Search Results (22)

The growing environmental impact of copper production necessitates innovative approaches for optimizing metallurgical processes and minimizing waste. This study addresses this challenge by leveraging advanced machine learning (ML) techniques to enhance the efficiency of pyrometallurgical operations such as slag optimization, composition prediction, and waste minimization. Using a combination of real-world and synthetic data, we developed models capable of both forward prediction, estimating slag and matte compositions from ore characteristics, and backward prediction, inferring ore compositions from output characteristics. Five ML algorithms were evaluated, with Gradient Boosting and Support Vector Regression demonstrating superior performance in capturing complex, non-linear relationships. Forward prediction achieved near-perfect accuracy, while backward prediction highlighted the inherent complexity of inverse modeling. This backward-driven strategy proposed in this research aims to determine optimal ore compositions to achieve desired outputs, reducing waste and energy consumption. By integrating ML models with a systematic hyperparameter optimization approach, this work advances the potential for sustainable and precise metallurgical processes. While challenges remain in refining backward predictions, the findings demonstrate the transformative potential of data-driven strategies in industrial metallurgy, paving the way for environmentally sustainable and economically efficient copper production practices. Full article

Electronic waste (e-waste) is becoming a serious problem that impacts the environment due to its fast-growing volume. This rise is linked to high electronic and electrical equipment production to meet the increasing demand for high-end electronic devices. Conventional e-waste recycling approaches, including hydrometallurgy and pyrometallurgy, often involve substantial water and energy consumption and the generation of by-products, such as the emission of toxic gases or hazardous effluents. Within this context, solvometallurgy has emerged as a compelling alternative, whereby green non-toxic non-aqueous solvents, namely deep eutectic solvents (DESs), are used to extract and recover the metals with minimal water and harsh acid/base chemical use. The current study presents the solvo-leaching results of critical and strategic metals, i.e., copper (Cu) and nickel (Ni), and precious metals, i.e., gold (Au), from waste printed circuit boards (PCBs). Five different DESs were tested at mild conditions, namely at a temperature of 65 °C, a stirring speed of 300 rpm, a solid/liquid ratio of 10 g/L, and in the presence of iodine (I₂) for 96 h. Among the different solvents tested, the one consisting of choline chloride (ChCl), acetic acid (AA), and I₂ emerged as the optimal solvent, leading to the selective extraction of 99% of Cu, 92% of Ni, and 90% of Au from the PCB powder. Full article

Copper anode slime (CAS) contains high concentrations of precious metals, particularly gold, which can reach up to 11 wt%. During copper anode electrorefining, 5–10 kg of CAS is generated per ton of copper cathode. Processing CAS is crucial for economic reasons, as gold significantly contributes to revenue for both miners and custom copper smelters. This paper provides a comprehensive review of industrial processes and technologies for CAS treatment, with a focus on gold recovery, covering studies from the early 1930s to the present. It documents traditional and recent trends and analyzes the advantages and disadvantages of existing methods. Key factors affecting revenue, such as gold production lead time, in-process inventory, and first-pass recovery rate, are discussed to mitigate losses in fluctuating gold markets. CAS processing routes are categorized into two main groups: traditional hybrid routes (involving hydrometallurgy, pyrometallurgy, and electrorefining/electrowinning) and rather recent purely hydrometallurgical routes. Traditional methods can take up to 45 days, with gold recovery occurring late in the process and losses arising in the anode, cathode, electrolyte, or slag. In contrast, purely hydrometallurgical routes have total processing times of 7–8 days, achieve early gold recovery, and can attain first-pass recovery rates as high as 99%. Additionally, the hydrometallurgical routes are more environmentally friendly, with lower pollution levels and reduced energy consumption compared to hybrid routes. These findings indicate that purely hydrometallurgical routes outperform traditional hybrid methods. This paper aims to serve as a guideline for industrial CAS processing, assisting custom copper smelters in navigating challenging market conditions marked by low treatment and refining charges, with an emphasis on enhancing gold recovery to promote sustainability. Full article

Residual arsenic in copper matte is a source of arsenic contamination in subsequent processes in the smelting section of copper pyrometallurgy. In order to solve the impact of arsenic in copper matte on the subsequent process of smelting, this study removes arsenic from copper matte by adding an arsenic removal agent to the molten copper matte. The results show that the most difficult arsenic phase in copper matte is the residual arsenic in copper-arsenic alloys, based on which sodium carbonate was selected as the arsenic removal agent. The arsenic content in the copper matte was reduced by 98% under the optimal experimental conditions of a reaction temperature of 1250 °C, 4% sodium carbonate addition, and a reaction time of 60 min. The experimental results of the reaction mechanism show that sodium carbonate plays two main roles in the process of removing the intractable residual arsenic in copper matte. One is that sodium carbonate has a low melting point, which enhances the fluidity of the reactants. The other is that it can provide oxygen to the reaction system and convert arsenic in the copper-arsenic alloy into gaseous arsenic and arsenate. This study can provide new ideas for controlling arsenic pollution in copper pyrometallurgy. Full article

The usage of copper (Cu) ores containing low or no arsenic (As) has reduced, and Cu ores containing high levels of As have emerged as vital mineral resources for Cu extraction and processing. The quality of the Cu ores has decreased from 1.6% to approximately 1.0%. The proportion of As to Cu in 15% of Cu resources currently reaches 1:5. However, during the extraction and processing of Cu ores, As presents significant environmental harm. Hence, safely and effectively removing As is paramount in Cu smelting and processing, holding substantial importance in fostering environmentally sustainable practices within the Cu extraction and processing industry. This article consolidates the resource distribution of As-containing Cu (ACC) ores, comprehensively and systematically evaluates the present advancements in extracting techniques for these minerals, and identifies the challenges inherent in pyrometallurgical and wet processes for treating ACC deposits. Pyrometallurgy is a simple primary roasting technique and has widespread applicability in the treatment of various ACC minerals. Its disadvantages are the emission of exhaust gas and the high treatment costs associated with it. The wet arsenic removal method boasts advantages including minimal air pollution and a high resource recovery rate, significantly aiding in Cu concentrate recovery; its major drawback is the production of As-containing wastewater. The hydrometallurgical removal of As from ACC mines involves extracting As through leaching. Recently, biometallurgy has presented innovative solutions using specialized microorganisms to bioleach or bioabsorb As, but large-scale industrial applications still lack specific practical implementation. This review explores the underlying causes of the challenges encountered in processing ACC minerals. Additionally, it highlights pyrometallurgical roasting coupled with high-temperature filtration as a pivotal advancement in the extraction and processing of ACC ores. Full article

Pyrometallurgy is the primary technique for the production of many nonferrous metals such as copper, lead, and zinc. The phase equilibrium information of smelting slags plays an important role in the efficient extraction of metals and energy consumption. The experimental technologies used in phase equilibrium studies are compared. The presentation and applications of the pseudo-ternary and pseudo-binary phase diagrams are demonstrated in the Fe–Si–Ca–Zn–Mg–Al–Cu–S–O system. Experimental results are also compared with the predictions of FactSage to evaluate the accuracy of the current thermodynamic database. This review paper provides comprehensive information for the operation of nonferrous metals and optimization of the thermodynamic database. Full article

The depletion of the ore reserves in the world necessitates the search for secondary sources such as waste products (tailings and slag). The treatment and cleaning up of such secondary sources also has a positive impact on the environment. A smelter in Namibia we examined had historic slag which accumulated over decades of its operating life, thus posing the challenge of how best to collect representative samples to evaluate and propose viable methods of recovering contained metals. In this study, analytical and mineralogical characterization of the slag was performed using X-ray fluorescence (XRF) analysis, atomic absorption spectrometer (AAS), ICP-OES, scanning electron microscopy energy dispersive spectroscopy (SEM-EDS) analysis, and optical microscopy analysis. The chemical analyses showed that the metal values contained in the slag were mainly copper, lead, and zinc whose average contents were approximately 0.35% Cu, 3% Pb, and 5.5% Zn. About 10.5% Fe was also contained in the slag. Germanium was detected by scanning electron microscopy, but was however below detection limits of the chemical analysis equipment used. Based on the results, approximate conditions under which the different slag phases were formed were estimated and the recovery routes for the various metals were proposed. Analysis by both optical and scanning electron microscopy revealed that Zn and Fe occurred mainly in association with O as oxides, while Cu and Pb were mainly associated with S as sulphides. The slag consisted of three different phases, namely the silicate phase (slag), metallic phase and the sulphide phases. The phases in the slag were mainly silicate phases as well as metallic and sulphide phases. It was observed that the metallic and sulphide phases were dominant in the finer size fractions (−75 µm) whereas the sulphide phase was also present in the coarser size fractions (+300 µm). An important finding from the microscopy examination was that the sulphide phases were interstitial and could be liberated from the slag. This finding meant that liberation and subsequent concentration of the sulphide phases was feasible using conventional processing techniques. Full article

The scope of this work is to improve the SAW process understanding and present an improved description of the SAW process in terms of gas-slag-metal reactions with alloy powder and Al powder additions. The scope does not include the materials properties of the weld metal. The latter may easily be optimised in the future by changing the weld metal chemistry once the process reactions of different element powders in SAW are understood. Aluminium as de-oxidiser element was applied to SAW to lower the oxygen partial pressure in the process. The results show the Al-Ni-Cr-Co-Cu alloyed weld metal total oxygen content was reduced to 257 ppm O, compared to the base case weld metal at 499 ppm O, made with the same flux and no metal powder additions. Thus, the aluminium that was added as a de-oxidiser element to the SAW process effectively lowered the original flux-induced partial oxygen pressure, both in the arc cavity and at the interface of the molten flux–weld pool phases. This partial oxygen pressure lowering effect of Al also prevents oxidation of Cr, preventing loss of Cr to the slag. Carbon steel was alloyed to 3.9% Al, 4.8% Ni, 4.9% Cr, 4.8% Co, 4.7% Cu at 62% Al yield, 76% Ni yield, 77% Cr yield, 75% Co yield, 74% Cu yield. SEM (scanning electron microscope) work on the three-dimensional (3D) post-weld slag sample show dome cavities with 3D rounded structures embedded in the dome cavity walls, as well as shards and nano-strands on the dome cavity walls. The 3D structures indicate vapour formation and re-condensation of oxy-fluorides. The novel application of the EERZ (effective equilibrium reaction zone) model simulates the mass transfer effects in the SAW process. This model is novel because it is the first model used to calculate the gas-slag-metal phase chemistry changes in SAW as a function of welding time. The novel SAW process modification of adding Al de-oxidiser powder with alloying element powders of the unique combination of Co-Cr-Co-Ni-Al was successfully applied. The results confirm that the gas phase and its reactions must be included in the interpretation and modelling of SAW process metallurgy. Full article

This study aimed at a quantitative analysis of the material flows associated with End of Life (EoL) lithium-ion batteries’ (LIBs) materials in Europe. The European electric vehicles fleet in 2020 was taken as a case study, assuming a 10-year lifetime for the batteries and that the related EoL LIBs would be processed by existing recycling plants via pyrometallurgy, hydrometallurgy, or their combination in sequence. The economic implications (recycling operative costs compared to the revenues from the sales of the recycled metals) and the environmental performances (CO₂ eq. emitted, energy demand and circularity performances) were assessed. Based on the gathered results, the existing European recycling capacity will overlook over 78% of the forecasted EoL LIBs. The treatment efficiencies of the full-scale recycling processes allow for the recovery of over 90% of copper, cobalt, nickel, and manganese, 87% of aluminum, and only 42% of lithium and 35% of iron entering the recycling facilities. In overall, LIBs recycling in 2030 will involve the emission of 3.7 Mt of CO₂ eq. and an energy demand of 33.6 GWh. Hydrometallurgy presents the best economic and environmental trade-off compared to other recycling strategies. In conclusion, this study demonstrated that current European LIBs’ recycling infrastructure will be inadequate in the near future and the direction (i.e., hydrometallurgy) that its strengthening should pursue. Full article

Aluminium metal is not typically added to the submerged arc welding (SAW) process because it is easily oxidised to form unwanted slag in the weld pool. The successful application of aluminium as a de-oxidiser is illustrated in this study by preventing oxidation of Cr and Co to their oxides, thereby preventing element loss to the slag. Unconstrained pure metals of Al, Cr, Co and Cu were applied to investigate the gas formation behaviour of these elements in the SAW arc cavity. Of interest is the effect of copper in the arc cavity in terms of its possible substitution for aluminium. The results confirmed that the Al-Cr-Co-Cu alloyed weld metal total oxygen content was lowered to 176 ppm O, in comparison to 499 ppm O in the weld metal formed from welding with the original flux, which excluded metal powder additions. This lower ppm O value of 176 ppm O confirms that the added aluminium powder effectively lowered the original flux-induced partial oxygen pressure in the arc cavity, and at the molten flux–weld pool interface. Carbon steel was alloyed to 5.3% Co, 5.5% Cr, 5.3% Cu and 4.5% Al at 78% Co yield, 82% Cr yield, 78% Cu yield and 66% Al yield. Thermochemical equilibrium calculations confirm the partial oxygen pressure-lowering effect of aluminium when considering the gas–slag–alloy equilibrium. BSE (backscattered electron) images of the three-dimensional (3D) post-weld slag sample show dome structures which contain features of vapour formation and re-condensation. SEM-EDX (scanning electron microscope-energy dispersive X-ray) maps show that the dome surface matrix phase consists of Al-Mg-Ca-Si-Na-K-Ti-Fe-Mn oxy-fluoride. The spherical 3D structures of 10–40 µm in diameter consist of Fe-Mn-Si fluorides with some Cr, Cu and Co contained in some of the spheres. Cr and Co were observed in distinctive porous structures of approximately 10 µm in size, consisting partly of Cr oxy-fluoride and partly of Co oxy-fluoride. Nano-sized oxy-fluoride strands and spheres in the dome structures confirm vaporisation and re-condensation of oxy-fluorides. Cu and Na formed a distinct condensation pattern on the surface of the Si-Cu-Na-Mn-Fe-Co oxy-fluoride sphere. The results confirm the importance of including gas phase reactions in the interpretation of SAW process metallurgy. Full article

Unconstrained metal powders of Cu, Cr, Ni and Al were applied to submerged arc welding (SAW) to clarify the chemical behaviour of copper in this modified SAW process. Aluminium metal is avoided in SAW because it is easily oxidised. Excessive aluminium oxides in the form of slag or inclusions in the weld metal will lead to poor weld metal materials properties. Aluminium is an effective deoxidiser and can be used to prevent Cr and Ni loss to the slag by preventing oxidation of these metals. The results show that carbon steel was alloyed to 5.3% Cr, 5.3% Ni, 3.6% Al and 5.2% Cu at 80% Cr yield, 81% Ni yield, 54% Al yield and 79% Cu yield. BSE (backscattered electron) images of the three-dimensional (3D) post-weld slag sample show 3D structures within the slag dome. The 3D structures contain features of vapour formation and recondensation. In addition, nano-strands appear in the 3D structures and confirm the vaporisation and recondensation of fluorides. The chemical behaviour of copper metal powder added in SAW is to vaporise as metallic copper and incorporate in the Al-Si-Mg-Ca-Mn-Fe-Cu-Na-Cr-Ni fluoride. Copper, in combination with aluminium, has a stabiliser effect in SAW due to its formation of an initial alloy melt of low liquidus temperature, thus decreasing the temperature required to melt high-melting-point metals such as Cr into the weld pool. Although Al and Cu have similar vapour pressures at specific temperatures, it appears that Cu does not substitute for Al in the gas phase. Gas-slag-alloy thermochemical equilibrium calculations confirm the partial oxygen pressure lowering effect of aluminium and the vaporisation of copper as metallic copper with very little copper-fluoride species expected to form. The quantity of metallic copper vaporisation calculated in the gas-slag-alloy thermochemical equilibrium is much higher than the vaporisation quantity measured in welding. This may be due to recondensation of vaporised copper which is not accounted for in the equilibrium calculation at the set arc cavity temperature, as well as the effect of surface-active elements such as sulphur and oxygen in limiting the vaporisation reaction of copper. Full article

The conversion of copper sulfide mattes lacks fundamental kinetic information for understanding the process. This work presents the results of the experimental measurement of the rate of oxidation of molten white metal by supplying individual air bubbles. The bubbles were characterized from information collected during the experiments and through theoretical and empirical correlations. Conversion tests were carried out at different temperature conditions and injection dynamics of the oxidizing gas. The results indicate that the conversion is controlled by the transport of oxygen into the bubble. A dependency between the characteristics of the injector and the shape, size and surface of the bubbles was identified. The oxidation rate of the white metal depended on the characteristics of the bubbles and the oxygen available for conversion. The results of this research provide relevant information to improve the operation of industrial conversion furnaces by controlling gas injection through the tuyeres. The criterion for improving conversion systems is the balance between the retention of the bubbles in the molten white metal and their size, such that the availability of oxygen for the conversion is guaranteed. Full article

Currently, the high demand for copper is in direct contrast with the decrease in the mineral grade and, more significantly, the concerns regarding the environmental impact that arise as a result of processing such low-grade materials. Consequently, new mineral processing concepts are needed. This work explores the chemical dissolution of chalcopyrite concentrate at ambient pressure and moderate temperatures in a deep eutectic solvent. Copper and iron are dissolved without changing their oxidation state, without solvent pH change, and stabilized as a chloride complex with no evidence of passivation. Chemical equilibria of the metallic chloride complexes limit the dissolution, and the step that is rate-controlling of the kinetics is the interdiffusion of species in the solvent. The chemical mechanism may involve initial chloride adsorption at positive sites of the solid surface, pointing out the importance of surfaces states on chalcopyrite particles. A model based on a shrinking particle coupled with pseudo-second-order increase in the liquid concentration of copper describes the dissolution kinetics and demonstrates the importance of the liquid to solid ratio. Iron and copper can be recovered separately from the solvent, which highlights that this concept is an interesting alternative to both redox-hydrometallurgy and pyrometallurgy to obtain copper by the processing of chalcopyrite concentrate. Full article

Copper slag is generated when copper and nickel ores are recovered from their parent ores using a pyrometallurgical process, and these ores usually contain other elements which include iron, cobalt, silica, and alumina. Slag is a major problem in the metallurgical industries as it is dumped into heaps which have accumulated into millions of tons over the years. Moreover, they pose a danger to the environment as they occupy vacant land (space problems). Over the past few years, studies have been conducted to investigate the copper slag-producing outlets to learn their behavior, as well as properties of slag, to have the knowledge of how to better reuse and recycle copper slag. This review article provides the environmental and socioeconomic impacts of slag, as well as a characterization of copper slag, with the aim of reusing and recycling the slag to benefit the environment and economy. Recycling methods are considered an attractive technological pathway for reducing waste and greenhouse gas emissions, as well as promoting the concept of circular economy through the utilization of waste. These metal elements have value depending on their characteristics; hence, copper slag is considered as a secondary source of valuable metals. Some of the pyrometallurgical and hydrometallurgical processes to consider are physical separation, magnetic separation, flotation, leaching, and direct reduction roasting of iron (DRI). Some of the possible metals that can be recovered from the copper slag include Cu, Fe, Ni, Co, and Ag (precious metals). Full article

The intensive exploitation of resources on a global level has led to a progressive depletion of mineral reserves, which were proved to be insufficient to meet the high demand for high-technological devices. On the other hand, the continuous production of Waste from Electrical and Electronic Equipment (WEEE) is causing serious environmental problems, due to the complex composition of WEEE, which makes the recycling and reuse particularly challenging. The average metal content of WEEE is estimated to be around 30% and varies depending on the manufacturing period and brand of production. It contains base metals and precious metals, such as gold and palladium. The remaining 70% of WEEEs is composed of plastics, resins, and glassy materials. The recovery of metals from WEEEs is characterized by two main processes well represented by the literature: Pyrometallurgy and hydrometallurgy. Both of them require the pre-treatment of WEEEs, such as dismantling and magnetic separation of plastics. In this work, the selective adsorption of precious metals has been attempted, using copper, gold, and palladium aqueous solutions and mixtures of them. A screening on different adsorbent materials such as granular activated carbons and polymers, either as pellets or foams, has been performed. Among these, PolyEther Block Amide (PEBA) was elected as the most performing adsorbent in terms of gold selectivity over copper. Spent PEBA has been then characterized using scanning electron microscope, coupled with energy dispersive spectroscopy, demonstrating the predominant presence of gold in most analyzed sites, either in the pellet or foam form. Full article