Valorization of wastes from the fertilizer industry: Current status and future trends

Abstract Based on a systematic literature search (Number of initial publications = 1571; Number of in-depth publications = 97), this paper reviews the different potential applications for phosphogypsum, the main unwanted by-product of the fertilizer industry, providing some insights into the new valorization routes, and critically describing the advantages and drawbacks of each one. Industry and policy makers face the challenge to manage the increasing loads of phosphogypsum generated worldwide, especially on reasons of cost, safety and environmental impact. The recycling of this material could be an environmentally friendly, safe and cost-effective solution for this quandary. Different phosphogypsum valorization routes were developed in the last years in agriculture, building, and environmental and energy sectors, and these topics are described along this review. The first barrier to be overcome is the shift of paradigm needed to consider phosphogypsum not as a waste but as a raw material and the harmonization of classification rules of this material worldwide. Another issue to be faced is the heterogeneity of phosphogypsum reported worldwide, which could make unfeasible certain applications due to chemical and physical differences. On the one hand, while technical and economic constraints are increasingly lifted, many applications of phosphogypsum valorization consume low amounts of waste, and thus cannot satisfy the purpose of mass consumption. In addition, the different valorization routes may cause a secondary pollution which must be evaluated and compared with that caused by traditional disposal options. In order to provide a solution to this waste management, a better social and political awareness is needed. Economic and technical constraints must be lifted by a higher economic investment on research and development. However, site by site studies and assessment of secondary pollution using suitable tools (e.g. life cycle analysis) must be performed in order to assure the success of each valorization route.

[1]  B. Das,et al.  Studies on Extraction of Potassium from Feldspar by Roast-leach Method Using Phosphogypsum and Sodium Chloride , 2016 .

[2]  John E. Gilley,et al.  Nutrient, Carbon, and Mass Loss during Composting of Beef Cattle Feedlot Manure , 1997 .

[3]  Radha Shivaramaiah,et al.  Location and stability of europium in calcium sulfate and its relevance to rare earth recovery from phosphogypsum waste , 2016 .

[4]  M. Belgacem,et al.  Preparation and application of Tunisian phosphogypsum as fillers in papermaking made from Prunus amygdalus and Tamarisk sp. , 2017 .

[5]  Yun Yan,et al.  Utilization of original phosphogypsum for the preparation of foam concrete , 2016 .

[6]  J. Römbke,et al.  Phosphogypsum as a soil fertilizer: Ecotoxicity of amended soil and elutriates to bacteria, invertebrates, algae and plants. , 2015, Journal of hazardous materials.

[7]  J. Arocena,et al.  Heterogeneous distribution of trace elements and fluorine in phosphogypsum by-product , 1995 .

[8]  V. Yilmaz,et al.  Infrared study on the refinement of phosphogypsum for cements , 1988 .

[9]  V. Morales-Flórez,et al.  New method for carbon dioxide mineralization based on phosphogypsum and aluminium-rich industrial wastes resulting in valuable carbonated by-products , 2017 .

[10]  M. Dudas,et al.  Environmental impacts of phosphogypsum , 1994 .

[11]  M. Mitrić,et al.  Removal of Co2+ from aqueous solutions by hydroxyapatite. , 2006, Water research.

[12]  Weigang Lin,et al.  Experimental study of enhanced phosphogypsum carbonation with ammonia under increased CO2 pressure , 2015 .

[13]  C. R. Cánovas,et al.  Pollutant flows from a phosphogypsum disposal area to an estuarine environment: An insight from geochemical signatures. , 2016, The Science of the total environment.

[14]  A. Rashad Phosphogypsum as a construction material , 2017 .

[15]  R. Cioffi,et al.  Energy-saving cements obtained from chemical gypsum and other industrial wastes , 1996 .

[16]  C. Sundaram,et al.  Defluoridation chemistry of synthetic hydroxyapatite at nano scale: equilibrium and kinetic studies. , 2008, Journal of hazardous materials.

[17]  R. García‐Tenorio,et al.  The cumulative effect of three decades of phosphogypsum amendments in reclaimed marsh soils from SW Spain: (226)Ra, (238)U and Cd contents in soils and tomato fruit. , 2008, The Science of the total environment.

[18]  B. Mazzilli,et al.  Lixiviation of natural radionuclides and heavy metals in tropical soils amended with phosphogypsum. , 2015, Journal of environmental radioactivity.

[19]  M. T. García-González,et al.  Potential use of gypsum and lime rich industrial by-products for induced reduction of Pb, Zn and Ni leachability in an acid soil. , 2010, Journal of hazardous materials.

[20]  S. Çoruh,et al.  Use of fly ash, phosphogypsum and red mud as a liner material for the disposal of hazardous zinc leach residue waste. , 2010, Journal of hazardous materials.

[21]  M. Rentería-Villalobos,et al.  Radiological, chemical and morphological characterizations of phosphate rock and phosphogypsum from phosphoric acid factories in SW Spain. , 2010, Journal of hazardous materials.

[22]  B. Mazzilli,et al.  Partitioning of radionuclides and trace elements in phosphogypsum and its source materials based on sequential extraction methods. , 2006, Journal of environmental radioactivity.

[23]  Guoxue Li,et al.  Effects of phosphogypsum and superphosphate on compost maturity and gaseous emissions during kitchen waste composting. , 2015, Waste management.

[24]  R. Sievert,et al.  Book Reviews : Recommendations of the International Commission on Radiological Protection (as amended 1959 and revised 1962). I.C.R.P. Publication 6. 70 pp. PERGAMON PRESS. Oxford, London and New York, 1964. £1 5s. 0d. [TB/54] , 1964 .

[25]  John S. Preston,et al.  The recovery of rare earth oxides from a phosphoric acid by-product. Part 1: Leaching of rare earth values and recovery of a mixed rare earth oxide by solvent extraction , 1996 .

[26]  J. Rechcigl,et al.  Phosphogypsum in agriculture: a review. , 1993 .

[27]  G. Azimi,et al.  Process investigation of the acid leaching of rare earth elements from phosphogypsum using HCl, HNO3, and H2SO4 , 2016 .

[28]  J. Corrente,et al.  Controlling ammonia losses during manure composting with the addition of phosphogypsum and simple superphosphate , 1995 .

[29]  M. F. Attallah,et al.  Treatment of phosphogypsum waste using suitable organic extractants , 2011, Journal of Radioanalytical and Nuclear Chemistry.

[30]  N. Curi,et al.  Increasing arsenic sorption on red mud by phosphogypsum addition. , 2013, Journal of hazardous materials.

[31]  H. El-Didamony,et al.  Treatment of phosphogypsum waste produced from phosphate ore processing. , 2013, Journal of hazardous materials.

[32]  O. A. Tareeva,et al.  Leaching of Lanthanides from Phosphohemihydrate with Nitric Acid , 2002 .

[33]  Y. M. Amin,et al.  Distribution of some trace metals in Syrian phosphogypsum , 2004 .

[34]  Xibing Li,et al.  Immobilization of phosphogypsum for cemented paste backfill and its environmental effect , 2017 .

[35]  Tom Van Gerven,et al.  Towards zero-waste valorisation of rare-earth-containing industrial process residues: a critical review , 2015 .

[36]  José Miguel Nieto,et al.  An anomalous metal-rich phosphogypsum: Characterization and classification according to international regulations. , 2017, Journal of hazardous materials.

[37]  B. Mazzilli,et al.  Phosphogypsum recycling in the building materials industry: assessment of the radon exhalation rate. , 2017, Journal of environmental radioactivity.

[38]  J. Bolívar,et al.  Radioactive impact in sediments from an estuarine system affected by industrial wastes releases. , 2002, Environment international.

[39]  Zygmunt Kowalski,et al.  Evaluation of the recovery of Rare Earth Elements (REE) from phosphogypsum waste – case study of the WIZÓW Chemical Plant (Poland) , 2016 .

[40]  J. Nieto,et al.  Assessment of phosphogypsum impact on the salt-marshes of the Tinto river (SW Spain): role of natural attenuation processes. , 2011, Marine pollution bulletin.

[41]  Yi Wang,et al.  Utilization of waste phosphogypsum to prepare hydroxyapatite nanoparticles and its application towards removal of fluoride from aqueous solution. , 2012, Journal of hazardous materials.

[42]  W. Choi,et al.  Nitrogen, carbon, and dry matter losses during composting of livestock manure with two bulking agents as affected by co-amendments of phosphogypsum and zeolite , 2017 .

[43]  L. D. Norton,et al.  EFFECTS OF SURFACE TREATMENT ON SURFACE SEALING, RUNOFF, AND INTERRILL EROSION , 1998 .

[44]  C. Ayora,et al.  The potential role of aluminium hydroxysulphates in the removal of contaminants in acid mine drainage , 2015 .

[45]  F. Larney,et al.  The effect of phosphogypsum on greenhouse gas emissions during cattle manure composting. , 2005, Journal of environmental quality.

[46]  C. R. Cánovas,et al.  Exploration of fertilizer industry wastes as potential source of critical raw materials , 2017 .

[47]  V. Morales-Flórez,et al.  Fractionation and fluxes of metals and radionuclides during the recycling process of phosphogypsum wastes applied to mineral CO₂ sequestration. , 2015, Waste management.

[48]  A. Valkov,et al.  Phosphogypsum Technology with the Extraction of Valuable Components , 2014 .

[49]  O. Al-Khashman,et al.  Health risk assessment of heavy metals contamination in tomato and green pepper plants grown in soils amended with phosphogypsum waste materials , 2015, Environmental Geochemistry and Health.

[50]  M. Dudas,et al.  Radioactivity and chemical characteristics of Alberta phosphogypsum , 1993 .

[51]  Tadashi Takahashi,et al.  Efficiency of gypsum application to acid Andosols estimated using aluminum release rates and plant root growth , 2006 .

[52]  J. Ranville,et al.  Bioavailability and mobility of trace metals in phosphogypsum from Aqaba and Eshidiya, Jordan , 2010 .

[53]  M. Onuki,et al.  Support Phosphorus Recycling Policy with Social Life Cycle Assessment: A Case of Japan , 2017 .

[54]  Aurora López-Delgado,et al.  Environmental impact and management of phosphogypsum. , 2009, Journal of environmental management.

[55]  P. Courjault-Radé,et al.  Heavy metal contamination and ecological risk assessment in the surface sediments of the coastal area surrounding the industrial complex of Gabes city, Gulf of Gabes, SE Tunisia. , 2015, Marine pollution bulletin.

[56]  Junliang Yang,et al.  Theoretical and experimental demonstration of lignite chemical looping gasification of phosphogypsum oxygen carrier for syngas generation , 2017 .

[57]  V. Morales-Flórez,et al.  Procedure to use phosphogypsum industrial waste for mineral CO2 sequestration. , 2011, Journal of hazardous materials.

[58]  J. Bolívar,et al.  Valorization of phosphogypsum waste as asphaltic bitumen modifier. , 2014, Journal of hazardous materials.

[59]  Tao Jiang,et al.  Effect of phosphogypsum and dicyandiamide as additives on NH3, N20 and CH4 emissions during composting. , 2013, Journal of environmental sciences.

[60]  K. Okada,et al.  Ion uptake properties of low-cost inorganic sorption materials in the CaO–Al2O3–SiO2 system prepared from phosphogypsum and kaolin , 2014 .

[61]  Bernd G. Lottermoser,et al.  Mine Wastes: Characterization, Treatment and Environmental Impacts , 2003 .

[62]  Barbara Paci Mazzilli,et al.  Radiochemical characterization of Brazilian phosphogypsum , 2000 .

[63]  J. Ober Mineral commodity summaries 2017 , 2017 .

[64]  C. R. Cánovas,et al.  Mobility of rare earth elements, yttrium and scandium from a phosphogypsum stack: Environmental and economic implications. , 2018, The Science of the total environment.

[65]  A. Jarosiński,et al.  Development of the Polish wasteless technology of apatite phosphogypsum utilization with recovery of rare earths , 1993 .

[66]  O. Polvillo,et al.  Implications for food safety of the uptake by tomato of 25 trace-elements from a phosphogypsum amended soil from SW Spain. , 2014, Journal of hazardous materials.

[67]  Konstantin Kovler,et al.  Radiological constraints of using building materials and industrial by-products in construction , 2009 .

[68]  Fenglian Fu,et al.  Removal of heavy metal ions from wastewaters: a review. , 2011, Journal of environmental management.

[69]  Sandra Belboom,et al.  Environmental impacts of phosphoric acid production using di-hemihydrate process: a Belgian case study , 2015 .

[70]  Jian Yu,et al.  Runoff and Interrill Erosion in Sodic Soils Treated with Dry PAM and Phosphogypsum , 2006 .

[71]  Nilgün Balkaya,et al.  Adsorption of cadmium from aqueous solution by phosphogypsum , 2008 .

[72]  Antonio Delgado,et al.  Fertilizer Phosphorus Recovery from Gypsum-Amended, Reclaimed Calcareous Marsh Soils , 2002 .

[73]  Health cancer risk assessment for arsenic exposure in potentially contaminated areas by fertilizer plants: a possible regulatory approach applied to a case study in Moscow region-Russia. , 2002, Regulatory toxicology and pharmacology : RTP.

[74]  J. Nieto,et al.  Environmental tracers for elucidating the weathering process in a phosphogypsum disposal site: Implications for restoration , 2015 .

[75]  Yunsheng Zhang,et al.  Utilization of original phosphogypsum as raw material for the preparation of self-leveling mortar , 2016 .

[76]  Fathi Habashi,et al.  The recovery of the lanthanides from phosphate rock , 2007 .