The modeling of ion exchange processes could significantly enhance their applicability in mine water treatment, as the modern synthetic resins give unique advantages for the removal of metals. Accurate modeling improves the predictability of the process, minimizing the time and costs involved in laboratory column testing. However, to date, the development and boundary conditions of such ion exchange systems with complex mine waters are rarely studied and poorly understood. A representative ion exchange model requires the definition of accurate parameters and coefficients. Therefore, theoretical coefficients estimated from natural exchange materials that are available in geochemical databases often need to be modified. A 1D reactive transport model was developed based on PhreeqC code, using three case scenarios of synthetic mine waters and varying the operating conditions. The first approach was defined with default exchange coefficients from the phreeqc.dat database to identify and study the main parameters and coefficients that govern the model: cation exchange capacity, exchange coefficients, and activity coefficients. Then, these values were adjusted through iterative calibration until a good approximation between experimental and simulation breakthrough curves was achieved. This study proposes a suitable methodology and challenges for modeling the removal of metals from complex mine waters using synthetic ion exchange resins.

The discharge of metal-loaded mining-influenced waters can significantly pollute downstream water bodies for many kilometers. Addressing this issue at the earliest discharge point is crucial to prevent further contamination of the natural environment. Additionally, recovering metals from these discharges and other sources of contamination can reduce the environmental impacts of mining and support the circular economy by providing secondary raw materials. This study focused on optimizing zinc recovery from mining-influenced water in the Freiberg mining region in Germany, where significant loads of zinc are released into the Elbe River. By employing pretreatment techniques, conducting 100 mL scale ion-exchange column experiments, and refining the regeneration process, we aimed to identify optimal conditions for efficient zinc removal and recovery. Initial tests showed that aminophosphonic functionalized TP 260 resin had a high affinity for aluminum, occupying 93% of the resin’s capacity, while zinc capacity was limited to 0.2 eq/L. To improve zinc recovery, selective precipitation of aluminum at pH 6.0 was introduced as a pretreatment step. This significantly increased the zinc loading capacity of the resin to 1 eq/L. Under optimal conditions, a concentrated zinc solution of 18.5 g/L was obtained with 100% recovery. Sulfuric acid proved more effective than hydrochloric acid in eluting zinc from the resin. Further analysis using SEM-EDX revealed residual acid on the resin, indicating a need for additional study on long-term resin performance and capacity variation. The research also highlighted the environmental impact of the Freiberg mining area, where three drainage galleries currently contribute nearly 85 tons of zinc annually to the Elbe River. This study underscores the feasibility of efficient zinc recovery from these point sources of pollution using advanced ion-exchange processes, contributing to circular economy efforts and environmental conservation.

Cobalt is globally recognized as a strategic and critical raw material due to its high-tech low carbon applications [1-3]. However, in terms of supply, cobalt is only found in potentially exploitable quantities in a few countries and is mainly produced as a co- or byproduct of the copper and nickel industry [4].