Search Results (564)

Copper smelting dust is a heterogeneous by-product of pyrometallurgical processing containing sulfate- and arsenic-bearing components, which accounts for its high chemical stability and environmental hazard. In this context, mechanochemical activation is considered a promising approach for initiating structural and phase transformations in such systems. The aim of this study was to investigate the effect of high-energy planetary milling in the “dust–Na₂S” and “dust–Na₂S–NaOH” systems on changes in the phase composition of arsenic-bearing dust. The samples were prepared by dry mechanochemical activation in a planetary mill for 15 and 30 min with varying reagent contents. According to X-ray diffraction analysis, PbSO₄ and ZnSO₄·H₂O remain the major phases in the binary system, while the formation of elemental sulfur (S₆) and the arsenic sulfide phase (As₄S₄) is observed against a decrease in the As₂O₃ content. In the presence of NaOH, a more pronounced redistribution of arsenic species is observed, accompanied by the appearance of a Na-containing As–O–S phase, preliminarily identified as Na₃AsO₂S₂, and a further decrease in the proportion of As₂O₃. Thermodynamic analysis indicates the energetic favorability of arsenic sulfidation when the oxidative contribution of the air atmosphere during milling is taken into account. The obtained results refine the possible mechanochemical pathways of arsenic transformation and may be used to substantiate preliminary activation regimes prior to subsequent leaching. Full article

This study investigated the kinetics of chalcopyrite dissolution in an alkaline monosodium glutamate (MSG) solution using H₂O₂ and KMnO₄. The aims were to optimize process conditions for maximum copper dissolution and to study the kinetic mechanism of dissolution under varying conditions, such as particle size, oxidant type and concentration, temperature, and the presence of gangue minerals. Results showed that KMnO₄ exhibited better oxidative efficiency and stability than H₂O₂, yielding copper recoveries above 90% in most conditions while keeping the dissolution of some gangue metals, such as calcium, magnesium, and iron, lower, thereby reducing MSG consumption. Temperature and particle size were the most important factors in the effects on leaching kinetics; smaller particles allow higher initial reaction rates, while larger particles allow prolonged dissolution. The shrinking core model (SCM) was thus used to perform kinetic analysis and determine that diffusion controls the leaching process through the product layer. The calculated activation energies of 18.2 kJ/mol of MSG-H₂O₂ and 17.3 kJ/mol of MSG-KMnO₄ confirm the diffusional mechanism. Full article

The wet recovery of spent lithium iron phosphate (LFP) batteries is severely hindered by the low efficiency of copper removal. Here, a new process has been developed using a copper-removing chelating resin with pyridine nitrogen, carboxyl, and hydroxyl groups for the selective separation of copper ions. This copper chelating resin achieved a copper removal efficiency of 96.99% and reduced the residual copper content to below 10 milligrams per liter, significantly outperforming the traditional iron powder method. The adsorption process is highly sensitive to pH, with the highest efficiency at pH 1.75. A concentration of 2.0 moles per liter of H₂SO₄ can achieve a desorption rate of approximately 95%. The adsorption process follows the Langmuir isothermal equation and the pseudo-second-order kinetic model, corresponding to single-layer chelated chemical adsorption. Mechanism studies have confirmed that the synergistic coordination effect of the multifunctional groups helps in the efficient capture of copper ions. This copper chelating resin exhibits excellent stability, reversibility, and reusability, providing a promising method for efficient copper removal and recovery in the wet metallurgical recycling of LFP. Full article

The rapid growth of photovoltaic panels installations has led to a dramatic increase in the end-of-life (EoL) panels, creating an urgent need for efficient recycling strategies. In the present study, a pretreatment system consisting of hydrochloric acid was developed to remove impurity metals such as aluminum and iron from EoL PV panel powder prior to the precious metals leaching step. Response surface methodology (RSM) based on a central composite design (CCD) was employed to optimize the effects of main operational parameters, i.e., HCl concentration, leaching time, and solid-to-liquid (S/L) ratio on the dissolution of Al, Fe, Pb, Sn, and Cu. Thermodynamic analysis with the help of HSC Chemistry^® 10 software, confirmed the feasibility of dissolution of the Al, Fe, Pb, Sn, and Cu in chloride media. Experimental results demonstrated that the dissolution rate of Al and Fe under optimal conditions were 86.05 and 91.77 percent, respectively. In all of the tests, copper dissolution remained negligible (<4%), and no silver was detected which confirms the selectivity of the pretreatment. The optimized conditions (1.5 M HCl, 198 min, 20% S/L) enabled effective impurity removal while preserving silver in the solid residue. This study highlights the importance of selective pretreatment in enhancing downstream silver recovery and provides a practical approach for the hydrometallurgical recycling of end-of-life PV waste. Full article

This paper presents the results of testing a copper bioleaching technology applied to two types of ore sampled from different sections of deposits within one of the deposits in the Balkhash region. Preliminary microbiological studies of microorganisms present in mineral raw material samples from the deposit revealed that, under conditions favorable for the growth of iron- and sulfur-oxidizing bacteria, active proliferation of yeast-like fungi was also observed, along with a bacterial culture identified as Skermanella aerolata. Preliminary experiments demonstrated that the effect of the identified bacterial culture, in association with Acidithiobacillus ferrooxidans and Acidithiobacillus thiooxidans, positively influences oxidative processes involved in the decomposition of sulfur- and iron-containing minerals. The complete consortium of endemic microorganisms used in bioleaching experiments exhibited the highest efficiency compared to both individual cultures and the conventional sulfuric acid leaching method. The effect of biological oxidation on a simple-composition ore sample resulted in a 5.4% increase in copper recovery, while the efficiency of sulfuric acid consumption improved by nearly 40%. The use of bacterial oxidation for a low-grade, high-acid-consuming ore sample showed comparable copper recovery; however, sulfuric acid consumption was reduced by a factor of 2.5. Full article

Mineral exploration in the Iberian Pyrite Belt follows increasingly deeper targets. The present study introduces an innovative methodology for the detection and identification of blind metallic mineral deposits, in particular volcanogenic massive sulfides based on surface rock coatings. This approach follows the identification pathways of upward metal escape routes and metal distribution in rock fractures located in different anisotropic or isotropic planes above the Neves-Corvo VMS deposit ore lenses, using VP-SEM-EDS and XRD. Coatings are dominated by poorly crystalline to amorphous phases, with goethite and birnessite as the main Fe- and Mn-bearing minerals. Copper, zinc and lead are systematically enriched in coatings developed above or near the ore bodies, reflecting chalcopyrite, sphalerite and galena acidic leaching. Tin shows a restricted and heterogeneous distribution, while Ni and Co display no systematic relationship with the ore bodies. Barium and late Ba–Pb–(Zn) mineralization along fault zones record VMS mineralization. Lead isotopic coating signatures overlap those of IPB massive sulfide deposits, confirming a dominant VMS-derived contribution. Fe–Mn coatings were formed by precipitation from ascending meteoric fluids that leached metals from massive sulfides, their alteration halos, and surrounding lithologies, preserving the geochemical footprint of buried mineralization. This approach constitutes a new patented exploration tool. Full article

Mining activities generate large volumes of waste that pose both environmental liabilities and potential secondary resource value. A significant fraction of these materials still contains recoverable copper, making leaching a promising strategy for reprocessing and valorization, given the natural decline in ore grade. This study presents a PRISMA-based systematic review of recent literature on leaching technologies applied to mining waste, with emphasis on technical performance, environmental implications, and economic feasibility. The reviewed residues include tailings, slags, copper smelter dusts, sludges, waste rock, leaching residues, and other secondary mining and metallurgical wastes. The main leaching routes identified were acidic, biological, alkaline, and hybrid systems, including conventional H₂SO₄ leaching, pressure oxidative leaching, chloride-based systems, glycine- and ammonia-based alkaline media, organic acids, deep eutectic solvents, and biologically mediated processes. Reported Cu recoveries ranged from low values in refractory systems to near-complete extraction under optimized conditions. Overall, copper recovery was controlled primarily by the mineralogical occurrence of Cu rather than by leaching category alone. In contrast, the highest recoveries were generally associated with intensified conditions capable of overcoming sulfide- and silicate-related constraints. Environmental and circular economy benefits were frequently claimed but less often demonstrated through direct evidence, while economic assessment remained limited. Future research should better integrate mineralogical interpretation, environmental verification, and economic feasibility. Full article

In situ leaching is increasingly used for rare earth element (REE) extraction because of its operational efficiency; however, acidic and chemically reactive leaching solutions may generate substantial environmental risks in riverine systems. This study evaluated water contamination and screening-level ecological risk following a cyanide leakage incident associated with a pilot REE mining operation in Houaphanh Province, northern Lao PDR. Surface water samples were collected from 12 downstream monitoring locations between February and April 2024. Physicochemical parameters, free cyanide (CN⁻), and dissolved metals, including arsenic (As), lead (Pb), copper (Cu), manganese (Mn), aluminum (Al), zinc (Zn), and iron (Fe), were analyzed using portable multiparameter probes, colorimetric cyanide determination, and ICP-OES. Contamination severity was interpreted using Pollution Index (PI) and Hazard Quotient (HQ) indicators based on Lao national standards and international guideline values. Results showed severe downstream contamination, with free cyanide and several dissolved metals substantially exceeding permissible thresholds. Observed elevated concentrations of As (30.29 mg/L), Pb (10.38 mg/L), Cu (14.97 mg/L), and CN⁻ (0.51 mg/L) indicated elevated ecological risk conditions, while acidic pH conditions may have enhanced metal mobilization and downstream transport. Descriptive spatial observations indicated apparent downstream contaminant dispersion within affected downstream river communities reliant on river water for domestic use, irrigation, and fisheries. Field observations additionally documented fish mortality, reduced irrigation usability, and deterioration of river water quality conditions in affected downstream communities. The findings suggest the potential vulnerability of Mekong-connected river systems to chemically intensive REE extraction activities and highlight the importance of preventive environmental governance, continuous monitoring, and operational risk management in emerging rare earth mining regions. Full article

Heap bioleaching is widely used to extract copper from low-grade sulfide ores thanks to its operational simplicity, low cost, and environmental sustainability. However, current control strategies rely primarily on single-factor optimization and often overlook the synergistic interactions of multiple key parameters, such as ore particle size, pore structure, pH, temperature, microbial activity, and oxygen transfer efficiency. As a result, issues such as low recovery rates, extended leaching periods, and high operational costs persist. Moreover, the “gray-box” nature of heap systems impedes real-time monitoring of internal physical, chemical, and biological processes. In addition, empirical multi-parameter optimization is time-consuming and inadequate for capturing complex interdependencies. This review was conducted to systematically examine the key factors influencing heap bioleaching efficiency and critically evaluate recent advances in numerical simulation and intelligent control strategies. As a result, we identified a major research gap: the existing models—including microscale shrinking core models (SCMs), mesoscale pore-network models based on CT reconstruction, and macroscale continuum models—have inherent limitations. SCMs assume idealized spherical particles with uniform mineral distribution while neglecting pore structure evolution and biofilm dynamics. Mesoscale models offer detailed pore characterization but lack robust multi-physics coupling (thermal–hydro–mechanical–chemical–biological, or THMCB). Macroscale models rely on homogenization assumptions that oversimplify spatial heterogeneity and temporal variations in permeability. This analysis covers the relevant literature from 1985 to 2025, with a focus on three methodological scales (micro, meso, and macro) and their integration with machine learning approaches. A notable finding is that hybrid neural network models (e.g., BP and RBF architectures) outperform purely physics-based models in predicting leaching kinetics under varying operational conditions. However, their accuracy depends heavily on high-quality field data—a limitation rarely addressed in prior reviews. By clearly delineating these model-specific limitations and scale-dependent trade-offs, this review makes two unique contributions: a structured framework for selecting and coupling numerical methods according to process requirements and a roadmap for integrating artificial neural networks with multi-physics simulations to achieve real-time intelligent control of heap bioleaching. The findings offer both theoretical guidance and practical references for optimizing the processing of low-grade copper sulfide ores. Full article

The printed circuit board (PCB), a central component of most electronic devices, represents a significant fraction of the electronic product waste stream. The complex composition of PCBs, consisting of metals, polymers, and fiberglass, requires specialized recovery steps to reclaim valuable and critical materials and the safe disposal of brominated compounds. In this review paper, we describe the current state of critical material recovery and traditional recycling technologies and identify key obstacles to large-scale implementation. Metals present at high concentrations, such as copper, lead, and iron, are conventionally recovered from PCBs using hydrometallurgical, pyrometallurgical, or electrometallurgical processes. Hydrometallurgical methods achieve high selectivity through chemical leaching but pose significant challenges for effluent and reagent recovery. Pyrometallurgical methods facilitate rapid metal separation through smelting but require substantial energy and may release harmful gases. Electrometallurgical techniques produce high-purity metals but are constrained by pretreatment requirements and the consumption of energy. The non-metallic fraction of PCB waste is recycled using thermochemical conversion, microwave-aided heating, and direct recycling of epoxy–fiberglass composites, enabling material or energy recovery. The recovered polymer from direct recycling may have reduced mechanical strength and poor compatibility with new polymer matrices, and the resulting products from the thermal conversion suffer from incomplete conversion, degradation of quality, and residual contamination, as compared to synthetic polymers. Recent process developments have focused on extracting rare earth and supply-critical materials present at lower concentrations in the waste stream. The literature on existing and emerging approaches for recycling PCB wastes is reviewed to identify sustainable, economically viable, and environmentally responsible strategies for the recovery and reuse of critical materials from waste streams. Full article

This article presents the results of developing a hydrometallurgical method for processing polymetallic sublimates containing arsenic, zinc, copper, and lead. Using sublimates from “BalkhashPolymetal” LLP (Kazakhstan) as an example, the optimal conditions for sulfuric acid leaching were determined as follows: t = 80–85 °C, H₂SO₄ = 25 g/dm³, τ = 60 min. Under these conditions, extraction of arsenic was 93%, zinc 80%, and copper 42% was achieved. Iron(II) hydroxide was used to remove arsenic from the solution, which made it possible to reduce the residual As content in the solution to 0.02 g/L and return approximately 97% of copper to the process cycle. Eh–pH analysis of the Fe–As–Cu–H₂O system confirmed the thermodynamic stability of Fe(II/III) arsenates in the selected pH range 3–5. The obtained results can be used to develop safe and resource-saving technologies for processing technogenic raw materials. Full article

Copper slag (CS) was considered a major by-product produced from the copper refining industry, which estimates about 2.2 to 3 tons generated during the production of every one ton of copper. At the same time, continuous dumping and improper disposal of this byproduct have led to serious environmental problems, especially due to the leaching of heavy metals into soil and water. This review carefully studies the potential of CS as a sustainable construction material through a clear distinction of its performance, especially when used as a fine aggregate and as a supplementary cementitious material (SCM). Due to the presence of higher content of iron and silica, higher hardness, and very low water absorption, it was found that CS helps in improving the density and durability of concrete. When used as a fine aggregate, CS enhances workability, strength, and durability at an optimum level of about 40%, mainly due to better particle packing and reduced pore connectivity. On the other hand, when used as an SCM, CS contributes to long-term strength through pozzolanic reactions and the formation of C–S–H gel, but its replacement level should be limited to about 20% to avoid loss of early-age strength caused by reduced alkalinity. In terms of durability, the use of CS can reduce water absorption by up to 60%, lower chloride penetration, and improve resistance to sulfate attack. Environmental Life Cycle Assessment studies show that CS can reduce global warming potential by about 12–19% and also decrease overall energy consumption. Statistical validation using multi-criteria decision analysis (MCDA) and separate regression modeling with an R² value of about 0.965, which supports these optimum replacement levels up to 40% for fine aggregate and 20% for cement, providing a good balance between strength, durability, environmental benefits, and cost. Overall, this review shows that CS is a valuable and multi-functional material that supports circular economy practices when used with a proper mix design based on specific applications. Full article

This study investigates the leaching behavior of the LiNi_0.65Co_0.25Mn_0.10O₂ cathode material in a phosphoric acid medium, with metallic copper recycled from spent battery components serving as a reducing agent. The aim was to develop an efficient approach for the recovery of Li, Ni, Co, and Mn while providing a mechanistic understanding. Leaching experiments were performed by varying key parameters, including copper addition, acid concentration (0.2–0.8 mol·L⁻¹), cathode mass (0.2–1.0 g), stirring rate (0–600 rpm), and temperature (35–80 °C). Thermodynamic analysis, supported by Pourbaix and species distribution diagrams, was used to interpret metal behavior. The results show that lithium is readily dissolved, whereas the extraction of Ni, Co, and Mn depends on the presence of copper, which enables their reduction and dissolution. Optimal conditions (0.4 mol·L⁻¹ H₃PO₄, 0.2 g Cu, 600 rpm, 80 °C) enabled rapid extraction, exceeding 90% within 30 min, while near-complete extraction (~100%, 99%, 99%, and 97% for Li, Ni, Co, and Mn) was achieved after 60 min. Structural analysis revealed a transformation from the layered structure to spinel-like intermediates, followed by their dissolution and formation of copper phosphate phases. The proposed system represents an efficient approach for the sustainable recycling of NMC cathodes. Full article

Aiming at the significant variation in clay content within the orebody of the Letpadaung copper mine in Monywa, Myanmar, this study conducted comprehensive research on ore classification based on clay content and its impact on bio-heap leaching performance. Pressure filtration tests confirmed that clay content is a critical factor affecting ore permeability and copper leaching efficiency. Accordingly, a classification standard centered on clay content was established based on the ore properties of the Letpadaung Copper Mine, categorizing the ore into four types: low-clay ore (<3%), medium-clay ore Type 1 (3%–10%), medium-clay ore Type 2 (10%–25%), and high-clay ore (>25%). Corresponding differentiated stacking strategies were proposed and applied for the first time in industrial operations at a scale of several hundred thousand tons. Industrial practice results demonstrated that, compared with the unclassified mixed ore with a leaching efficiency of 45.92%, the implementation of classified heap leaching increased the copper leaching rates of low-clay ore and medium-to-high-clay ore to 68.07% and 63.41%, respectively. Moreover, multi-layer heap leaching within the same leaching unit showed consistent leaching efficiency across different layers after ore classification. These results further validate that ore classification based on clay content combined with differentiated heap leaching processes serves as a vital technical approach for ensuring efficient and stable heap leaching operations at the Letpadaung copper mine. Full article

Copper anodic slime is often smelted with lead to improve silver and gold recovery, generating a fine lead-rich fly ash that contains notable amounts of selenium and tellurium. Due to its high lead content and sub-micron particle size, this residue poses significant environmental and occupational health risks. This study evaluates sodium carbonate (Na₂CO₃) leaching as an environmentally benign pre-treatment aimed at partially removing selenium and tellurium while stabilizing lead through carbonate formation. The goal is detoxification rather than maximum metal recovery, enabling safer disposal or subsequent recycling. A central composite design (CCD) in Design-Expert software (Version 12) was used to assess the effects of Na₂CO₃ concentration, temperature, solid-to-liquid ratio, and time on selenium and tellurium dissolution. Selenium recovery reached up to 53.9%, while tellurium recovery peaked at approximately 33.9%. Scanning electron microscopy showed the dust to consist mainly of semi-spherical and elongated particles, with lead carbonate forming preferentially on particle surfaces during leaching. Energy-dispersive spectroscopy confirmed conversion of lead sulfate phases to lead carbonate, which increasingly restricted selenium and tellurium dissolution. Kinetic evaluation suggested selenium leaching follows mixed control involving both surface reaction and diffusion through product layers, whereas tellurium dissolution lacked consistent kinetic behavior. Thermodynamic calculations supported the stabilization of lead as cerussite (PbCO₃), indicating improved environmental safety. The overall dissolution trends were successfully represented using an apparent Shrinking Core Model (SCM) based on measurements collected at 20 °C, 60 °C, and 100 °C. Full article