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Minerals Engineering
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A R T I C LE I N FO A B S T R A C T
Keywords: In this study, eggshell (ES) powder was evaluated as a cheap and biocompatible waste material for the pre-
Acid mine drainage treatment of acid mine drainage (AMD) leachate from coal dump. First, the composition of the AMD and phy-
Eggshell siochemical properties of the ES powder were determined using various standard characterization techniques.
Neutralisation Then the removal efficiency of the target metal contaminants and the acid-neutralisation effect were explored in
Removal
batch and kinetic set-ups. Thereafter, the settling rate of sludge formed after separately reacting ES and lime-
Treatment
stone powders with AMD was explored. Results revealed that the AMD leachate was highly acidic and con-
taminated with both cations and anions. Thermogravimetric analysis (TGA) and X-ray fluorescence (XRF)
analyses demonstrated that ES powder was thermally stable up to 700 °C and CaO was the main component,
respectively. Scanning electron microscopy (SEM) and EDX spectra confirmed the removal of contaminants. Both
the decrease in particle size and increase in mass of ES enhanced the treatment efficiency. Although complete Fe
and Al removal was achieved, Mn and sulphates posed a challenge as they were partially removed. Meanwhile,
ES demonstrated superior acid-neutralizing effect to limestone and the mine water clarity and pH were shifted to
acceptable levels. Both Fe and Al removal proceeded through an exothermic process while it was opposite for
Mn. Kinetics were rapid and the sludge from ES powder settled faster compared with that from limestone
powder. Cost analysis indicated that significant financial savings can be realised by substituting limestone with
ES material. The findings suggest that ES waste could be an efficient and cheap material in the pre-treatment of
AMD effluents.
1. Introduction et al., 2010; Enslin et al., 2010; Tutu et al., 2008). Consequently, to
ameliorate the AMD problem, pragmatic efforts have been constantly
Mining industry plays an integral part towards the growth and de- sought to offer innovative, efficient and less costly treatment methods
velopment of South Africa’s economy. However, fragmentation of sul- that could serve as a supplement or as alternative to the existing AMD
phide bearing minerals (FeS2) during mining and mineral extraction treatment technologies and to improve the level of compliance.
exposes them to oxygenated environment leading to a series of complex Numerous methods such as lime neutralisation and precipitation
geochemical reactions that generate acid mine drainage (AMD). Acid (Coulton et al., 2003), ion-exchange (Khan, 2014), adsorption (Hong
mine drainage is highly acidic (pH < 3), has a high concentration of et al., 2014; Masindi et al., 2015), electrochemical (Chartrand and
dissolved iron, aluminium, manganese and sulphates; causing a de- Bunce, 2003) and bioremediation (Johnson and Hallberg, 2005;
vastating impact on water resources and consequent damage to the Rakotonimaro et al., 2017; Sierra-Alvarez et al., 2006) are used for
health of biota (Colvin and Burns, 2011; Ríos et al., 2008). Although AMD treatment. Amongst these, limestone/lime neutralisation and
certain rocks, especially those containing large amounts of dolomite or precipitation of metals in the form of hydroxides and gypsum, followed
calcite can naturally neutralise AMD, this is not the situation in South by a period of settling in sedimentation basins is by far the most widely
Africa’s coal and gold mine deposits as natural neutralisation effects are used method for AMD pre-treatment (Gitari et al., 2008; Johnson and
overwhelmed (McCarthy, 2011). Numerous cases of highly acidic water Hallberg, 2005; Maree et al., 2013). Although effective, chemical pre-
with elevated concentrations of metal ions and sulphates beyond ac- cipitation requires large quantity of treatment reagents, resulting in
ceptable standards have been reported (da Silveira et al., 2009; De Beer voluminous and highly hydrated sludge, which dries and compacts
⁎
Corresponding author.
E-mail address: MuliwaAM@tut.ac.za (A.M. Muliwa).
https://doi.org/10.1016/j.mineng.2018.04.009
Received 17 January 2018; Received in revised form 28 March 2018; Accepted 14 April 2018
Available online 24 April 2018
0892-6875/ © 2018 Elsevier Ltd. All rights reserved.
A.M. Muliwa et al. Minerals Engineering 122 (2018) 241–250
poorly, posing disposal and storage challenges. Moreover, limestone collected, prepared, characterised and evaluated for the removal of
mining may have significant negative impact on the environment and main cations (Al, Fe, Mn) and anions (SO42−) present in the AMD.
the public health. Although limestone is cheap, it exhibits slow reaction Batch equilibrium and kinetic experiments were conducted to explore
time, and its properties are geologic dependant, meaning inconsistency the influence of different process variables on the overall treatment
in grade can affect the overall performance of a given treatment system efficiency. In addition, the performance of eggshell in terms of neu-
(da Silveira et al., 2009; Skousen, 2014). Due to such limitations, it is an tralisation efficiency, sludge settling rate and volume was compared
important challenge for industries and researchers to explore other with raw limestone of similar properties. Results obtained from this
natural materials for effective and economical pre-treatment/neu- study provides important insights into the possible application of the ES
tralising of AMD. Furthermore, such alternative solutions would be waste as a cheap and effective substitute material for the pre-treatment
more viable if they can be used in an existing treatment facility with of AMD.
minimal changes.
Recently, adsorption technology, employing naturally-derived ma-
2. Materials and methods
terials has received increasing attention (Bulut and Tez, 2007), as an
effective, efficient and economical method for sequestration of heavy
2.1. Materials
metals from aqueous solution (Bulut and Tez, 2007; Faur-Brasquet
et al., 2002; Gupta and Nayak, 2012; Yu et al., 2001). This is because
Eggshell waste was collected from the Tshwane University of
most of the reported synthetic adsorbents require long preparation re-
Technology restaurant. Multi-ions standards solutions and analytical
cipe and are generally expensive. Thus, there has been a shift in focus
reagent grade (AR) chemicals were purchased from Merck (Pty) Ltd-
towards low-cost agriculturally-derived materials with desirable ad-
South Africa. Limestone powder was obtained from G&W Mineral
sorptive and acid neutralisation characteristics (Oke et al., 2008). Lit-
Resources (South Africa). Before use in adsorption experiments, all the
erature reports indicate that activated carbon (Goher et al., 2015),
glassware and polyethylene bottles were firstly soaked with 10% nitric
chitosan (Bassi et al., 2000), banana and orange peels (Annadural et al.,
acid for 24 h and thereafter were rinsed with deionised water and dried
2003), sugar cane bagasse (Joseph et al., 2009), sawdust (Yu et al.,
in a clean oven.
2001) and rice husks (Hegazi, 2013) among others, have the potential
to sequestrate metal ions from polluted water.
Recently, increased egg production and processing has resulted in 2.2. Acid mine water
increased eggshell (ES) waste; a non-edible product with very limited
use and value. The disposal of ES waste is an environmental burden Acid mine drainage (AMD) samples were obtained as Toe Seep
worldwide, and especially in countries where the egg product industry Leachate from a waste coal dump in Anglo American Thermal Coal,
is well developed (Hassan and Aigbodion, 2015). According to Witbank (South Africa). Standard sampling procedures (EPA, 2007)
Windhorst et al. (2013), approximately 124,800 tons of ES waste was were followed after which the samples were filtered using 45 µm cel-
produced globally in the year 2010 as a result of industrial egg pro- lulose acetate filters and were stored in polyethylene bottles at 4 °C. The
cessing. Furthermore, statistics by the Food and Agricultural Organi- concentration of metal ions in the samples was determined using in-
zation (FAO) indicates that the global egg production is likely to hit ductively coupled plasma atomic emission spectrometer (ICP-AES,
86.8 million tons by 2030 (FAO, 2014). The projected increase in egg 9000, Shimadzu-Japan). Anions were quantified using the Metrohm
production therefore, means large quantities of ES will be produced and 861 compact ion chromatograph (Switzerland) with a Metrosep A Supp
disposed of as waste. As a result, high disposal cost will continue to 5 (6.1006.520) 150 × 4.0 mm analytical column. Before any analysis,
increase due to increase in landfill taxes and environmental concerns both instruments were calibrated using standard solutions. The pH was
(Hassan and Aigbodion, 2015). Therefore, it is necessary to find alter- measured with Orion Star A211 pH meter (Thermo Scientific). The
native ways to transform ES into a valuable item for overcoming en- meter was calibrated with 4.0, 7.0 and 10.0 buffer solutions before each
vironmental challenges. set of trials.
The main component of the ES is calcium carbonate (CaCO3), which The main chemical composition of AMD was determined and are
can be used as a complexing, binding or ions exchange agent for metal displayed in Table 1. As it can be seen, the AMD is highly acidic
ions in liquid solution. Moreover, CaCO3 is a significant alkalizing agent pH = 2.43; which was way far below the recommended values
and when equilibrated with acidic water, it neutralises it; meaning (6.5–8.5) by the World Health Organization (WHO, 2011). Also, the
heavy metals can precipitate and adsorb on ES particles’ surface. Such
characteristic make eggshell waste a potential material for removing Table 1
contaminants, especially cations from the liquid phase. Few studies Main chemical composition of raw AMD (toe seep leachate from coal discard
have explored ES as a promising scavenger for metal ions in aqueous dump) sample from Anglo American thermal coal, Witbank (South Africa).
solution (Ahmad et al., 2012; Elabbas et al., 2016; Ipeaiyeda and Tesi, Parameter Value Drinking guideline value
2014; Jai et al., 2007; Rubcumintara, 2014; Suheila, 2013; Zheng et al.,
2007). Nonetheless, there is still a lack of practical applicability because pH (at 25 °C) 2.43 6.5–8.5a
K (mg/L) 10.2 10a
previous studies focused mainly on removing dilute concentrations of
Na (mg/L) 149.7 250a
metal ions from synthetic solutions, instead of using environmental Ca (mg/L) 606 200a
water samples. Besides, adsorption alone is mainly suitable as a pol- Mg (mg/L) 648 100a
ishing step, and for it to be effective in highly contaminated waters, it Fe (mg/L) 6120 0.3b
Al (mg/L) 506 0.2b
may be considered important to supplement it with neutralisation. In
Mn (mg/L) 155 0.1b
view of the aforementioned, it can be a considerable task to examine SO42− (g/L) 28.98 0.25b
the ability of ES waste for use as an effective precipitation and ad- PO43− (mg/L) 75 10b
sorption surface for both cations and anions present in highly acidic and NO3− (g/L) 137 50b
contaminated environmental samples. EC (mS/cm) 12.41 1.4a
Turbidity (NTU) 65.32 5a
Thus the aim of this study was to examine ES waste as a cheap and
TDS (g/L) 10.27 1.0a
biocompatible material for the pre-treatment and attenuation of AMD
from toe seep coal dump leachate. To the best of our knowledge, there TDS = (0.8 * EC) + (2.2 * 10^−6 * EC^2).
a
is hardly any literature report available regarding the application of ES World Health Organisation (WHO).
b
waste for remediation of highly polluted AMD. Eggshell waste was Department of Water Affairs (DWA) South Africa.
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A.M. Muliwa et al. Minerals Engineering 122 (2018) 241–250
AMD had a conductivity value of 12.41 mS/cm suggesting that in- produced by ES and limestone powder (53–160 µm) was determined by
organic ions were present in reasonable concentration. Total dissolved adding 8 g of each material in 400 mL of raw AMD in a beaker. The
solids (TDS), Fe, Al, Mn and sulphates were all present in high levels mixtures were stirred at 180 rpm using an overhead stirrer at room
exceeding discharge limit values recommended by most environmental temperature for 24 h. Thereafter, the mixtures were separately in-
regulatory bodies. Generally, the AMD was highly polluted and offered troduced into 500 mL graduated cylinders at the same time and the
a platform to provide factual data for application purposes. depth of sludge blanket were monitored periodically until the final
reading remained constant. The final reading was considered as the
2.3. Eggshell preparation and characterization sludge volume. In another set of experiments, the effect of temperature
(25–45 °C) on the metal removal was explored by varying their initial
The collected eggshell waste was first washed with tap water and concentrations as follows: Fe (146.8–6120 mg/L), Al (12.14–506 mg/L)
afterwards with deionized water to remove albumin, dirt and other and Mn (3.72–155 mg/L). For an equilibrium to be attained, 0.15 g of
impurities (organics and salts). Then, the washed eggshells were placed ES powder was used instead of 0.5 g. Finally, the effect of contact time
in the oven and dried at 100 °C. The sample was crushed and graded on metal removal efficiency was explored by adding 20 g of ES powder
into various fractions using a series of sieves ranging between into 1 L of raw. The mixture was stirred continuously at room tem-
0.053 mm and 1.000 mm. The chemical composition of unused ES (ES perature and samples were collected at predetermined time intervals,
before reacting with AMD) and used ES (AMD-reacted ES) powders was they were filtered and analysed for residual metal ions. Thereafter, the
analysed by X-ray fluorescence (XRF) ARL Perform'X Sequential XRF removal efficiency at any given time was calculated using Eq. (1). The
instrument. In a typical procedure, the samples were roasted at 1000 °C concentrations of the Ca2+, K+, Mg2+, Na+, SO42−, PO43−, and NO3−
to determine Loss On Ignition (LOI). Then 1 g of the roasted sample was in both raw and treated AMD were determined.
placed together with 6 g of Li2B4O7 into a Pt/Au crucible and fused and
the analyses were executed using the Quantas software. The software 3. Results and discussion
analysis for all elements in the periodic table between Na and U, but
only elements found above the detection limits were reported. The re- 3.1. Eggshell (ES) characterisation
sults were also monitored and filtered to eliminate the presence of some
of the flux, wetting and oxidising agents’ elements. Blank and certified Thermal properties of unused ES and used ES powders are shown in
reference materials were also analysed with each batch of samples and Fig. 1. As shown, the weight decreased by 6% and 9% for unused ES
were represented in the results. The morphological and elemental as-
pects were observed by field emission scanning electron microscopy
(FE-SEM JEOL JSM-7600F) fitted with energy dispersive X-ray spec-
troscopy (EDX). The functional groups were identified by Fourier
transform infra-red (FT-IR) spectrometer instrument while thermal
properties were examined using thermo-gravimetric analyser (TGA)
and differential thermal analyser (DTA) (Perkin-Elmer Pyris 1 TGA
instrument) at 10 °C/min heating rate in an air environment. For TGA
analysis a given amount of the dried eggshell powder was loaded in the
TGA/DTA analyser and then pyrolysis was performed up to 900 °C at an
elevation of temperature 10 °C/min with continuous injection of air.
Ci−Cf ⎞
R% = ⎛ ⎜ × 100
⎟
⎝ Ci ⎠ (1)
where Ci and Cf are initial and final concentrations (mg/L) in the raw
and treated AMD, respectively.
The effect of ES dose (0.075–1.25 g) on the removal efficiency was
investigated with 53–160 µm particles; owing to their positive pre-
liminary results. After the equilibration the final pH of each treated
AMD sample solution was measured and recorded. For comparison
purposes, limestone powder (53–160 µm) was also tested under similar
conditions. The effect of initial pH (1.75–3.30) on the removal effi-
ciency was investigated by adding 0.5 g of ES into 25 mL of AMD. This
pH range was chosen to prevent precipitations of Fe and Al. Fig. 1. TGA and DTA profiles for (a) unused ES and (b) used ES powder
Meanwhile, a comparison of the settling rate and sludge volume (53–160 µm).
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A.M. Muliwa et al. Minerals Engineering 122 (2018) 241–250
Table 2
XRF analyses of ES powder before and after AMD treatment.
Component (%) SiO2 TiO2 Al2O3 Fe2O3 MnO MgO CaO Na2O P2O5 SO3 LOI
Before 0.03 < 0.1 0.01 0.02 < 0.1 0.63 51.40 < 0.1 0.24 0.23 47.50
After 0.15 < 0.1 0.74 5.39 0.13 0.55 46.40 < 0.1 0.24 1.48 44.90
244
A.M. Muliwa et al. Minerals Engineering 122 (2018) 241–250
Fig. 3. SEM micrographs and EDX spectra [(a) and (c)] unused ES and [(b) and (d)] used ES powder (particle size 53–160 µm).
Fig. 5. Effect of adsorbent dose on metals’ removal efficiency (Fe = 6120 mg/L,
Fig. 4. Effect of particle size on metal removal efficiency (Fe = 6120 mg/L,
Al = 506 mg/L, Mn = 155 mg/L, particle size = 53–160 µm, volume = 25 mL,
Al = 506 mg/L, Mn = 155 mg/L, mass = 0.5 g, volume = 25 mL,
pH = 2.43, temp = 25 °C, speed = 180 rpm, time = 24 h).
temp = 25 °C, speed = 180 rpm, time = 24 h).
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A.M. Muliwa et al. Minerals Engineering 122 (2018) 241–250
Fig. 6. Influence of ES mass on final pH (mass = 0.5 g, volume = 25 mL, initial Fig. 7. Influence of initial pH on Fe, Al and Mn removal (Fe = 6120 mg/L,
pH = 2.43, temp = 25 °C, speed = 180 rpm, time = 24 h). Al = 506 mg/L, Mn = 155 mg/L, Volume = 25 mL, mass = 0.5 g,
temp = 25 °C, speed = 180 rpm, particle size = 53–160 µm, time = 24 h).
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A.M. Muliwa et al. Minerals Engineering 122 (2018) 241–250
Table 3
Overall AMD pre-treatment efficiency using ES (mass = 0.5 g, particle
size = 53–160 µm, volume = 25 mL, Temperature = 25 °C).
Parameter Untreated Pre-treated % Change WHO
AMD AMD standards
The study of the rate of sludge formation and settling during water
treatment process is an important undertaking because it provides in-
formation regarding the sizing of the sedimentation and drying ponds.
In order to evaluate this characteristic, ES and limestone powders of
same particle sizes (53–160 µm) were continuously contacted with
AMD for 12 h. Fig. 10 shows that complete settling of the ES/AMD
sludge was achieved within 10 min whilst about 40 min was required
247
A.M. Muliwa et al. Minerals Engineering 122 (2018) 241–250
creased sludge volume (as it was the case with ES/AMD system) can AMD flow rate (Ml/day) 1.75 1.75
lower the capital cost in terms of sizes and number of sedimentation Optimal pre-treatment dosage (mg/L) 20,000 20,082
ponds and filter presses, as well as the operation cost in terms of ef- Monthly eggshell preparation cost (ZAR) 956,340 –
fluent volume treated in a short period. Since sludge constitutes a sig- Price per ton (ZAR/t) 910 1200
Cost of pre-treating one cubic metre 18.2 24.10
nificant proportion of the overall treatment costs, it is important to
(ZAR/m3)
suggest appropriate management options. In this study, authors suggest Total daily pre-treatment cost (ZAR/day) 31, 850 42, 172
that the ES/AMD sludge may be used as a raw material for pigment Total annual pre-treatment cost 11, 625,250 15, 392,853
production, or alternatively, it could be disposed-off appropriately, (ZAR/year)
Cost ratio 1 1.32
reprocessed, solidified/stabilised, or reused as discussed comprehen-
sively by Zinck (2006). These results demonstrated the ES powder could Note: ZAR symbolises South African Rand; t stands for metric ton; m3 stands for
serve as a low-cost material for the pre-treatment of AMD. cubic metre; the cost will depend on assumptions made and/or factors con-
sidered for each scenario.
Key assumptions considered here: 1 kwh = ZAR 1.96; Transport unit cost = ZAR
3.10. Proposed flow sheet for continuous pre-treatment of AMD using
16/t/km; miscellaneous cost = 10% of the material preparations cost;
eggshell Equipment for ES preparation are supplied by SHANGHAI SCM MACHINERY
CO., Ltd.
Fig. 11 shows the proposed two-phase flow sheet for the pre-treat-
ment of AMD using ES material. In the first phase (the main focus of the
present study), the ES material is used as a limestone substitute to
provide CaCO3 for the pre-treatment/neutralisation (to raise pH to 6) of solid contents and avoid mixing the sludge produced at each stage. The
the highly acidic AMD to remove free acid, Fe, Al (main dissolved ca- proposed treatment process will utilise the existing treatment facility
tions of AMD) and for partial removal of SO42− (gypsum crystal- without major alteration in design. The suitability of this will be ad-
lisation). The second phase (not explored in this study) is expected to dressed in follow-up paper.
utilise commercial grade lime to further neutralise (raise pH to 9.5) to
remove Mn and other metals present, such as Ca and Mg. The entire 3.11. Approximated AMD pre-treatment cost analysis
treatment process is operated under atmospheric conditions to provide
oxygen for complete metal ions oxidations. The two-phase process may The estimated cost analysis for pre-treating AMD using the ES ma-
be less costly compared to a process that uses lime only because the use terial was done based on the previous limestone cost analysis data by
of ES waste in the first phase of the treatment process will substantially Maree et al. (2013). Table 4 shows a comparison of the cost of pre-
reduce the amount of commercial lime required in the second phase. treating toe seep leachate using ES and limestone at the feed flow rate
Each phase comprises a clarifier to allow sufficient settling time for of 1.75 megalitres (Ml)/day. More details on treatment cost (excluding
Fig. 11. Proposed two-phase flow sheet for AMD treatment using ES waste and commercial grade lime.
248
A.M. Muliwa et al. Minerals Engineering 122 (2018) 241–250
capital cost) are provided in the supplementary file. Results show that mine water reclamation using the ABC process. International Mine Water Association
20,000 mg and 20,082 mg are the respective dosages for ES and lime- Symposium, Cape Brenton University, Sydney, Nova Scotia, Canada.
Dizz, H.R., Novak, J.T., Rimstidt, J.D., 1999. Iron precipitation kinetics in synthetic acid
stone, required to pre-treat 1 L of the toe seep leachate. The price of one mine drainage. Mine Water Environ. 18, 1–14.
metric ton of limestone is 1100 South African Rand (ZAR) while the Edwards, J.D., Barton, C.D., Karathanasis, A.D., 2009. A small scale sulfate reducing
estimated cost of ES powder will be ZAR 910/ton. Consequently, the bioreactor for manganese removal from synthetic acid mine drainage. Water, Air Soil
Pollut. 203, 267–275.
unit cost of AMD pre-treatment will be ZAR 18/m3 when using ES Elabbas, S., Mandi, L., Berrekhis, F., Pons, M.N., Leclerc, J.P., Ouazzani, N., 2016.
material and ZAR 24/m3 when using commercial limestone. This Removal of Cr(III) from chrome tanning wastewater by adsorption using two natural
translates to total pre-treatment costs of ZAR 11.6 million and ZAR carbonaceous materials: eggshell and powdered marble. J. Environ. Manage. 166,
589–595.
15.4 million per annum (p.a), respectively. The results indicate that Emmanuela, K.A., Rao, A.V., 2008. Adsorption of Mn (II) from aqueous solutions using
significant financial saving could be gained using ES material. pithacelobium dulce carbon. Rasayan J. Chem. 840–852.
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4. Conclusions
EPA, 2007. EPA Guidelines: Regulatory Monitoring and Testing Water and Wastewater
Sampling. Environment Protection Authority, South Australia.
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neutralise highly acidic and contaminated AMD leachate from coal (FAOSTAT) Production: Livestock Primary: Eggs Primary.
Faur-Brasquet, C., Kadirvelu, K., Cloirec, P.L., 2002. Removal of metal ions from aqueous
mine dump. Standard characterisation techniques such as TGA, FT-IR, solution by adsorption onto activated carbon cloths: adsorption competition with
XRF, SEM and EDX revealed that ES underwent physiochemical organic matter. Carbon 40, 2387–2392.
changes after it was reacted with AMD. Process variables such as par- Freire, M.N., Holanda, J.N.F., 2006. Characterization of avian eggshell waste aiming its
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Hegazi, H.A., 2013. Removal of heavy metals from wastewater using agricultural and
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Acknowledgements Sci. Total Environ. 338, 3–14.
Joseph, O., Rouez, M., Métivier-Pignon, H., Bayard, R., Emmanuel, E., Gourdon, R., 2009.
Adsorption of heavy metals on to sugar cane bagasse: improvement of adsorption
Authors wish to acknowledge financial support received from Rand capacities due to anaerobic degradation of the biosorbent. Environ. Technol. 30,
Water, South Africa through the Rand Water Research Chair in Water 1371–1379.
Utilisation. Khan, A., 2014. Ion Exchange-A treatment option for acid mine drainage, Department of
Hydraulic and Environmental Engineering. Norwegian University of Science and
Technology, Norway.
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Supplementary data associated with this article can be found, in the
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