Design of a fixed-bed ion-exchange process for the treatment of rinse waters generated in the galvanization process using Laminaria hyperborea as natural cation exchanger

In this study, the removal of zinc from galvanization wastewaters was performed in a fixed bed column packed with brown macro-algae Laminaria hyperborea, acting as a natural cation exchanger (resin). The rinse wastewater presents a zinc concentration between 9 and 22 mg/L, a high concentration of light metals (mainly Na and Ca), a high conductivity (0.5-1.5 mS/cm) and a low organic content (DOC = 7 -15 mg C/L). The zinc speciation diagram showed that approximately 80% of zinc is in the form of Zn2+ and congruent to 20% as ZnSO4, considering the effluent matrix. From all operational conditions tested for zinc uptake (17 < bed height <27 cm, 4.5 < flow rate < 18.2 BV/h, 0.8 < particle equivalent diameter < 2.0 mm), the highest useful capacity (7.1 mg Zn/g algae) was obtained for D/dp = 31, LID = 11, 9.1 BV/h, tau = 6.4 min, corresponding to a service capacity of 124 BV (endpoint of 2 mg Zn/L). Elution was faster and near to 100% effective using 10 BV of HCl (1 M, 3.0%, 363 g HCl/L of resin), for flow rates higher than 4.5 BV/h. Calcium chloride solution (0.1 M) was selected as the best regenerant, allowing the reuse of the natural resin for more than 3 saturation/elution/regeneration cycles. The best operation conditions were scaled-up and tested in a pre-pilot plant. The scale-up design of the cation exchange process was proposed for the treatment of 2.4 m(3)/day of galvanization wastewater, resulting in an estimated reactants cost of 2.44 (sic)/m(3)