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

Key Factors and Evaluation Model of Valuable Metal Separation in Low-Concentration Smelting Slag

The low concentration of valuable metals in smelting slags poses a significant challenge for separation. Despite the effective separation achieved by current pyrometallurgical or hydrometallurgical methods, the intricate mineralogy of slag and numerous leaching factors present considerable challenges in selecting the appropriate separation techniques and parameters for efficient and rapid extraction. In this study, copper slag flotation tailings (CSFT) were taken as an example, and the microexistence forms of valuable metals were analyzed through XRD and SEM-EDS. By integrating theoretical calculations and TGA analysis, a method involving concentrated sulfuric acid roasting and subsequent water leaching was employed to sufficiently extract valuable metals Mg, Cu, and Ni, concurrently achieving depth separation from Fe in the slag. Concurrently, a dynamic evaluation model correlating metal leaching efficiency (X t ) with key factors has been established, enabling the quantification of valuable metal leaching performance under various conditions. Based on the kinetics equation and Arrhenius formula, with roasting temperature (T), roasting time (t), acid-to-solid ratio (r), and particle size (d) as key parameters, using experimental data, a dynamic evaluation model with kinetic characteristics was established as follows: 1/3ln(1- X t ) - [1 - (1 - X t )-1/3] = 9.36r 1.55 d -1.40 e -21957.8/RT t. The influence order was determined as roasting temperature > acid-to-solid ratio > particle size. The simulated values closely matched the experimental values, allowing the model to accurately predict the metal leaching rates. This provides an essential method for the design of metal recovery reaction parameters and optimization of engineering outcomes in the treatment of smelting slag.

Heavy metals release in lead-zinc tailings: Effects of weathering and acid rain

Heavy metals (HMs) release from lead (Pb)-zinc (Zn) tailings poses significant environmental risks to surrounding areas. Furthermore, with the natural weathering and frequently happened acid rain events, the release of HMs could be elevated. This study conducted a series of laboratory column experiments with thermodynamics and hydrogeochemical analysis to investigate the environmental behavior of HMs release in Pb-Zn tailings under natural weathering conditions and acid rain events. Results showed that the weathering of calcite facilitates the release of Pb (17.9 mg/kg) and cadmium (Cd) (0.15 mg/kg), while acid rain promotes Zn release (10.5 mg/kg) from the Fe-Mn oxides, with no significant change for arsenic (As). Among the influencing factors during the column experiments, the oxidation-reduction potential (ORP) was identified as the primary indicator for the predictions of the HMs release behavior based upon the Random Forest model (R2 = 0.973 - 0.997). Correlation analysis revealed a strong relationship between coexistent ions and HM release patterns. Therefore, saturation index (SI) could effectively identify the influence range of each mineral phase on HM release. This study provides scientific evidence for effective management in carbonate-type tailings ponds.

Efficient cadmium removal from industrial wastewater generated from smelter using chemical precipitation and oxidation assistance

The effective treatment of cadmium (Cd) in smelting wastewater is of great industrial importance. This study investigates the efficient removal of Cd from real industrial smelting wastewater via chemical precipitation using a series of experiments. In particular, the effects of different precipitants, agitation conditions, and the addition of NaOCl on Cd removal and pH variation are investigated. CaO (3.75 g/L), NaOH (3.50 g/L), and Ca(OH)2 (3.75 g/L) are found to be effective in elevating the wastewater pH and achieving high Cd removal rates (>99.9%), while the use of NaOH as a precipitant maintains a high Cd removal rate even at low agitation intensities. The properties of the produced sludge and supernatant are also determined using moisture content, particle size, and sludge leaching analyses due to the importance of economic and environmental sustainability in filtration, dewatering, and waste disposal processes. In addition, the addition of 2% NaOCl is tested, revealing that it can improve the Cd removal efficiency of Ca(OH)2, thus potentially reducing processing costs and enhancing the environmental benefits. Overall, these findings offer valuable insights into the removal of Cd from smelting wastewater, with potential implications for both environmental sustainability and economic viability. PRACTITIONER POINTS: CaO, NaOH, and Ca(OH)2 effectively remove Cd (>99.9%) from smelting wastewater. The use of NaOH leads to high Cd removal rates even at low agitation speeds. Adding 2% NaOCl can reduce the Ca(OH)2 dose for more economical Cd removal.

A green method to clean copper slag and rapidly recover copper resources via reduction-sulfurizing smelting and super-gravity separation at low temperature

Massive copper slag containing heavy metals is produced in copper making and 0.5 - 8.0 wt% Cu is lost into it, deserving to be recovered. In this study, the waste coke and gypsum were employed to clean the copper slag, the lost copper was reduction-sulfurized and enriched to the matte droplets. However, the free-settling of matte droplets under normal gravity needed a higher temperature of 1350 ℃. On this basis, the matte droplets were efficiently separated from the cleaned slag via super-gravity at a low temperature of 1200 ℃ within 3 min, the recovery ratio of Cu was up to 99.56%, and the grade of Cu in the matte phase and cleaned slag was 85.84 wt% and 0.08 wt%, respectively. Moreover, the migration, distribution and leaching behavior of heavy metal elements (Pb, Zn, Ni, etc.,) were performed and analyzed, and the treatment and utilization of volatilized vapors and tailings were also discussed. This study proposed a green method to clean the copper slag and simultaneously recover copper resources via reduction-sulfurizing smelting and super-gravity separation at a low temperature, providing scientific guidance and application prospects for the synergistic treatment of hot copper slag with waste coke and gypsum.

A critical review on the migration and transformation processes of heavy metal contamination in lead-zinc tailings of China

The health risks of lead-zinc (Pb-Zn) tailings from heavy metal (HMs) contamination have been gaining increasing public concern. The dispersal of HMs from tailings poses a substantial threat to ecosystems. Therefore, studying the mechanisms of migration and transformation of HMs in Pb-Zn tailings has significant ecological and environmental significance. Initially, this study encapsulated the distribution and contamination status of Pb-Zn tailings in China. Subsequently, we comprehensively scrutinized the mechanisms governing the migration and transformation of HMs in the Pb-Zn tailings from a geochemical perspective. This examination reveals the intricate interplay between various biotic and abiotic constituents, including environmental factors (EFs), characteristic minerals, organic flotation reagents (OFRs), and microorganisms within Pb-Zn tailings interact through a series of physical, chemical, and biological processes, leading to the formation of complexes, chelates, and aggregates involving HMs and OFRs. These interactions ultimately influence the migration and transformation of HMs. Finally, we provide an overview of contaminant migration prediction and ecological remediation in Pb-Zn tailings. In this systematic review, we identify several forthcoming research imperatives and methodologies. Specifically, understanding the dynamic mechanisms underlying the migration and transformation of HMs is challenging. These challenges encompass an exploration of the weathering processes of characteristic minerals and their interactions with HMs, the complex interplay between HMs and OFRs in Pb-Zn tailings, the effects of microbial community succession during the storage and remediation of Pb-Zn tailings, and the importance of utilizing process-based models in predicting the fate of HMs, and the potential for microbial remediation of tailings.

Synchronous stabilization of Pb, Zn, Cd, and As in lead smelting slag by industrial solid waste

In order to prevent heavy metal (HM) pollution from lead smelting slag (LSS) to the surrounding environment, this work investigated the feasibility, influencing factors, and mechanisms of using industrial solid waste such as fly ash (FA), oil sludge pyrolysis residue (PR), and steel slag (SS) as remediation amendments. The results demonstrated that the stabilization process was influenced by the material dosage, water content, and LSS particle size. Compared to single materials, the combination amendment PR2FA1 (with a mass ratio of PR to FA as 2:1) exhibited the best stabilization effect, simultaneously reducing the leaching concentrations of As, Zn, Cd, and Pb in LSS to 0.032, 0.034, 0.002, and 0.014 mg/L, respectively. The pH value of the leachate remained between 8 and 9, which met the requirements of surface water quality class IV (GB3838-2002). Through morphological analysis, microscopic characterization, and simulated solution adsorption experiments, it was determined that the stabilization process of HMs was controlled by various mechanisms, including electrostatic attraction, physical adsorption, ion exchange, and chemical precipitation. PR2FA1 had more active components, and its fine-porous structure provided more active sites, resulting in good stabilization performance for As, Zn, Cd, and Pb. Furthermore, cost analysis showed that PR2FA1, as an environmentally friendly material, could generate profits of 157.2 ¥/ton. In conclusion, the prepared PR2FA1 not only addressed the HMs pollution from lead smelting slag to the surrounding environment but also achieved the safe and resourceful disposal of hazardous waste-oil sludge. Its excellent performance in stabilizing HMs and cost-effectiveness suggested promising commercial applications.

Arsenic release pathway and the interaction principle among major species in vacuum sulfide reduction roasting of copper smelting flue dust

The efficient release of arsenic in copper smelting flue dust (CSFD) with complicated production conditions and composition under the premise of environmental safety is difficult for the copper smelting industry. The vacuum environment is conducive to the volatilization of low-boiling arsenic compounds, which is beneficial to the physical process and chemical reaction of increasing the volume. In the present study, combined with thermodynamic calculations, the roasting process of pyrite and CSFD mixed in proportion in vacuum was simulated. Additionally, the release process of arsenic and the interaction mechanism of the main phases were performed in detail. The addition of pyrite facilitated the decomposition of stable arsenate in CSFD into volatile arsenic oxides. The results indicated that exceeding 98% of arsenic in CSFD volatilized into the condenser, while the arsenic content in the residue was reduced to 0.32% under optimal conditions. Pyrite could reduce the oxygen potential during the chemical reaction with CSFD, reacting with sulfates in CSFD to convert into sulfides and magnetic iron oxide (Fe₃O₄) simultaneously, and Bi₂O₃ would be transformed into metallic Bi. These findings are significant for developing arsenic-containing hazardous waste treatment routes and the application of innovative technical approaches.

Analysis of driving factors of spatial distribution of heavy metals in soil of non-ferrous metal smelting sites: Screening the geodetector calculation results combined with correlation analysis

Heavy metals (HMs) discharged from smelting production may pose a major threat to human health and soil ecosystems. In this study, the spatial distribution characteristics of HMs in the soil of a non-ferrous metal smelting site were assessed. This study employed the geodetector (GD) by optimizing the classification condition and supplementing the correlation analysis (CA). The contribution of driving factors, such as production workshop distributions, hydrogeological conditions, and soil physicochemical properties, to the distribution of HMs in soil in the horizontal and vertical dimensions was assessed. The results showed that the main factors underlying the spatial distribution of As, Cd, Hg, Pb, Sb, and Zn in the horizontal direction were the distance from the sintering workshop (the maximum q value of that factor, q=0.28), raw material yard (q=0.14), and electrolyzer (q=0.29), while those in the vertical direction were the soil moisture content (q=0.17), formation lithology (q=0.12), and soil pH (q=0.06). The findings revealed that the CA is a simple and effective method to supplement the GD analysis underlying the spatial distribution characteristics of HMs at site scale. This study provides useful suggestions for environmental management to prevent HMs pollution and control HMs in the soil of non-ferrous metal smelting sites.

The mechanistic insights into the leaching behaviors of potentially toxic elements from the indigenous zinc smelting slags under the slag dumping site scenario

Since lager quantities of the zinc (Zn) smelting slags were traditionally dumped at the indigenous Zn smelting sites, the release characterization of potentially toxic elements (PTEs) from the Zn smelting slags under various environmental conditions were of great significance for an environmental risk analysis. The acidification of the Zn smelting slags to pH= 4 and 6 would result in the leaching concentrations of Cd and Mn exceeding the fourth-class standard of surface water quality standard in China (GB3838-2002). Notably, most metals exhibited an amphoteric leaching pattern, where the highest leached concentrations of As, Cd, Cu, Mn, Pb, and Zn were 4.15, 4.21, 140.0, 78.1, 156.9 and 477.0 mg/L, respectively. In addition, the highest release of toxic metals within 96 h reached 0.17 % of As, 3.50 % of Cd, 2.77 % of Cu, 6.92 % of Mn, 0.13 % of Pb, and 2.57 % of Zn, respectively. The combined results of various characterization techniques suggested that the PTEs remobilization effected by rhizosphere-like organic acids were mainly controlled by the precipitation of newly formed Fe, Mn and Al (hydr) oxides and the complexation of organic ligands. The present study results could provide valuable insights into the long-term leaching behaviors of PTEs from the Zn smelting slags to reduce ecological hazard.

Effect of Sulfur Content on Copper Recovery in the Reduction Smelting Process

This work discussed the advantages of reducing copper in molten copper slag with low S content. FactSage calculated the distribution of copper at equilibrium under different sulfur contents. The effect of sulfur content on copper recovery under different oxygen partial pressures in 1400 °C was pointed out. The effect of sulfur content on copper recovery in the actual reduction process was explored through experimental research. Under the condition of low sulfur, the recovery ratio of copper and the stability of the experiment have an ideal result in fixed C/O in the experiment.