Leaching of Waste Pharmaceutical Blister Package Aluminium in Sulphuric Acid Media

In this study, the leaching behaviour of aluminium from waste pharmaceutical blister packages (WPBs) is investigated in sulphuric acid media to build future strategies for aluminium recycling from this non-recycled waste fraction. The results suggest that in hydrometallurgical recycling, passivation of aluminium during leaching can be mitigated in dilute sulphuric acid solutions (0.25 M), at high temperatures (60–80 °C) and specifically with H₂O₂ addition. With this system, 100% extraction was achieved within five hours under optimized conditions (H₂SO₄ = 0.25 M, T = 80 °C, H₂O₂ = 1.25 vol.%). The leaching mechanism is suggested to be based on electrochemical dissolution of metallic aluminium oxidized by H⁺ or H₂O₂, followed by fast passivation by Al₂O₃ and consequent chemical dissolution of Al₂O₃ at slower kinetics. The calculated activation energy (~69 kJ/mol) suggests that the leaching reaction is controlled by the chemical or electrochemical reaction step rather than diffusion. By WPB leaching, an aluminium sulphate solution could be obtained, suitable for further aluminium sulphate crystallization. This may provide a potential route for the valorisation of aluminium from a currently overlooked waste fraction of pharmaceutical blister packages.