by electrolysis, depending on pH and working pressure, are presented in
Figure 17.
Over the entire pH range (
Figure 17) the fluxes increase with increasing operating pressure from 6 to 10 bar. Each time, from pH 0 to 2, the values of the permeate flows increase up to about 30 L/m
2h which is obtained at 10 bars. Starting at pH 4, the flow values increase slightly until pH 10, after which there is a slight decrease.
The recorded flux results are consistent with the speciation of thorium and of the C–PHF–M membrane. At low pH, below 2, thorium is found as ion, and after pH 2 thorium dioxide is formed. It is likely that the size of thorium dioxide nanoparticles increases with the pH, which improves filterability. However, after pH 8 the viscosity of the alkaline solution causes a slight decrease in the permeate flow.
From the point of view of the nanofiltration results, the pH in the electrolysis installation can be up to 2, when we have thorium ions and tungstic acid in the solution, or between 8 and 10 when we have thorium dioxide and tungstate ions in the solution.
The presence of aluminum in the system, even in traces, could impose electrolysis with the anodic space at strongly alkaline pH when aluminum is found as aluminate, tungsten as tungstate, both in solution, and thorium as insoluble precipitated of thorium dioxide. In the latter case, the separation of the anodic and cathodic spaces through the sPEEK membrane becomes unnecessary, the recovery of thorium dioxide being done through a first nanofiltration. The separation of aluminum is done by the second nanofiltration, after adjusting the pH between 5 and 9 when the aluminum will be retained on the membrane in the form of insoluble aluminum hydroxide.