Simultaneous separation of Fe & Al and extraction of Fe from waste coal fly ash: Altering the charge sequence of ions by electrolysis

A significant amount of coal fly ash is generated and this type of waste material causes severe environmental hazards. Metal (Al and Fe) extraction from coal fly ash is beneficial to the resource utilization of waste coal fly ash. However, the coexistence of Al and Fe in coal fly ash means that the separation of Al and Fe is required, which is a key and difficult step to prepare high value-added products from coal fly ash. This work presents a novel electrolysis method to alter the charge sequence of Al3+, Fe3+, and H2O, leading to a process different from their natural tendency for simultaneous separation of Fe3+ and Al3+, and extraction of Fe. The single iron removal efficiency was 43.48%, and the aluminum extraction efficiency was <0.30% under optimal conditions. The iron product had a purity of 98.3 wt% Fe, 0.45 wt% Al, and 0.18 wt% S. This process occurs without chemical additions and expensive membranes, avoiding impurity introduction, slag generation, and membrane limitations. Fe(s), H2(g), Al2(SO4)3(aq), and O2(g) are the main products during the electrolysis. Flake Fe is selectively produced instead of colloidal Fe(OH)3. Fe is a magnetic substance and is easier to remove from the solution by magnets than colloidal Fe(OH)3. H2 is a green fuel. Wastewater (Al2(SO4)3(aq)) can be directly used to further extract alumina. Therefore, this study provides an alternative method of zero pollution discharge for simultaneous separation of Fe3+ and Al3+, and extraction of Fe from coal fly ash leachate.