Characterization and pH-dependent environmental stability of arsenic trioxide-containing copper smelter flue dust

Characteristics and risk assessment of heavy metals in groundwater at a typical smelter-contaminated site in Southwest China

To explore the characteristics and evaluate the risk of heavy metals in groundwater at a typical smelter-contaminated site, this study focuses on a representative a historical arsenic smelting plant in Southwest China, where the primary historical products were metallic arsenic (∼1000 tons/year) and arsenic trioxide (∼2000 ton/year). The results demonstrated As and Pb as the main pollutants in soil, and As and Cd as main pollutants in groundwater through soil profiling and quarterly groundwater analysis. The maximum As and Pb in the surface soil were 76800 and 2290 mg/kg, respectively, with As vertically infiltrating the deep gravel-sand layer (18-20 m). The groundwater pollution distribution progressively increased along flow direction, influenced by seasonal surface runoff and infiltration fluctuations. The groundwater pollutant concentrations during the dry season notably surpassed those during the wet season, with maximum As and Cd concentrations of 111.64 mg/L and 19.85 μg/L during the dry season, respectively. Furthermore, the analytic hierarchy process (AHP) was applied to evaluate the comprehensive risk of contaminated-site across pollution source load, regional groundwater intrinsic vulnerability, and evaluation of nearby sensitive receptors. The results revealed that the carcinogenic risk of lead in surface soil was moderate to high, while arsenic posed a high carcinogenic risk, contributing to an overall carcinogenic risk proportion of 89.6% in surface soil. Exposure through groundwater intake was identified as the primary pathway, with carcinogenic and noncarcinogenic risks exceeding those through skin contact. The final weights result demonstrated that the principal risk factors are the intrinsic arsenic load and protective target characteristics of regional groundwater at this site. This study provides a reference for comprehensive assessments of similarly contaminated industrial and smelting sites.

Speciation Characterization and Environmental Stability of Arsenic in Arsenic-Containing Copper Slag Tailing

The increasing presence of arsenic-containing impurities within Cu ores can adversely affect the smelting process and aggravate the environmental impact of slag tailing. This study investigates the geochemical, mineralogical, and chemical speciation characteristics to better understand the association and environmental stability of metal(loid)s in copper slag tailing. The results indicate that the predominant chemical compositions of the selected slag tailing are Fe2O3 (54.8%) and SiO2 (28.1%). These tailings exhibit potential for multi-elemental contamination due to elevated concentrations of environmentally sensitive elements. Mineral phases identified within the slag tailings include silicate (fayalite), oxides (magnetite and hematite), and sulfides (galena, sphalerite, arsenopyrite, and chalcopyrite). The consistent presence of silicate, iron, arsenic, and oxygen in the elemental distribution suggests the existence of arsenic within silicate minerals in the form of Si-Fe-As-O phases. Additionally, arsenic shows association with sulfide minerals and oxides. The percentages of arsenite (As(III)) and arsenate (As(V)) within the selected slag tailings are 59.4% and 40.6%, respectively. While the slag tailings are deemed non-hazardous due to the minimal amounts of toxic elements in leachates, proper disposal measures should be taken due to the elevated carbonate-bound levels of As and Cu present in these tailings.

Mineralogical transformation of arsenic at different copper smelting workshops: The impact on arsenic bioaccessibility

Soil arsenic (As) contamination associated with the demolition of smelting plants has received increasing attention. Soil As can source from different industrial processes, and also participate in soil weathering, making its speciation rather complex. This study combined the usage of chemical sequential extraction and advanced spectroscopic techniques, e.g., time of flight secondary ion mass spectrometry (ToF-SIMS), to investigate the mineralogical transformation of soil As at different processing sites from a typical copper smelting plant in China. Results showed that the stability of arsenic species decreased following the processes of storage, smelting, and flue gas treatment. Arsenic in the warehouse area was incorporated into pyrite (FeS2) as well as its secondary minerals such as jarosite (KFe3(SO4)2(OH)6). At the smelting area, a large proportion of As was adsorbed by iron oxides from smelting slags, while some As existed in stable forms like orpiment (As2S3). At the acid-making area, more than half of As was adsorbed on amorphous iron oxides, and some were adsorbed on the flue gas desulfurization gypsum. More importantly, over 86% of the As belonged to non-specifically and specifically adsorbed fractions was found to be bioaccessible, highlighting the gypsum-adsorbed As one of the most hazardous species in smelting plant soils. Our findings indicated the importance of iron oxides in As retention and suggested the potential health risk of gypsum-adsorbed As. Such detailed knowledge of As speciation and bioaccessibility is vital for the management and remediation of As-contaminated soils in smelting plants.

Mechanistic insights into Pb and sulfates retention in ordinary Portland cement and aluminous cement: Assessing the contributions from binders and solid waste

Identifying immobilization mechanisms of potentially toxic elements (PTEs) is of paramount importance in the field application of solidification/stabilization. Traditionally, demanding and extensive experiments are required to better access the underlying retention mechanisms, which are usually challenging to quantify and clarify precisely. Herein, we present a geochemical model with parametric fitting techniques to reveal the solidification/stabilization of Pb-rich pyrite ash through conventional (ordinary Portland cement) and alternative (calcium aluminate cement) binders. We found that ettringite and calcium silicate hydrates exhibit strong affinities for Pb at alkaline conditions. When the hydration products are unable to stabilize all the soluble Pb in the system, part of the soluble Pb may be immobilized as Pb(OH)₂. At acidic and neutral conditions, hematite from pyrite ash and newly-formed ferrihydrite are the main controlling factors of Pb, coupled with anglesite and cerussite precipitation. Thus, this work provides a much-needed complement to this widely-applied solid waste remediation technique for the development of more sustainable mixture formulations.

Comparative Study for Flue Dust Stabilization in Cement and Glass Materials: A Stability Assessment of Arsenic

Arsenic is a poisonous element and its super mobility can pose a major threat to the environment and human beings. Disposed arsenic-bearing waste or minerals over time may release arsenic into the groundwater, soil and then the food chain. Consequently, safe landfill deposition should be carried out to minimize arsenic bleeding. Cement-based stabilization/solidification and glass vitrification are two important methods for arsenic immobilization. This work compares the stability and intrinsic leaching properties of sequestered arsenic by cement encapsulation and glass vitrification of smelter high-arsenic flue dust (60% As2O3) and confirms if they meet or exceed the requirement of landfill disposition over a range of environmentally relevant conditions. The toxicity characterization leaching procedure (TCLP, 1311), synthetic precipitation leaching procedure (SPLP, 1312) and Australian standard (Aus. 4439.3) in short-term (18 h) and mass transfer from monolithic material using a semi-dynamic leaching tank (1315) in longer-term (165 days) were employed to assess arsenic immobility characteristic in three arsenic-cement (2%, 8.4% and 14.4%) and arsenic-glass (11.7%) samples. Moreover, calcium release from different matrices has been taken into consideration as a contributor to arsenic bleeding. Based on the USEPA guidelines, samples can be acceptable for landfilling only if As release is < 5 mg/L. Results obtained from short-term leaching were almost similar for both cement and glass materials. However, high calcium release was observed from the cement-encapsulated materials. The pH of leachates after the test was highly alkaline for encapsulated materials; however, in glass material it was near neutral or slightly acidic. Method 1315 tests made a huge difference between the two materials and confirmed that cement encapsulation is not the best method for landfilling arsenic waste due to the high arsenic and calcium release over time with alkaline pH. However, glass material has shown promising results, i.e., the insignificant release of arsenic over time with an acceptable change in pH value. Overall, arsenic sequestration in glass is a better option compared with the cement-based solidification process.

Recovering metals from flue dust produced in secondary copper smelting through a novel process combining low temperature roasting, water leaching and mechanochemical reduction

Flue dust from secondary copper smelting (FDSC) is a hazardous waste as well as a secondary resource due to the high content of Cl, Br, and valuable metals (Pb, Cu, Zn, Cd). Herein, a novel process, combined low-temperature roasting, water leaching, and mechanochemical reduction, was developed for recovering metals from the FDSC. The phase conversion and behavior of the main elements in the whole process were explored based on thermodynamic analysis, experimental research, and various characterization. First, thermodynamics calculation revealed that adding H₂SO₄ could significantly decrease the roasting temperature and promote the generation of soluble metal sulfates. The experimental results showed that more than 99% of Cl and Br were removed by roasting at 325 °C and 1.5 times H₂SO₄ addition. Subsequently, the Cu, Zn, and Cd were almost completely leached by water under the conditions of 80 ℃, 2 h and L/S = 5 mL·g^-1, while Pb was rejected and enriched in the residue. Finally, using iron powder as a reductant, 96.7% of PbSO₄ was reduced to elemental lead at room temperature with the aid of mechanical force. The findings illustrated that the recovery performance of metals and environmental benefits will be greatly improved by the proposed process.

An experimental comparison: Horizontal evaluation of valuable metal extraction and arsenic emission characteristics of tailings from different copper smelting slag recovery processes

This study comprehensively investigated arsenic's enrichment, distribution, and characteristics in tailings. XRD and SEM-EDS characterized the phase and morphology of tailings from various smelting processes. At the same time, the embedding characteristics of arsenic in the ore phase were analyzed by EPMA. The differences between arsenic's leading ore phase carriers in different recovery processes were found. It was discussed that this phenomenon would be related to the element-binding ability and the precipitation priority of the ore phase. The occurrence state of arsenic was discussed by sequential chemical extraction experiments. The proportion of leachable arsenic is higher than the low-risk limit, whatever which smelting method is adopted, which leads to high environmental risk. In the experiment of comparing the leaching toxicity of tailings by different leaching methods, the arsenic concentration in the leaching solution of tailings recovered by the flotation method exceeds the specified safety range. Although the tailings after reduction smelting did not show high leaching toxicity, a large number of accumulations also would not represent absolute safety.

Nitric Acid Dissolution of Tennantite, Chalcopyrite and Sphalerite in the Presence of Fe (III) Ions and FeS2

This paper describes the nitric acid dissolution process of natural minerals such as tennantite, chalcopyrite and sphalerite, with the addition of Fe (III) ions and FeS₂. These minerals are typical for the ores of the Ural deposits. The effect of temperature, nitric acid concentration, time, additions of Fe (III) ions and FeS₂ was studied. The highest dissolution degree of sulfide minerals (more than 90%) was observed at a nitric acid concentration of 6 mol/dm³, an experiment time of 60 min, a temperature of 80 °C, a concentration of Fe (III) ions of 16.5 g/dm³, and an addition of FeS₂ to the total mass minerals at 1.2:1 ratio. The most significant factors in the break-down of minerals were the nitric acid concentration, the concentration of Fe (III) ions and the amount of FeS₂. Simultaneous addition of Fe (III) ions and FeS₂ had the greatest effect on the leaching process. It was also established that FeS₂ can be an alternative catalytic surface for copper sulfide minerals during nitric acid leaching. This helps to reduce the influence of the passivation layer of elemental sulfur due to the galvanic linkage formed between the minerals, which was confirmed by SEM-EDX.

Chemical Composition Data of the Main Stages of Copper Production from Sulfide Minerals in Chile: A Review to Assist Circular Economy Studies

The mining industry has faced significant challenges to maintaining copper production technically, economically, and environmentally viable. Some of the major limitations that must be overcome in the coming years are the copper ore grade decline due to its intense exploitation, the increasing requirements for environmental protection, and the need to expand and construct new tailings dams. Furthermore, the risk of a supply crisis of critical metals, such as antimony and bismuth, has prompted efforts to increase their extraction from secondary resources in copper production. Therefore, improving conventional processes and developing new technologies is crucial to satisfying the world’s metal demands, while respecting the policies of environmental organizations. Hence, it is essential that the chemical composition of each copper production stage is known for conducting these studies, which may be challenging due to the huge variability of concentration data concerning the ore extraction region, the process type, and the operational conditions. This paper presents a review of chemical composition data of the main stages of copper production from sulfide minerals, such as (1) copper minerals, (2) flotation tailings, (3) flotation concentrates, (4) slags and (5) flue dust from the smelting/converting stage, (6) copper anodes, (7) anode slimes, (8) contaminated electrolytes from the electrorefining stage, (9) electrolytes cleaned by ion-exchange resins, and (10) elution solutions from the resins. In addition, the main contributions of recent works on copper production are summarized herein. This study is focused on production sites from Chile since it is responsible for almost one-third of the world’s copper production.

Metal(loid)s remobilization and mineralogical transformations in smelter-polluted savanna soils under simulated wildfire conditions

The surroundings of mines and smelters may be exposed to wildfires, especially in semi-arid areas. The temperature-dependent releases of metal(loid)s (As, Cd, Cu, Pb, Zn) from biomass-rich savanna soils collected near a Cu smelter in Namibia have been studied under simulated wildfire conditions. Laboratory single-step combustion experiments (250-850 °C) and experiments with a continuous temperature increase (25-750 °C) were coupled with mineralogical investigations of the soils, ashes, and aerosols. Metals (Cd, Cu, Pb, Zn) were released at >550-600 °C, mostly at the highest temperatures, where complex aerosol particles, predominantly composed of slag-like aggregates, formed. In contrast, As exhibited several emission peaks at ~275 °C, ~370-410 °C, and ~580 °C, reflecting its complex speciation in the solid phase and indicating its remobilization, even during wildfires with moderate soil heating. At <500 °C, As was successively released via the transformation of As-bearing hydrous ferric oxides, arsenolite (As₂O₃) grains attached to the organic matter fragments, metal arsenates, and/or As-bearing apatite, followed by the thermal decomposition of enargite (Cu₃AsS₄) at >500 °C. The results indicate that the active and abandoned mining and smelting sites, especially those highly enriched in As, should be protected against wildfires, which can be responsible for substantial As re-emissions.

Separation and recovery of arsenic from As, Cu, and Zn rich leaching liquor using a reduction-crystallization approach

As, Cu, and Zn rich leaching liquor is generated in the leaching process of copper dust, which contains various metals with high recovery value. Herein, an approach for the direct separation and recovery of arsenic from As, Cu, and Zn rich leaching liquor was proposed. The approach includes two steps, namely SO2 reduction and arsenic crystallization. The factors affecting the reduction of As(v) to As(iii) were investigated, including the pH, SO2 dosage, and reduction temperature. In the crystallization stage, the impacts of sulfuric acid consumption and temperature on the crystallization of arsenic (As2O3) were studied. The results show that the optimal H+ concentration, temperature, and SO2 input for the arsenic reduction were 3.95 mol L-1, 45 °C, and 1.14 L g-1 As(v), respectively. While the optimal temperature and sulfuric acid dosage in As recovery process were 5 °C and 0.1 L L-1 leaching liquor, respectively. Under these conditions, the As2O3 recovery percentage reached 96.53%, and the losses of Cu and Zn were only 3.12% and 0.75%, respectively. The precipitate contained 96.72% of As2O3, 0.83% of Cu, and 0.13% Zn. Compared with the traditional technologies, this new method can improve the recovery efficiency of As2O3 and reduce the loss percentage of other valuable metals (Cu and Zn).

Efficient removal and recovery of arsenic from copper smelting flue dust by a roasting method: Process optimization, phase transformation and mechanism investigation

The efficient removal and recovery of arsenic from copper smelting flue dust have received widespread attention due to its extremely high toxicity and carcinogenicity. In this research, a roasting method used for treating the dust at a relatively low temperature (300-400 ℃), with adding sulfuric acid and bitumite, was proposed, in which the reduction of As(Ⅴ) and oxidation of arsenic sulfides were achieved simultaneously. It was proved by thermodynamic analysis and experiments that adding sulfuric acid was favorable for the removal of arsenic, through enhancing the thermodynamic driving force and promoting the transformation of arsenate and arsenic sulfides to As₂O₃. The phase transformation of arsenic was analyzed using XRD, SEM-EDS and XPS, which indicated that coal addition, roasting temperature and H₂SO₄ dosage play essential roles in arsenic removal. Based on the lab-scale experiments, the optimal conditions for arsenic removal were found to be at the roasting temperature of 300-400 °C, roasting time of 2-3 h, coal addition of 5% and H₂SO₄ dosage of 0.2-0.3 mL/g. Around 98% of arsenic was volatilized from the dust, while arsenic content in the residue was decreased to 0.57%. Eventually, arsenic was recovered as As₂O₃ with a high purity of 99.05%.

Study on Extraction Separation of Thioarsenite Acid in Alkaline Solution by CO 3 2 - -Type Tri-n-Octylmethyl-Ammonium Chloride

To overcome the problem of arsenic separation and enrichment from an alkaline leaching solution in arsenic-containing dust, a CO 3 2 - -type tri-n-octylmethyl-ammonium chloride (TOMAC) method for extracting thioarsenite is proposed in this paper. Considering an alkaline leaching solution as the research object, after vulcanization pretreatment, TOMAC transformation and organic phase saturated extraction capacity were measured, and the extraction mechanism was preliminarily studied. First, Cl^--type quaternary ammonium salt was effectively transformed to HCO 3 - -type by treating organic phase with saturated NaHCO_3five times. TOMAC was effectively transformed from HCO 3 - to CO 3 2 - type by alkaline washing with 1.0 mol/l NaOH solution; this washing was repeated thrice. Thereafter, the effects of organic phase composition, phase ratio, extraction time, and temperature on the extraction and separation of arsenic were investigated. The results show that under the conditions of 30% CO 3 2 - -type TOMAC + 15% sec-octanol + 55% sulfonated kerosene, V_O/V_A = 1/1, and 5 min extraction at room temperature, the single-stage extraction rate of As^III is 85.2%. The As^III concentration in raffinate can be reduced to less than 1.33 × 10^-3 mol/l by four-stage countercurrent extraction, and the extraction rate of As^III can exceed 98.4%.

An effective separation process of arsenic, lead, and zinc from high arsenic-containing copper smelting ashes by alkali leaching followed by sulfide precipitation

Separation of arsenic and valuable metals (Pb, Zn, Cu, Bi, Sn, In, Ag, Sb, etc.) is a core problem for effective utilization of high arsenic-containing copper smelting ashes (HACSA). This study developed an effective separation process of arsenic, lead, and zinc from HACSA via alkali leaching followed by sulfide precipitation. The separation behaviors and optimum conditions for alkali leaching of arsenic and sulfide precipitation of lead and zinc were established respectively as follows: NaOH concentration 3.81 M; temperature 80°C; time 90 minutes; liquid-to-solid ratio 4:1; agitation speed 450 revolutions/minute (r/min) and 2.0 times of theoretical quantity of sodium sulfide (Na₂S); temperature 70°C; and time 60 minutes. The results indicated that the leaching rates of As, Pb, and Zn were 92.4%, 36.9% and 13.4%, respectively. More than 99% of lead and zinc were precipitated from the alkali leachate. The scanning electron microscopy/energy dispersive X-ray spectroscopy study confirmed that arsenic was dissolved from HACSA into the alkali leachate. Furthermore, lead and zinc were precipitated as sulfides from the alkali leachate. The proposed process was a good technique for separation of arsenic and enrichment of valuable metals for further centralized treatment separately. It provided high separation efficiency of arsenic and valuable metals, as well as low environmental pollution.

Selective Separation of Arsenic from Lead Smelter Flue Dust by Alkaline Pressure Oxidative Leaching

This study investigated the feasibility of using an alkaline pressure oxidative leaching process to treat lead smelter flue dust containing extremely high levels of arsenic with the aim of achieving the selective separation of arsenic. The effects of different parameters including NaOH concentration, oxygen partial pressure, liquid-to-solid ratio, temperature, and time for the extraction of arsenic were investigated based on thermodynamic calculation. The results indicated that the leaching efficiency of arsenic reached 95.6% under the optimized leaching conditions: 80 g/L of NaOH concentration, 1.0 MPa of oxygen partial pressure, 8 mL/g of liquid-to-solid ratio, 120 °C of temperature, 2.0 h of time. Meanwhile, the leaching efficiencies of antimony, cadmium, indium and lead were less than 4.0%, basically achieving the selective separation of arsenic from lead smelter flue dust. More than 99.0% of arsenic was converted into calcium arsenate product and thus separated from the leach solution by a causticization process with CaO after other metal impurities were removed from the solution with the addition of Na2S. The optimized causticization conditions were established as: 4.0 of the mole ratio of calcium to arsenic, temperature of 80 °C, reaction time of 2.0 h. The resulting product of calcium arsenate may be used for producing metallic arsenic.

Oral bioaccessibility of metal(loid)s in dust materials from mining areas of northern Namibia

Ore mining and processing in semi-arid areas is responsible for the generation of metal(loid)-containing dust, which is easily transported by wind to the surrounding environment. To assess the human exposure to dust-derived metal(loid)s (As, Cd, Cu, Pb, Sb, Zn), as well as the potential risks related to incidental dust ingestion, we studied mine tailing dust (n = 8), slag dust (n = 5) and smelter dust (n = 4) from old mining and smelting sites in northern Namibia (Kombat, Berg Aukas, Tsumeb). In vitro bioaccessibility testing using extraction in simulated gastric fluid (SGF) was combined with determination of grain-size distributions, chemical and mineralogical characterizations and leaching tests conducted on original dust samples and separated PM₁₀ fractions. The bulk and bioaccessible concentrations of the metal(loid)s were ranked as follows: mine tailing dusts < slag dusts ≪ smelter dusts. Extremely high As and Pb bioaccessibilities in the smelter dusts were caused by the presence of highly soluble phases such as arsenolite (As₂O₃) and various metal-arsenates unstable under the acidic conditions of SGF. The exposure estimates calculated for an adult person of 70 kg at a dust ingestion rate of 50 mg/day indicated that As, Pb (and also Cd to a lesser extent) grossly exceeded tolerable daily intake limits for these contaminants in the case of slag and smelter dusts. The high risk for smelter dusts has been acknowledged, and the safety measures currently adopted by the smelter operator in Tsumeb are necessary to reduce the staff's exposure to contaminated dust. The exposure risk for the local population is only important at the unfenced disposal sites at Berg Aukas, where the PM₁₀ exhibited high levels of bioaccessible Pb.