Eco-Friendly and Complex Processing of Vanadium-Bearing Waste for Effective Extraction of Valuable Metals and Other By-Products: A Critical Review

Achieving the New World Sustainability Vision 2030 leads to enacting environmental restrictions, which aim to partially or totally reduce the negative impacts of different forms of waste and develop alternative technologies for eco-friendly and cost-effective utilization. Solid waste is a hazardous waste with many environmental and economic problems resulting from its storage and disposal. However, at the same time, these wastes contain many valuable elements. One of these solid wastes is heavy oil fly ash “HOFA” generated in power stations using heavy oil as fuel. HOFA is produced annually in massive amounts worldwide, the storage of which leads to the contamination of water resources by the contained heavy metals, resulting in many cancerogenic diseases. At the same time, these ashes contain many valuable metals in significant amounts, such as vanadium “V” and nickel “Ni” that can be extracted effectively compared to their low content and difficulty processing in their main ores. Hence, recycling these types of wastes reduces the environmental adverse effects of their storage and the harmful elements in their composition. This paper critically reviews the world resources of vanadium-bearing waste and various approaches described in the literature for recovering V, Ni, as well as other valuable metals from (HOFA) and other wastes, including pyro- and hydro-metallurgical processes or a combination. Hydro-metallurgical processes include alkaline or acidic leaching using different reagents followed by chemical precipitation, solvent extraction, and ion exchange to extract individual elements. The pyro-metallurgical processes involve the non-salt or salt roasting processes followed by acidic or alkaline leaching processes. The operational parameters and their impact on the efficiency of recovery are also discussed. The digestion mixtures of strong mineral acids used to dissolve metal ions in HOFA are also investigated. Bioleaching is a promising eco-friendly technology for recovering V and Ni through appropriate bacteria and fungi. Oxidation leaching is also a promising environmentally friendly approach and more effective. Among all these processes, the salt roasting treatment showed promising results concerning the cost, technological, and environmental effectiveness. The possibility of complex processing of HOFA has also been investigated, proposing innovative technology for completely utilizing this waste without any remaining residue. Effective zeolite for wastewater treatment has been formulated as a good alternative for conserving the available water resources.