Treatment of electroplating wastewater using electrocoagulation and integrated membrane.

Electroplating wastewater contains heavy metal ions and organic matter. These contaminants not only endanger the environment but also pose risks to human health. Despite the development of various treatment processes such as chemical precipitation MBR, electrocoagulation (EC) ceramic membrane (CM), coagulation ultrafiltration (UF) reverse osmosis (RO), and CM RO. These methods are only effective for low concentrations of heavy metals and struggle with high concentrations. To address the challenge of treating electroplating wastewater with high heavy metal content, this study focuses on the wastewater from Dongfang Aviation Machinery Processing Plant. It introduces an EC and integrated membrane (IM) treatment process for electroplating wastewater. The IM comprises microfiltration (MF) membrane, nanofiltration (NF) membrane, and RO membrane. Results indicated that under specific conditions, such as a pH of 8, current density of 5 A/dm2, electrode plate spacing of 2 cm, 35 min of electrolysis time, and influent pH of 10 for the IM, removal rates of Zn2+, Cu2+, Ni2+, and TCr in the wastewater exceeded 99%. The removal rates of chemical oxygen demand (COD), suspended solids (SS), total phosphorus (TP), total nitrogen (TN), and petroleum in wastewater exceed 97%. Following a continuous cleaning process, the membrane flux can consistently recover to over 94.3%.

Biomass hydrothermal carbonization solution-assisted synthesis of intercalation-expanded core-shell structured molybdenum disulfide for efficient adsorption of Cr (VI) in electroplating wastewater treatment.

Cr (VI) is a common heavy metal pollutant in electroplating wastewater. This study introduces the liquid-phase product from the hydrothermal reaction of coffee grounds (CGHCL) into the synthesis process of molybdenum disulfide, assisting in the fabrication of an intercalated, expanded core-shell structured molybdenum disulfide adsorbent (C-MoS2), designed for the adsorption and reduction of Cr (VI) from electroplating wastewater. The addition of CGHCL significantly enhances the adsorption performance of MoS2. Furthermore, C-MoS2 exhibits exceedingly high removal efficiency and excellent regenerative capability for Cr (VI)-containing electroplating wastewater. The core-shell structure effectively minimizes molybdenum leaching to the greatest extent, while the oleophobic interface is unaffected by oily substances in water, and the expanded interlayer structure ensures the long-term stability of C-MoS2 in air (90 days). This study provides a viable pathway for the resource utilization of biomass and the application of molybdenum disulfide-based materials in wastewater treatment.

Rapid electrodeposition of Cu nanoparticle film on Ni foam as an integrated 3D free-standing electrode for non-invasive and non-enzymatic creatinine sensing.

High cost, inherent destabilization, and intricate fixing of enzyme molecules are the main drawbacks of enzyme-based creatinine sensors. The design of a low-cost, stabilizable, and enzyme-free creatinine sensing probe is essential to address these limitations. In this work, an integrated three-dimensional (3D) free-standing electrode was designed to serve as a non-enzymatic creatinine sensing platform and was fabricated by rapid electrodeposition of a dense copper nanoparticle film on nickel foam (Cu NP film/NF). This low-cost, stable, easy-to-fabricate, and binder-free Cu NP film/NF electrode has abundant active sites and excellent electrochemical performance. Cyclic voltammetry measurements show a wide linear range (0.25-24 mM), low detection limit (0.17 mM), and high sensitivity (306 µA mM-1 cm-2). The developed sensor shows high recovery of creatinine concentration in real urine. Besides, it has better specificity, reproducibility, and robustness in detecting creatinine. These excellent results suggest that a non-enzymatic creatinine sensor based on an integrated 3D free-standing Cu NP film/NF electrode has good potential for non-invasive detection of urinary creatinine.

One-step electrodeposited hybrid nanofilms in amperometric biosensor development.

This review summarizes recent developments in amperometric biosensors, based on one-step electrodeposited organic-inorganic hybrid layers, used for analysis of low molecular weight compounds. The factors affecting self-assembly of one-step electrodeposited films, methods for verifying their composition, advantages, limitations and approaches affecting the electroanalytical performance of amperometric biosensors based on organic-inorganic hybrid layers were systemized. Moreover, issues related to the formation of one-step organic-inorganic hybrid functional layers with different structures in biosensors produced under the same electrodeposition parameters are discussed. The systemized dependencies can support the preliminary choice of functional sensing layers with architectures tuned for specific biotechnology and life science applications. Finally, the capabilities of one-step electrodeposition of organic-inorganic hybrid functional films beyond amperometric biosensors were highlighted.

Near-complete recycling of real mix electroplating sludge as valuable metals via Fe/Cr co-crystallization and stepwise extraction route.

In electroplating sludge, iron (Fe) and aluminum (Al) are common impurities that need to be separated before recycling valuable heavy metals. However, the traditional Fe/Al separation process often leads to significant losses of heavy metals. To address this issue, a new approach was developed to sequentially separate Fe/Al and recycle chromium (Cr) and nickel (Ni) from real electroplating sludge. The sludge contained 4.5% Cr, 1.2% Al, 1.1% Ni, and 14.6% Fe. Initially, the sludge was completely dissolved in a mixture of hydrochloric and nitric acids. The resulting acid solution was then heated to 160 °C for 10 h with the addition of saccharose. This hydrothermal treatment led to the hydrolysis and crystallization of 98.3% of Fe, 31.8% of Cr, 1.1% of Al, and 4.9% of Ni, forming akaganeite-bearing particles. It was observed that the excessive amount of saccharose also improved the removal of Cr, Al, and Ni, but decreased the removal of Fe. After the hydrothermal treatment, the remaining supernatant was adjusted to different pH levels (1.9, 2.9, and 4.5, respectively), and then Al, Cr, and Ni were stepwise extracted using di-(2-ethylhexyl) phosphate acid (P204). The recycling efficiencies achieved were 97.4% for Al, 61.2% for Cr, and 89.3% for Ni. This approach provides a promising method for the stepwise separation of Fe/Al and the recycling of heavy metals from electroplating sludge.

Effective oxidation decomplexation of Cu-EDTA and Cu2+ electrodeposition from PCB manufacturing wastewater by persulfate-based electrochemical oxidation: Performance and mechanisms.

Complex wastewater matrices such as printed circuit board (PCB) manufacturing wastewater present a major environmental concern. In this work, simultaneous decomplexation of metal complex Cu-EDTA and reduction/electrodeposition of Cu2+ was conducted in a persulfate-based electrochemical oxidation system. Oxidizing/reductive species were simultaneously produced in this system, which realized 99.8% of Cu-EDTA decomplexation, 94.5% of Cu2+ reduction/electrodeposition under the conditions of original solution pH = 3.2, electrode distance = 3 cm, [Na2S2O8]0 = 5 mM, current density = 12 mA/cm2, and reaction time = 180 min. The total treatment cost is as low as 0.80 USD/mol Cu-EDTA. Effective mineralization (74.1% total organic carbon removal) of the solution was obtained after 3 h of treatment. •OH and SO4•- drove the Cu-EDTA decomplexation, destroying the chelating sites and finally it was effectively mineralized to CO2, H2O and Cu2+. The mechanisms of copper electrodeposition on the stainless steel cathode and persulfate activation by the BDD anode were proposed based on the electrochemical measurements. The electrodes exhibited excellent reusability and low metal (total iron and Ni2+) leaching during 20 cycles of application. This study provide an effective and sustainable method for the application of the electro-persulfate process in treating complex wastewater matrices.

Deep removal of phosphate from electroplating wastewater using novel Fe-MOF loaded chitosan hydrogel beads.

Since the electroplating industry is springing up, effective control of phosphate has attracted global concerns. In this study, a novel biosorbent (MIL-88@CS-HDG) was synthesized by loading a kind of Fe-based metal organic framework called MIL-88 into chitosan hydrogel beads and applied in deep treatment of phosphate removal in electroplating wastewater. The adsorption capacities of H2PO4- on MIL-88@CS-HDG could reach 1.1 mmol/g (corresponding to 34.1 mg P/g and 106.7 mg H2PO4-/g), which was 2.65% higher than that on single MOF powders and chitosan hydrogel beads. The H2PO4- adsorption was well described by the Freundlich isotherm model. Over 90% H2PO4- could be adsorbed at contact time of 3 h. It could keep high adsorption capacity in the pH range from 2 to 7, which had a wider pH range of application compared with pure MIL-88. Only NO3- and SO42- limited the adsorption with the reduction rate of 11.42% and 23.23%, proving it tolerated most common co-existing ions. More than 92% of phosphorus could be recovered using NaOH and NaNO3. Electrostatic attraction between Fe core and phosphorus in MIL-88@CS-HDG and ion exchange played the dominant role. The recovered MIL-88@CS-HDG remained stable and applicable in the treatment process of real electroplating wastewater even after six adsorption-regeneration cycles. Based on the removal properties and superb regenerability, MIL-88@CS-HDG is potentially applicable to practical production.

Co/P co-doped bamboo-based woodceramics with a sandwich structure modified by carbon nanotube electrodeposition as supercapacitor electrodes.

Exploring new electrode structures and co-doped composite biomass material electrodes is considered to be an effective way of developing cheap, efficient carbon-based supercapacitors. A bamboo-based sandwich-structured matrix was prepared from thin bamboo veneer and bamboo fiber by pretreatment with H3PO4 and Co2+-catalyzed graphitization. The pore structure was modulated by hydrothermal activation with NaOH and electrodeposition of carbon nanotubes (CNTs) to obtain CNTs modified, Co/P co-doped sandwich-structured woodceramics electrode (CNT@Co/P). It not only has an obvious sandwich structure, but also retains the natural structural characteristics of bamboo. The specific capacitance of the resulting electrode (CNT@Co/P-20) is as high as 453.72F/g using 1 wt% of carboxylated multi-walled carbon nanotubes (CMWCNT) solution as the deposition electrolyte at a current density of 0.2 A/g for 20 min at room temperature. When the power density is 500 W/kg, the energy density reaches 21.3Wh /kg, showing a good electrochemical performance.

Controlling Gold Morphology Using Electrodeposition for the Preparation of Electrochemical Aptamer-Based Sensors.

Nanostructuring of gold surfaces to enhance electroactive surface area has proven to significantly enhance the performance of electrochemical aptamer-based (E-AB) sensors, particularly for electrodes on the microscale. Unlike for sensors fabricated on polished gold surfaces, predicting the behavior of E-AB sensors on surfaces with varied gold morphologies becomes more intricate due to the effects of surface roughness and the shapes and sizes of surface features on supporting a self-assembled monolayer. In this study, we explored the impact of gold morphology characteristics on sensor performance, evaluating parameters such as signal change in response to the addition of the target analyte, aptamer probe packing density, and continuous sensing ability. Our findings reveal that surface area enhancement can either enhance or diminish sensor performance for gold nanostructured E-AB sensors, contingent upon the surface morphology. In particular, our results indicate that the aptamer packing density and target analyte signal change results are heavily dependent on gold nanostructure size and features. Sensing surfaces with larger nanoparticle diameters, which were prepared using electrodeposition at a constant potential, had a reduced aptamer packing density and exhibited diminished sensor performance. However, the equivalent packing density of polished electrodes did not yield the equivalent signal change. Other surfaces that were prepared using pulsed waveform electrodeposition achieved optimal signal change with a deposition time, tdep, of 120 s, and increased deposition time with enhanced electroactive surface area resulted in minimized signal changes and more rapid sensor degradation. By investigating sensing surfaces with varied morphologies, we have demonstrated that enhancing the electroactive surface does not always enhance the signal change of the sensor, and aptamer packing density alone does not dictate observed signal change trends. We anticipate that understanding how electrodeposition techniques enhance or diminish sensor performance will pave the way for further exploration of nanostructure-aptamer relationships, contributing to the future development of optimized, miniaturized electrochemical aptamer-based sensors for continuous, in vivo sensing.

Electrodeposition of CoFeS nanoflakes on Cu2O nanospheres as an ultrasensitive sensing platform for measurement of the hydrazine and hydrogen peroxide in seawater sample.

Nanoarchitectured design of the metal sulfides with highly available surface and abundant electroactive centers and using them as electrocatalyst for fabricate the electrochemical sensors for the detection of hydrazine (N2H4) and hydrogen peroxide (H2O2) is challenging and desirable. Herein, Cu2O nanospheres powder is firstly prepared using chemical reduction of copper chloride and then drop-casted on the glassy carbon electrode (GCE) surface. In the next step, CoFeS nanoflakes are electrodeposited on Cu2O nanospheres by cyclic voltammetry method to form CoFeS/Cu2O nanocomposite as a detection platform for measuring N2H4 and H2O2. Accordingly, Cu2O nanospheres are not only used as substrate, but also guided the CoFeS nanoflakes to adhere to the electrode surface without need to any binder or conductive additive, which enhances the electrical conductivity of the sensing active materials. As the hydrazine sensor, the CoFeS/Cu2O/GCE displayed wide linear ranges (0.0001-0.021 mM and 0.021-1.771 mM), low detection limit (0.12 µM), very high sensitivities (103.33 and 21.23 mA mM-1 cm-2), and excellent selectivity. The as-made nanocomposite also exhibited low detection limit of 1.26 µM for H2O2 sensing with very high sensitivities (12.31 and 3.96 mA mM-1 cm-2) for linear ranges of 0.001-0.03 mM and 0.03-2.03 mM, respectively, and negligible response against interfering substances. The superior analytical performance of the CoFeS/Cu2O for N2H4 electro-oxidation and H2O2 electro-reduction can be attributed to structure stability, high electroactive surface area, and good availability to analyte species and electrolyte diffusion. Moreover, to examine the potency of the prepared nanocomposite in real applications, the seawater sample was analyzed and results display that the CoFeS/Cu2O/GCE can be utilized as a reliable and applicable platform for measuring N2H4 and H2O2.

A label-free aptasensor based on electrodeposition of gold nanoparticles on silver-based metal-organic frameworks for measuring ochratoxin A in black and red pepper.

Since ochratoxin A (OTA) is immunotoxic, teratogenic and carcinogenic, it is very important to monitor this compound in food samples. In the present work, the development and fabrication of a label-free electrochemical aptasensor based on the gold nanoparticles/silver-based metal-organic framework (AuNPs/Ag-MOF) for the determination of ochratoxin A (OTA) is introduced. The aptasensor was fabricated by electrodeposition of AuNPs on a glassy carbon electrode modified with Ag-MOF. The characteristics of the synthesized Ag-MOF were determined by field emission scanning electron microscopy (FESEM), energy-dispersive X-ray spectroscopy (EDS), Fourier transform infrared spectroscopy (FTIR) and UV-Visible spectroscopy. The aptamer was immobilized on the modified electrode and then OTA was incubated on it. The process of different stages of the aptasensor construction has been confirmed by two methods of electrochemical impedance spectroscopy (EIS) and cyclic voltammetry (CV) and using [Fe(CN)6]3-/4- as a redox probe. The EIS method has also been used for the OTA quantitative determination. The difference in charge transfer resistance (Rct) before and after the interaction of OTA with the immobilized aptamer was considered as the analytical response of the aptasensor. Using the developed aptasensor, it is possible to measure OTA in the concentration range of 1.0 × 10-3 to 200.0 ng mL-1 with a detection limit of 2.2 × 10-4 ng mL-1. Finally, the ability of the aptasensor to measure OTA in red and black pepper was investigated and completely satisfactory results were obtained.

Contamination and health risk assessment of heavy metals in soil surrounding an electroplating factory in JiaXing, China.

A total of 30 samples from the downwind direction of a certain electroplating company in Jiaxing were collected in layers to analyze their heavy metal content. The soil risk assessment was conducted from the perspective of ecological and human health risks using the ground accumulation index method and human health risk assessment method. The results showed that in all samples, cadmium and arsenic far exceeded the soil background values, with an average exceeding multiple of 14.31 and 64.42, respectively, and a exceeding rate of 100%. After evaluation by the ground accumulation index, among these six heavy metals, arsenic and cadmium belong to extremely serious pollution levels. The human health risk assessment of electroplating plants found that in the exposure risk assessment, the ingestion value was much greater than the harm caused by breathing and skin, and the maximum exposure damage value of arsenic to children and adults was 4.17 × 10-3, among the carcinogenic risks, the risk brought by consumption is much greater than the respiratory and skin carcinogenic risk index, with the highest value score of 3.37 for cadmium, arsenic, and zinc carcinogenic risks 3.37 × 10-6, 2.42 × 10-3, 1.10 × 10-4.

Biological upcycling of nickel and sulfate as electrocatalyst from electroplating wastewater.

Upcycling nickel (Ni) to useful catalyst is an appealing route to realize low-carbon treatment of electroplating wastewater and simultaneously recovering Ni resource, but has been restricted by the needs for costly membranes or consumption of large amount of chemicals in the existing upcycling processes. Herein, a biological upcycling route for synchronous recovery of Ni and sulfate as electrocatalysts, with certain amount of ferric salt (Fe3+) added to tune the product composition, is proposed. Efficient biosynthesis of bio-NiFeS nanoparticles from electroplating wastewater was achieved by harnessing the sulfate reduction and metal detoxification ability of Desulfovibrio vulgaris. The optimal bio-NiFeS, after further annealing at 300 °C, served as an efficient oxygen evolution electrocatalyst, achieving a current density of 10 mA·cm-1 at an overpotential of 247 mV and a Tafel slope of 60.2 mV·dec-1. It exhibited comparable electrocatalytic activity with the chemically-synthesized counterparts and outperformed the commercial RuO2. The feasibility of the biological upcycling approach for treating real Ni-containing electroplating wastewater was also demonstrated, achieving 99.5 % Ni2+removal and 41.0 % SO42- removal and enabling low-cost fabrication of electrocatalyst. Our work paves a new path for sustainable treatment of Ni-containing wastewater and may inspire technology innovations in recycling/ removal of various metal ions.

Ultrasound assisted electrodeposition of photocatalytic antibacterial MoS2-Zn coatings controlled by sodium dodecyl sulfate.

Photocatalytic MoS2 with visible light response is considered as a promising bactericidal material owing to its non-toxicity and high antibacterial efficiency. However, photocatalysts always exist as powder, so it is difficult to settle photocatalysts on the metal surface, which limits their application in aqueous environments. To solve this problem, ultrasound and sodium dodecyl sulfate (SDS) were introduced into the co-deposition process of MoS2 and zinc matrix, so that novel MoS2-Zn coatings were obtained. In this process, ultrasound and SDS strongly promoted the dispersion and adsorption of MoS2 on the co-depositing surfaces. Then MoS2 were proved to be composited into the Zn matrix with effective structures, and the addition of SDS effectively increased the loading content of MoS2 in the MoS2-Zn coatings. Besides, the antibacterial performance of the MoS2-Zn coatings was evaluated with three typical fouling bacteria E.coli, S.aureus and B.wiedmannii. The MoS2-Zn coating showed high and broad-spectrum antibacterial properties with over 98 % inhibition rate against these three bacteria. Furthermore, it is proved that the MoS2-Zn coatings generated superoxide (·O2-) and hydroxyl radicals (·OH) under visible light, which played the dominant and subordinate roles in the antibacterial process, respectively. The MoS2-Zn coatings also showed high antibacterial stability after four "light-dark" cycles. According to the results of the attached bacteria, the MoS2-Zn coatings were considered to effectively repel the living pelagic bacteria instead of killing the attached ones, which was highly environmentally friendly. The obtained MoS2-Zn coatings were considered promising in biofilm inhibiting and marine antifouling fields.

Transformation behavior of heavy metal during Co-thermal treatment of hazardous waste incineration fly ash and slag/electroplating sludge.

In this study, the behavior of heavy metal transformation during the co-thermal treatment of hazardous waste incineration fly ash (HWIFA) and Fe-containing hazardous waste (including hazardous waste incineration bottom slag (HWIBS) and electroplating sludge (ES)) was investigated. The findings demonstrated that such a treatment effectively reduced the static leaching toxicity of Cr and Pb. Moreover, when the treatment temperature exceeded 1000 °C, the co-thermal treated sample exhibited low concentrations of dynamically leached Cr, Pb, and Zn, indicating that these heavy metals were successful detoxified. Thermodynamic analyses and phase transformation results suggested that the formation of spinel and the gradual disappearance of chromium dioxide in the presence of Fe-containing hazardous wastes contributed to the solidification of chromium. Additionally, the efficient detoxification of Pb and Zn was attributed to their volatilization and entry into the liquid phase during the co-thermal treatment process. Therefore, this study sets an excellent example of the co-thermal treatment of hazardous wastes and the control of heavy metal pollution during the treatment process.

Effect of Strontium-Substituted Calcium Phosphate Coatings Prepared by One-Step Electrodeposition at Different Temperatures on Corrosion Resistance and Biocompatibility of AZ31 Magnesium Alloys.

As potential degradable biomaterials, magnesium (Mg) alloys have development prospects in the field of orthopedic load-bearing, whereas the clinical application has encountered a bottleneck due to a series of problems caused by its rapid corrosion. In this study, strontium-substituted calcium phosphate (CaP) coatings with different structures were prepared on the surface of the Mg matrix by a simple one-step electrodeposition method at different temperatures, which enhanced the poor corrosion resistance of the Mg matrix. The coated sample prepared at 65 °C reduced the corrosion current density by 3 orders of magnitude and increased the impedance by nearly 2 orders of magnitude compared with bare Mg alloy, thanks to its dense fibrous structure similar to that of natural bones. Although the coating composition varies with different preparation temperatures, CaP, as an inorganic component similar to natural bone, has good cytocompatibility. Doping the right amount of strontium, which is a trace element in human bones, is beneficial to stimulate osteoblast differentiation, inhibit the activity of osteoclasts, and induce the formation of bone tissues. This provides a new option for modifying the Mg alloy with CaP coatings as a base.

Trapping of heavy metal ions from electroplating wastewater with phosphorylated double-shelled hollow spheres.

The mesoporous multi-shelled hollow structures are promising for trapping of non-degradable heavy metal ions in wastewater but difficult to synthesize. We successfully demonstrated a simple strategy for the construction of mesopore windows on double-shelled α-Fe2O3 hollow spheres. A step-by-step proof of concept synthesis mechanism has been revealed by using mainly electron microscopy and thermogravimetric analysis. We proved that mesopore windows are indispensable to realize the complete surface coverage of phosphonate ligands on α-Fe2O3 double-shelled hollow spheres. The phosphonic groups inherently coordinated with Ni(II) and Cu(II) ions and formed complexes of high stability. Importantly, owing to the structural merits, the phosphorylated double-shelled hollow spheres selectively removes Ni(II) and Cu(II) at wider sample pH range with a high capacity of 380 mg g-1 and 410 mg g-1, respectively. In addition, no significant decrease in the removal efficiency was observed under high salt matrix. For electroplating industry wastewater, the novel structure performs simultaneous Ni(II) and Cu(II) removal, thus producing effluent of stable quality that meets local discharge regulations.

Electrodeposition of paracetamol oxide for intelligent portable ratiometric detection of nicotine and ethyl vanillin ß-D-glucoside.

Herein, the electrodeposition of paracetamol oxide (PA ox) for the intelligent portable ratiometric detection of nicotine (NIC) and ethyl vanillin ß-D-glucoside (EVG) is reported. PA ox electrodeposited on a screen-printed carbon electrode (SPCE) was used as a new fixed state ratiometric reference probe. A portable electrochemical workstation combined with a smart phone was applied as an intelligent portable electrochemical sensing platform. The sensor was studied by scanning electron microscopy (SEM), Fourier transform infrared spectrophotometry (FT-IR), ultraviolet-visible spectrophotometry (UV-vis), theoretical calculation, chronoamperometry, cyclic voltammetry (CV), electrochemical impedance spectroscopy (EIS) and square wave voltammetry (SWV). Under optimized conditions, the detection range of NIC is 10-200 µmol L-1, and the detection limit is 0.256 µmol L-1. The detection range of EVG was 10-180 µmol L-1, and the detection limit was 0.058 µmol L-1. The sensor can realize the real-time detection of NIC and EVG concentration in cigarette samples quickly and accurately, and has good anti-interference, repeatability and stability.

Unlocking sustainable solutions: controlled Cu2+ dosing enables efficient recovery and reuse of high-purity copper pyrophosphate from electroplating wastewater.

The electroplating process of copper pyrophosphate (Cu2P2O7) results in the production of a large volume of wastewater that contains a high concentration of copper (Cu). Currently, conventional lime precipitation creates a substantial amount of secondary pollution, which adds extra economic and environmental burdens. In this study, we suggest a straightforward method for on-site recovery of Cu from Cu2P2O7 electroplating wastewater. By optimizing various parameters, characterizing the resulting product, assessing its electroplating capabilities, and analyzing the speciation during the reaction, we comprehensively investigated the feasibility and mechanism of this technique. The results demonstrated that, under the optimal conditions (Cu/P molar ratio of 0.96, pH of 5.0, and a reaction time of 5.0 min), the concentration of residual Cu remained stable between 22.2 and 27.7 mg/L, even when the initial Cu concentrations varied. The addition of Cu triggered a series of hydrolysis and ionization reactions, primarily leading to the formation of Cu2P2O7·3H2O. The harvested Cu2P2O7·3H2O proved to be suitable for practical electroplating applications, exhibiting comparable performance to commercially available Cu2P2O7·3H2O. This demonstrates the feasibility of recovering high-purity Cu2P2O7·3H2O from copper electroplating wastewater, offering a promising approach for on-site copper reuse and concurrently reducing the demand for natural copper resources. Furthermore, this approach significantly reduces the generation of solid waste, aligning with the principles of sustainable development.

Acid-leaching mechanism of electroplating sludge: based on a comprehensive analysis of heavy-metal occurrence and the dynamic evolution of coexisting mineral phases.

Electroplating sludge is a typical heavy metal-containing hazardous waste with tens of millions of tons produced annually in China. Acid leaching is the most common method to extract valuable heavy metals for resource recycling and environmental protection. However, the coexisting elements, which are released from electroplating sludge to the leaching solution, will hinder the recycling of valuable heavy metals. In this work, dynamic acid-leaching experiments, X-ray diffraction analysis, and simulation calculations were conducted. It was found that coexisting elements (mainly Ca, Fe, and Al) account for a large proportion, and calcium salts as coexisting mineral phase (especially CaCO3) are ubiquitous in electroplating sludge. Moreover, the evolution of coexisting mineral phase plays an essential role in the acid-leaching process: (1) the dissolution of CaCO3 contributed a strong acid-neutralization capability and released Ca2+; (2) H2SO4 is the optimal extracting reagent, since it triggered the transformation of calcium salts to CaSO4·2H2O, reducing the Ca2+ concentration; (3) the coexisting elements Fe and Al would form ferrous and aluminum salt minerals with the acid-leaching process, which reduces the leaching of low-value elements. This work provides a new perspective on the acid-leaching mechanism of electroplating sludge, where the evolution of the mineral phase effect the release of valuable heavy metals and coexisting elements. This work also provides as comprehensive information as possible on electroplating sludge and inspires the improvement of the acid-leaching method.