Optimization of process parameters and kinetics of fluoride extraction from spent potlining using response surface methodology

Over the years, spent potlining (SPL) treatment has only focused on the extraction of its hazardous compounds, especially fluorides and cyanides. The literature has not sufficiently addressed the optimization and kinetics of fluoride extraction using statistical modeling to determine relevant factors for efficient, cost-effective, and sustainable SPL treatment. Hence, this study is focused on response surface methodology (RSM) combined with central composite design (CCD) to statistically model fluoride extraction of SPL behaviour in acidic environments. Shrinkage core model (SCM) was used to investigate the kinetics of fluoride extraction. The RSM analyses suggested a second-order quadratic model with outstanding accuracy, statistically supported by R² and adjusted R² values of 0.986 and 0.973, respectively. The quadratic model indicates the main factors influencing fluoride extraction, showing the complex interactions of temperature, particle size, acid concentration, and leaching time. These main factors were observed to have significant effects on fluoride extraction, except for particle sizes of the SPL. The optimization process, a key success of this study, achieved fluoride extraction of 87.49% at specific factor levels of 48.43 °C, 0.752 mm, 1.2 M, and 10 min. Subsequently, the SCM investigations suggested that diffusion through a liquid film mechanism best approximates the fluoride extraction kinetic behaviour with R² > 0.80 across varying temperatures. Investigations into temperature dependence with the Arrhenius plot further validated that the reaction kinetics were principally controlled by diffusion through liquid film, with an activation energy of 36.26 kJ/mol. Integrating these kinetic frameworks provides a novel approach to analyzing and optimizing SPL fluoride extraction. Overall, adopting the present study in the industrial settings with the optimized parameters will ensure efficient, sustainable, and cost-effective treatment of SPL.