Comparison of ultrasound-assisted and traditional caustic leaching of spent cathode carbon (SCC) from aluminum electrolysis

The spent cathode carbon (SCC) from aluminum electrolysis was subjected to caustic leaching to investigate the different effects of ultrasound-assisted and traditional methods on element fluorine (F) leaching rate and leaching residue carbon content. Sodium hydroxide (NaOH) dissolved in deionized water was used as the reaction system. Through single-factor experiments and a comparison of two leaching techniques, the optimum F leaching rate and residue carbon content for ultrasound-assisted leaching process were obtained at a temperature of 70 °C, residue time of 40 min, initial mass ratio of alkali to SCC (initial alkali-to-material ratio) of 0.6, liquid-to-solid ratio of 10 mL/g, and ultrasonic power of 400 W, respectively. Under the optimal conditions, the leaching residue carbon content was 94.72%, 2.19% larger than the carbon content of traditional leaching residue. Leaching wastewater was treated with calcium chloride (CaCl2) and bleaching powder and the treated wastewater was recycled caustic solution. All in all, benefiting from advantage of the ultrasonication effects, ultrasound-assisted caustic leaching on spent cathode carbon had 55.6% shorter residue time than the traditional process with a higher impurity removal rate.