Fluoride-immobilized co-processing and resource utilization of aluminum-electrolyzed spent cathode carbon in brick-fired kiln

Spent cathode carbon (SCC) is hazardous waste from the electrolytic aluminum industry due to its high levels of soluble fluoride, while brick-fired kiln provides the clay and heating conditions needed to immobilize fluoride. However, SCC reusing is still understudied, meanwhile co-processing and resource utilization of SCC in brick-fired kiln were still not reported in the literatures in addition to a Chinese patent of the authors. Here, the effects of firing temperatures, firing time, clay doses and calcium doses on the fluoride-immobilized performance of SCC co-processing were explored in a simulated brick-firing kiln, and their mechanisms were analyzed by SEM and XRD. The results indicated that clay-added co-processing in brick-fired kiln was a preferred choice without required additional additives or operations. The leached fluoride met Chinese standards by clay-added co-processing at ≥ 800 °C/ ≥ 40 g clay/ ≥ 120 min. Clay and calcium-added co-processing in brick-fired kiln was another alternative choice with higher fluoride-immobilization rates. The leached fluoride met Chinese standard (GB5085.3–2007) by clay and calcium-added co-processing at ≥ 500 °C/ ≥ 30 min/ ≥ 5 g clay/ ≥ 0.5 g CaCO 3 . SEM and XRD indicated that SiO 2 in clay reacted with sodium in SCC and formed vitreous analog (Na 1.55 Al 1.55 Si 0.45 O 4 ) to prevent fluoride ion migration and the newly-formed k-Feldspar (K 2 O.Al 2 O 3 .6SiO 2 ) may adsorb fluoride ions in clay-added co-processing. Soluble fluoride NaF in SCC were converted into water-insoluble cuspidine in clay and calcium-added co-processing, in addition to the crystalline phase conversion in clay-added co-processing. Therefore, the risks of finished bricks to human health and the environment were greatly reduced after clay-added or clay and calcium-added treatments. Graphical abstract