Leaching kinetics of ash impurities from aphanitic graphite by combining dual-ultrasound and hydrochloric acid-potassium hydrogen fluoride

The hydrochloric acid-fluoride salt is useful for purifying graphite. Ultrasonic-assisted technique can significantly reduce the leaching time and improve the leaching efficiency. Compared with single-frequency, dual-frequency ultrasound has the advantages of high energy efficiency and wide cavitation area. In this study, the combination of a dual-frequency ultrasound-assisted technique and hydrochloric acid-potassium hydrogen fluoride leaching agent was proposed for the leaching of aphanitic graphite to remove impurity minerals. First, the effects of probetype ultrasonic power, tank-type ultrasonic power, temperature, HCl concentration, ultrasonication time, and KHF2 concentration on the purification efficiency of impurities from aphanitic graphite with the assistance of dual-frequency ultrasound were investigated. It was found that the combination of dual-frequency ultrasound and hydrochloric acid-potassium hydrogen fluoride can reduce the ash content of aphanitic graphite from 13.02 % to 1.02 % with an ash removal rate of 94.17 %. Second, volumetric reaction models and unreacted shrinkage nucleation models were used to fit the kinetics of impurities from aphanitic graphite with dual-frequency ultrasound-assisted HCl-KHF2 leaching. Kinetic analysis shows that the volumetric reaction model with chemical control was better to fit the leaching process. This is consistent with the calculation results of the activation energy of the reaction (Ea = 58.13 kJ/mol). Finally, laser particle size analyzer, X-ray diffraction (XRD), scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS), X-ray fluorescence spectroscopy (XRF), transmission electron microscopy-energy dispersive X-ray spectroscopy (TEM-EDS) were used to analyze the fugacity of impurity minerals during the process of dual-frequency ultrasound-assisted HCl-KHF2 leaching. It was revealed that combining ultrasonic cavitation fragmentation with chloric acid-potassium fluoride generated SiF4 with high solubility, thereby removing silica-bearing impurities more efficiently. The challenges in further reducing ash content from 1.02 % in the leached concentrate of aphanitic graphite could be attributed to the existence of titanium-bearing mineral impurities on the surface of graphite particles and the presence of silicabearing minerals between graphite carbon layers.