Cryolite (Na₃AlF₆) crystallization for fluoride recovery using an electrolytic process equipped with a sacrificial aluminum anode

An electro-crystallization process equipped with a sacrificial aluminum anode was operated under an optimum condition to promote the formation of crystalline cryolite for the recovery of fluoride from synthetic F-containing wastewater. The effects of pH, Al/F molar ratio, initial F concentration, and electrolytes were investigated experimentally, and the results were compared with data obtained from chemical equilibrium modeling. Cryolite was successfully produced under optimum pH values of 5 to 6 and Al/F molar ratios of less than 1/6. The F removal increased with increasing Al/F molar ratio until reaching the molar ratio of 1/6 and decreased thereafter due to the formation of AlF_n³⁻ⁿ species. The adsorption of AlF_n³⁻ⁿ by Al(OH)₃ precipitates contributed part of F removal. The removal efficiency reached 100% when the initial fluoride concentration was high while it was around 90% with the low initial fluoride concentration. XRD and SEM/EDX analysis showed that the obtained solids matched well to the commercial cryolite. Finally, the operating costs of chemical-crystallization (the process with Al ions added chemically) and electro-crystallization were compared, and the cost of the former was less than the latter. Energy consumption was the main contributor to the operating cost of the electro-crystallization process.