Novel process for high value utilization of high-alumina fly ash: valuable metals recovery and mesoporous silica preparation.

Extraction of valuable metals besides silica from high-alumina fly ash is one of the most important high-value utilization pathways. However, it is difficult to realize high-efficiency extraction due to the stable structure of quartz and mullite. In this paper, mineral phase transformation for valuable metal recovery and mesoporous silica preparation from fly ash by a selective acid leaching method was proposed. The mineral phase transformation, dissolution behavior of each metal, and pore structure of fly ash derived mesoporous silica were systematically investigated. The results show that the co-activation of fly ash by NaCO-KCO formed the phases of kalsilite and (Na, K)AlSiO. During the acid leaching process, Al, Li, and Ga could be leached with the efficiencies of 86.17%, 89%, and 80% in the FK system. In the FN system, the efficiencies of Al, Li, and Ga are 92.38%, 95%, and 83%, respectively. The crystal plane (002) was destroyed for kaliophilite while all the crystal planes were destroyed for nepheline. With the increase of HCl solution concentration, the porous silica exhibited the same change order of pore shape. The pore structure of as-prepared porous silica was type IV and the hysteresis loop was type H3, and the specific surface areas could be 565.54, 448.02, and 746.76 m g, respectively. Finally, the leaching liquors can be used to produce crystal aluminum chloride, lithium carbonate and gallium. This paper might provide technical support for full recycling of high-value resources from fly ash.