Carbothermal treatment of municipal solid waste incineration fly ash: Purification and valuable elements extraction.

[Display omitted] • Carbothermal reduction was proposed as a new method of MSWI fly ash purification. • Excessive carbon was adversed to heavy metal separation for NaCl/KCl condensation. • Zn & Pb in condensate had recovery value for their concentration up to 20% & 7%. • Finally, two paths for ash utilization were proposed for industrial applications. Thermal separation of heavy metals from municipal solid waste incineration fly ash (MSWI FA) is a promising approach for both fly ash purification and heavy metal recovery. However, its commercial viability is hindered by excessive energy consumption. In this study, we introduce carbothermal reduction for MSWI FA treatment as an innovative strategy to enhance heavy metal volatilization and reduce the required heating temperature. By incorporating carbon (FA/Carbon = 1:0.2), the volatilization fractions of Pb, Cd and Zn reached 96.5 %, 100 %, and 63.9 %, respectively, when subjected to 900 °C for 2 h. Remarkably, these volatilization amount surpassed the volatilization fractions attained when raw fly ash (RFA) was independently calcined at 1000 °C for 2 h: Pb (90.2 %), Cd (92.9 %) and Zn (30.2 %). Conversely, Cu volatilization was impeded by carbon inclusion. Comparable trends were shown in washing fly ash (WFA). Notably, concentrated carbothermal reduction led to substantial concentrations of Pb (2.5–7.1 %) and Zn (4.9–20.7 %), rendering them amenable for recycling through metallurgical routes. Intriguingly, higher carbon content (FA/Carbon = 1:0.3) hindered rather than enhanced heavy metal volatilization from RFA. We found that condensation of NaCl and KCl occurred in carbon pores, causing the formation of molten eutectic which trapped the heavy metals at high temperatures. Therefore, more carbon showed more enhancement of heavy metal volatilization from WFA which was free of NaCl and KCl. Ultimately, two comprehensive pathways for the resourceful utilization of fly ash based on carbon thermal reduction were proposed and compared. This study demonstrates carbothermal reduction as an effective approach for simultaneous purification and metal recovery of MSWI FA, exhibiting promising potential for industrial application. [ABSTRACT FROM AUTHOR]