Chemical Engineering

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An attainable region approach for the recovery of iron and zinc from electric arc furnace dust
(2019) Siame, M.C.; Kaoma, J.; Hlabangana, N.; Danha, G.
This study investigated the application of the attainable region optimization technique to establish the optimum hybrid hydrometallurgical and pyro-metallurgical process conditions required to treat the electric arc furnace dust. The analysis of the results obtained showed that a combination of an agitation speed of 800 rpm, sodium hydroxide concentration of 8.0 mol/L and a leaching temperature of 80 °C were the optimum conditions for the hydrometallurgical process, while a roasting temperature of 1200 °C, carbon content of 35.27% and a roasting period of 36 h were the optimum conditions for the pyro-metallurgical process. The iron recovered from the dust was recycled in order to upgrade the iron content of the electric arc furnace charge, thereby reducing both process loses and process wastes.
Application of amine-modified tannins gels as coagulants in wastewater treatment
(Research Square, 2024-08-28) Thelmmer, M.; Ncube, S.; Moyo, L.B.; Mamvura, T.A.; Danha, G.; Simate, G.S.; Tshuma, N.
Tannin (T) is an organic substance that may potentially be used as an inexpensive, environmentally friendly, and effective bio-coagulant to remove impurities from residential and commercial wastewater. In this study, bio-coagulants were prepared using tannins obtained from the wattle tree (Acacia mearnsii). The bio-coagulants were modified using formalin and optionally, ethanolamine (ETA) and ammonium chloride (NH 4 Cl) as amine sources through the Mannich Reaction scheme. Three coagulants were prepared, T-ETA modified tannin, T-NH 4 Cl modified tannin and a mixture of T-ETA: T-NH 4 Cl in molar ratio 1: 1. Aluminium sulphate [Al 2 (SO 4) 3], a metal-coagulant was also used as the standard for comparison. The three coagulants were tested at varied concentrations (500–1250 mg/L) using jar tests on laundry wastewater to see their effect on remediation of wastewater. A mixture of bio-coagulant T-NH 4 Cl and T-ETA was most effective with highest removal efficiencies for turbidity (94%), COD (85%), Total solids (87%) and nitrates (99%). For colour removal T-NH 4 Cl modified tannin showed the highest removal efficiency of 92%. The results support the use of cheaper and environmentally friendly amine modified tannin-based flocculants in laundry wastewater treatment as they showed less toxicity on the treated water.
Effect of ball and feed particle size distribution on the milling efficiency of a ball mill: An attainable region approach
(2018) Hlabangana, N.; Danha, G.; Muzenda, E.
In this article, alternative forms of optimizing the milling efficiency of a laboratory scale ball mill by varying the grinding media size distribution and the feed material particle size distribution were investigated. Silica ore was used as the test material. The experimental parameters that were kept constant in this investigation was the grinding media filling, powder filling and the mill rotational speed. The data obtained from these batch tests was then analyzed using a model free technique called the Attainable Region method. This analysis technique showed that the required product fineness is a function of grinding media and feed material size distributions. It was also observed from the experimental results that in order to increase the milling efficiency of a ball mill, towards optimum production of material in the desired size class, there is a need to correlate the ball size and the feed size distributions.
Effect of media shape on particle breakage in a batch ball mill: Lessons learnt from population balance model and attainable region technique. Procedia Manufacturing, 35.
(Elsevier, 2019) Khumalo, S.; Hlabangana, N.; Danha, G.; Muzenda, E
The batch grinding equation and the Attainable region technique tools were used in evaluating data obtained from the breakage of quartz ore in a laboratory batch ball mill. Using the same milling conditions and grinding equipment, test results were evaluated through the breakage distributions of different size fractions. Results prove that mixing different grinding media increases volume of grinding zones and that translates to an improvement in grinding kinetics and amount of required PSD. The tools are valuable and practical ways of evaluating the breakage of materials on the size fractional base and results of which can be used in the mathematical modelling and optimising of ball milling unit operations.
Investigating the feasibility of using agricultural waste as an adsorbent of gold ions in small scale gold processing plants.
(2019) Tapfuma, A.; Chakawa, D.P.; Moyo, L.B.; Hlabangana, N.;; Danha, G.; Muzenda, E.
The recovery of precious metals like gold is increasing each day due to its high market prices along with diverse applications. Bio-sorption represents a biotechnological innovation as well as a cost effective and excellent tool for recovery of precious metals from aqueous solutions. This study offers an overview of a recent scenario of bio-sorption studies carried out on the use of some promising bio-sorbents which could serve as an economical means for recovering gold for small scale gold processing plants. Results show that activated carbon (control) has the highest adsorption efficiency since it contains more active site on the carbon molecules. The activated maize corn cob had the highest adsorption efficiency (77.09%) compared to all other agricultural adsorbents. Banana peels showed a significant adsorption efficiency of 56.87%.
Optimization of pulp production from groundnut shells using chemical pulping at low temperatures
(2020) Musekiwa, P.; Moyo, L.B.; Mamvura, T.A.; Danha, G.; Simate, G.S.; Hlabangana, N.
Paper production through chemical pulping has been identified as one of the ideal avenues of exploring the uses of groundnut shells as they are rich in cellulose. Ideally, the cellulose can be used to synthesize fibres that can be converted into useful paper products. In this study, chemical pulping was the chosen process for liberating the fibres as it is effective in dissolving lignin embedded within the cellulose. In addition, the fibres produced have superior physical properties compared to mechanical pulping. It is imperative that optimal conditions are identified for the chemical treatment process, in order to ensure that energy and chemical consumption are minimized. All these measures are aimed at reducing production costs and make chemical pulping economically viable, as compared to the mechanical pulping process which is less costly. Response surface methodology (RSM) was used in this study to evaluate the effect of three independent variables (cooking time, temperature, and sulphidity) on pulp yield and kappa number. These parameters are critical in the chemical pulping process and the optimal conditions obtained were 180 min, 100 C and 23.6 wt.%, respectively. At the optimal conditions, the pulp yield was 64.39wt% with a kappa number of 19.5. The results showed that all parameters investigated, had a statistically significant effect on the production of pulp. The increased cooking time was efficient in ensuring complete impregnation of the groundnut shells with chemicals for pulping and ensuring that the dissolution of lignin is not selective and does not result in dead spots inherently compromising the quality of the pulp. On the other hand, lower temperatures limited the peeling effect due to hydrolysis of carbohydrates which increased pulp yield due to a higher cellulose retention. Consequently, this contributed towards obtaining pulp that is well cooked, has a low bleach consumption and a higher quality.
Pressurized torrefaction of waste biomass to improve bio coal quality: Synergistic effect between animal waste and wood chips
(Elsevier, 2025-04-19) Tshuma, N.M.; Moyo, L.B.; Danha, G.; Mamvura, T.A.; Simate, G.S.; Artur, C.D.; Charis, G.
This study aims to investigate the effect blending waste material to improve its fuel properties using pressurized torrefaction. This research explored the benefits of blending animal waste with wood chips to produce a bio-coal with improved fuel properties. The process conditions investigated were temperature and pressure intervals of 200◦C to 280◦C and atmospheric pressure (AP) to 4MPa, respectively. The results showed that an increase in temperature and pressure improved the fixed carbon content of the blend almost threefold from 19.87 % to 66.93 % and the higher heating value (HHV) to 27.32MJ/kg from 13.90MJ/kg at mild torrefaction temperature of 280◦C and gas pressure of 4MPa compared to atmospheric pressure conditions and the lowest temperature investigated. The HHV increased primarily due to a release of bound and unbound moisture and volatile matter. Wood chips had an HHV of 27.00MJ/kg at a torrefaction temperature of 280◦C due to the decomposition of hemicellulose and cellulose which enhanced the thermal stability, fixed carbon content and calorific value. However, animal waste had the least incremental increase in HHV (16.45MJ/kg) due to a high initial content of volatile matter and moisture. The improved properties of the blend of materials indicated that pressurized torrefaction was effective in increasing fixed carbon content through secondary polymerization reactions. Moreover, it facilitated the decomposition of cellulose at a lower temperature than the typical range of 315-400◦C if conducted at atmospheric pressure. This study elucidates the notable role of the synergistic effects of blending feed materials prior to torrefaction towards improving the properties and pyrolysis performance of biomass components.
Treatment of efuent from a malting processing plant using bio‑coagulants
(Discover Civil Engineering, 2024-07-05) Murisa, V.; Murisa, V.,; Ncube, S.; Moyo, L.B.; Danha, G.; Mamvura, T.A.
Stringent measures by water authorities worldwide on water clarification has resulted in the use of chemical-based coagulants to be a formidable challenge. This has driven the need to find alternative sustainable coagulants such as plant-based bio coagulants which are readily available, abundant and cost effective in developing countries such as Zimbabwe. In this regard, the effectiveness of treating effluent from a brewery malting processing plant using bio-coagulants (Aloe Vera, Cactus opuntia and Okra seeds) was investigated compared to that of a chemical coagulant (Alum). The water pollution parameters that were investigated include turbidity, total dissolved solids, electrical conductivity, temperature and pH. The results showed that Alum was the most effective coagulant as it reduced the turbidity from 734 NTU to 68.3 NTU and Total Dissolved Solids (TDS) from 19,800 ppm to 880 ppm at a dosage of 40 mg/L. Okra seeds had an optimum dosage of 35 mg/L with a turbidity and TDS removal of 88.83% and 95.25% respectively. Aloe Vera had an optimum dosage of 40 mg/L with a turbidity and TDS removal of 74.25% and 95.40% respectively. For Cactus opuntia it was 50 mg/L obtaining turbidity and TDS removal of 74.66% and 95% respectively. The best blend of the bio coagulants had a ratio of (0.17, 0.17, and 0.67) for Aloe Vera, Cactus opuntia and Okra seeds respectively. At a dosage of 40 mg/L the turbidity removal was 83.92% and TDS removal was 95.12%. The results indicated that blending the plant-based coagulants had a positive synergistic effect. Highlights Aluminum sulphate (Alum) is more effective in reduction of suspended solids and dissolved solids compared to Aloe Vera, Cactus and Okra seeds. The effectiveness of Aloe Vera, Cactus and Okra seeds as plant-based coagulants indicates that they have active compounds effective as coagulation agents. There were positive synergistic effects upon blending Aloe Vera, Cactus and Okra seeds this was observed in the reduction of turbidity this was higher than when Aloe Vera and Cactus were used individually as coagulants.
Use of coal fly ash to manufacture a corrosion resistant brick.
(Elsevier, 2019) Moyo, V.; Mguni, N.G.; Hlabangana, N.; Danha, G.
In this article, we investigate the use of an environmental waste (coal fly ash) in the manufacture of an ammonium nitrate corrosion resistant brick. Ammonium nitrate (AN) fertilizer spillages and vapors continuously corrode the civil structures in a fertilizer manufacturing plant situated in Zimbabwe. This situation is a safety hazard to more than a hundred plant personnel and hence a priority area for research. Our experimental results show that addition of sodium silicate improved the performance of the brick. Water absorption of bricks generally decreased with an increase in the amount of sodium silicate added. Our results also show that the compressive strength generally increased with increase in amount of sodium silicate added and that the corrosion resistance increases with the amount of sodium silicate added to the coal ash bricks.

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