Combined Process of Chlorination Roasting and Acid Leaching of Lead and Silver from Lead Cake

This study evaluates an integrated approach for recovering lead and silver from lead cake through chlorination roasting followed by acid leaching. The lead cake originates from sulfuric acid leaching of zinc ferrite residues obtained during the hydrometallurgical processing of zinc calcine. The effects of roasting temperature, lead cake-to-NaCl mass ratio, and roasting duration on metal recovery were systematically examined to determine optimal process conditions. Based on the experimental results, roasting at 550 °C for 1.5 h with a lead cake-to-NaCl mass ratio of 1:3, followed by leaching in 1 M HCl, was selected as a representative and sufficiently effective condition for the combined process. Under these conditions, nearly complete dissolution of Pb and Ag was achieved, reducing their contents in the final solid residue to 0.90% and 0.0027%, respectively. Compared to direct chloride leaching, the combined process provided higher extraction efficiencies (Pb 98.67%, Ag 98.09%) and a lower final residue mass (34% vs. 45%). The roasting step enables the solid-state conversion of PbSO₄ into highly soluble chloride phases (PbCl₂ and Pb(OH)Cl), while ZnFe₂O₄, Fe₂O₃ and SiO₂ remain stable and form the inert matrix of the residue. Acid leaching at a lower solid-to-liquid ratio (1:10) ensures near-complete dissolution of Pb and Ag, whereas aqueous leaching at a high ratio (1:100) results in incomplete Pb removal. The compliance leaching test (EN 12457-2) confirmed that the residue produced after the optimized two-step treatment meets the EU criteria for inert waste. Overall, the proposed combined process enhances Pb and Ag recovery, minimizes environmental risk, and offers a technically robust and sustainable route for treating lead-containing industrial residues.