Co-treatment of diamond-wire-saw silicon kerf and spent automotive catalysts for simultaneous recovery of PGMs, REEs, Zr, and high-purity Si

Spent automotive catalysts (SACs) and diamond-wire-saw silicon kerf (DWSSK) are classified as hazardous wastes. Currently, the two wastes are treated separately using unrelated approaches. More than two independent approaches are required to recover platinum group metals (PGMs), Zr and rare earth elements (REEs) from SACs, and recover Si from DWSSK, which is time-consuming and laborious. In this study, a new approach was proposed to co-treat the two wastes based on the concept of using waste treats waste: using DWSSK (∼89.85 wt% Si) as a new metal collector to extract PGMs, REEs, and Zr simultaneously from SACs to obtain a Si-VM alloy (VM: valuable metal); meanwhile, using the carrier of SACs to form molten slag to eliminate the main impurity, O, from DWSSK. The largest recovery ratios of Pd, Rh, Zr, Ce, La, and Nd from SACs were 99.50 ± 0.10%, 99.14 ± 0.14 %, 96.19 ± 0.76%, 67.18 ± 4.57%, 61.24 ± 4.93% and 47.65 ± 7.27%, respectively, and the largest removal ratio of O from DWSSK was 99.96%. After smelting, the Si-VM alloy was separated into high-purity Si and VM-containing acid solutions via acid leaching. The leaching ratios of Pd, Rh, Ce, La, Nd, and Zr were 99.78%, 98.15%, 99.93%, ∼100%, 99.76% and 99.98%, respectively. The purity of Si was upgraded from 89.85 wt% (in DWSSK) to 99.98 wt% after acid leaching. The new approach proposed in this study is considered more environmentally friendly and cost-effective than the regular approaches that treat the two wastes separately.