Search Results (295)

The copper industry generates approximately 24.6 million tons of copper slag (CS) annually, equivalent to about 2.2 tons of CS per ton of copper produced, creating a major waste management challenge. Meanwhile, concrete is one of the most widely used construction materials worldwide, with nearly 11 billion tons produced each year. This high demand requires large volumes of natural aggregates, leading to environmental impacts associated with their processing and transportation. This study evaluates mortar and concrete mixtures incorporating CS to assess the feasibility of valorising this industrial waste as an alternative aggregate in cementitious materials. The experimental programme included in this study tests to determine the workability and mechanical properties for different aggregate replacement ratios. The results show that replacing 40% of the fine aggregate with CS improves mortar performance, increasing compressive and flexural strength by at least 13.9% compared with reference mixtures. For concrete, up to 100% aggregate replacement was feasible, achieving compressive strength gains of up to 11.9%. Given that aggregates represent about 70–80% of the concrete volume, the incorporation of CS offers a promising strategy for large-scale waste valorisation and natural resource conservation. Full article

Copper (Cu) smelting slags are considered secondary reserves of technology metals (TMs) and base metals (BMs), which are crucial for the transition to renewable energy and mechatronic applications. In this study, thermochemical and experimental analyses were conducted to investigate the pyrometallurgical extraction of TMs and BMs from Cu smelting slag. FactSage thermochemical simulations and smelting experiments were carried out at temperatures from 1300 to 1600 °C and with carbon (reductant) additions of 2% to 10% relative to the mass of the feed slag. The results showed that during smelting, gallium (Ga), germanium (Ge), cobalt (Co), and copper (Cu) deported into the iron-based alloy product. Zinc (Zn) and lead (Pb) oxidised to ZnO and PbO, respectively, which were subsequently collected as fumes. The produced alloy mass was more sensitive to carbon addition than to smelting temperature variation. The TM and BM contents in the alloy decreased with increasing carbon addition in the feed; this was attributed to dilution by Fe, Si, and C from the increasing reduction of iron and silicon oxides in the feed slag and dissolution of C in the alloy. High recovery degrees of TMs and BMs in the alloy stream—over 90% for Co and Cu, over 50% for Ga, and over 70% for Ge—were achieved when smelting at 1500 °C with 4% carbon addition. The final alloy comprised 70.5% Fe, 6.6% Co, 23.6% Cu, 0.11% Ga, and 0.13% Ge. The fumes primarily comprised ZnO and, to a lesser extent, PbO, with recovery degrees over 90% for Zn and Pb. These alloy and fume products would be processed following conventional hydrometallurgical separation and purification processes to produce high-purity metals. The pyrometallurgical extraction of TMs and BMs presents an opportunity for the valorisation of Cu smelting slag dumps, especially in Southern Africa, aiming to attain zero-waste industrial processes. Full article

The recycling of spent lithium iron phosphate (LiFePO₄, LFP) batteries is receiving increasing attention as electric-vehicle deployment accelerates worldwide. Pyrometallurgical reduction offers a viable route for large-scale recovery of iron-rich products from spent LFP batteries; however, the resulting Fe-based alloys often retain residual copper (Cu), which deteriorates alloy quality and constrains downstream utilization and refining. In this study, a sulfidation–slag refining process was developed to selectively remove Cu from an Fe–P–Cu alloy produced by dry reduction of spent LFP batteries. FeS was employed as a sulfidizing agent to promote preferential conversion of Cu into sulfide phases, while fayalite (Fe₂SiO₄) slag was introduced to enhance phase separation between metallic and sulfide/slag phases. Thermodynamic calculations coupled with high-temperature experiments were conducted at 1400–1600 °C under various Cu:FeS ratios to identify operating conditions that maximize Cu removal while minimizing Fe loss. The results indicate that Cu is selectively transferred from the metallic phase to Cu–Fe–S sulfide phases, whereas Fe remains predominantly in the metal phase. Under the optimal condition (1400 °C, Cu:FeS = 2:1), the refined metal reached an Fe content of 90.80 wt.%, achieving an Fe recovery of 87.42% and a Cu removal efficiency of 81.13%. The proposed approach provides a practical stepwise refining strategy for upgrading Fe-rich secondary resources recovered from spent LFP batteries and facilitates subsequent impurity-control processes. Full article

The accumulation of copper smelting slags generated by non-ferrous metallurgy represents both an environmental challenge and a potential source of technogenic raw materials for value-added products. In this study, the feasibility of producing magnesia–quartz proppants from secondary copper smelting slag formed after the pyrometallurgical extraction of iron and zinc was investigated. The slag, primarily composed of oxides of the SiO₂–CaO–Al₂O₃–MgO system, was processed by centrifugal melt granulation to obtain spherical granules suitable for proppant applications. The initial granules exhibited an amorphous glassy structure and insufficient mechanical strength, with up to 70% of particles destroyed under a pressure of 34.5 MPa. Controlled heat treatment within the temperature range of 300–1000 °C induced crystallization of silicate and aluminosilicate phases, leading to a significant improvement in mechanical performance. Optimal properties were achieved after holding at 800 °C for 60 min, where the fraction of crushed granules decreased to 10%, meeting the requirements of GOST R 54571-2011. The influence of MgO content on microstructure and strength was also examined. Increasing the MgO concentration from 5 to 16 wt.% resulted in grain refinement and improved crushing resistance, reducing the fraction of destroyed granules to 3%. To enhance chemical durability, a phenol–formaldehyde protective coating was applied, decreasing proppant solubility in a hydrochloric–hydrofluoric acid mixture from 19% to 2%. These results demonstrate that secondary copper smelting slag can serve as a promising raw material for producing standard-compliant proppants while contributing to the efficient utilization of metallurgical waste. Full article

With ongoing development in the process industries, the accumulation of industrial inorganic solid wastes (IISWs) has become increasingly significant. IISWs are characterized by large volume and toxicity and pose challenges in treatment and control. IISWs from chemical processes mainly include red mud (RM), zinc slag, lithium slag (LS), electrolytic manganese residue (EMR), phosphogypsum (PG), water treatment sludge (WTS), sewage sludge, blast furnace slag (BFS), steel slag (SS), coal fly ash (CFA), coal gasification slag (CGS), copper smelting slag (CSS), and lead smelting slag (LSS). Having been chemically processed, they exhibit complex compositions that pose challenges for further utilization. In this paper, we comprehensively review the preparation of adsorbents from IISWs as raw materials, the applications of IISW-derived adsorbents, and their adsorption mechanisms. The obtained adsorbents include modified IISWs, zeolites, porous ceramics, and composite and hybrid adsorbents. The adsorption mechanisms, such as van der Waals forces, electrostatic interactions, and π–π interactions, contribute to the rapid adsorption kinetics and high adsorption capacity observed in these adsorbents. Full article

Copper smelting slags represent a growing environmental and metallurgical challenge due to their large volumes and their content of unrecovered critical metals such as copper. Although conventional treatment relies mainly on acidic leaching, more sustainable hydrometallurgical routes are required to valorise these residues. In this study, an alternative copper extraction process is proposed based on alkaline glycine complexation and the use of ferromanganese crusts as an unconventional oxidising agent. Leaching tests were performed using two slags (A and B) at ambient conditions. Copper recoveries up to 59.7% (slag A) and 25.7% (slag B) were achieved at 1 M glycine without external oxidants. The addition of ferromanganese crusts (1:1 and 2:1) resulted in marginal increases (up to 61.1% and 29.1%, respectively), attributed to the limited oxidative performance of MnO₂ at near-neutral pH. The results demonstrate that glycine is a viable lixiviant for copper recovery from slags at room temperature and highlights, for the first time, the use of naturally occurring Fe–Mn crusts as oxidants in alkaline leaching systems. This work contributes to the development of more sustainable valorisation strategies for metallurgical slags and offers a basis for future optimisation of alkaline complexation routes. Full article

Copper and cobalt are critically important metals for the transition to renewable energy and various aspects of modern life. Their production from primary sources, ores, necessitates metallurgical separation from the unwanted host materials, resulting in the generation of a huge amount of waste. Copper smelting slag is one of these metallurgical wastes, with 39 million tonnes of slag generated and discarded globally each year. These massive amounts of slag occupy a considerable and growing land footprint, often close to residential areas, and present a hazard that potentially releases contaminants into the environment. On the other hand, they also represent a material that often contains a significant residual amount of valuable copper and cobalt. To better understand and address the challenge of reducing the adverse impacts of the waste, as well as the possible commercial opportunity the contained critical metals present, this study reviews global smelting slag production over the last 25 years, its composition, and technical reprocessing options. A summary of the chemical and mineralogical characterization of the copper slag from diverse research is thus provided, as well as a comprehensive overview of the processing strategies for metal recovery from copper slag, such as flotation, pyrometallurgy, and hydrometallurgy. The study demonstrates that a huge amount of smelting slag has been produced, with great variation and complexity, which represents a major potential resource for cobalt and copper metals. The chemical and mineralogical composition of smelting slag varies from location to location, depending on the properties of the feed concentrate, type of fluxes, furnace type, and cooling rates employed during and after the smelting processes. The overview of the production trends and reprocessing techniques shows that while some notable effective options exist or are emerging, further research is needed into the reprocessing of smelting slag waste in order to create economic value, improve energy efficiency in metal production, increase critical metal supply, and reduce negative environmental impacts. Full article

Molybdenum (Mo) finds extensive applications in the steel industry, and the recycling of secondary molybdenum resources is crucial for the green development of the molybdenum sector. Meanwhile, the large-scale stockpiling of copper slag, a bulk industrial solid waste, poses severe environmental and resource-related challenges. Addressing the common issues of the refractory nature of waste molybdenum disilicide (MoSi₂) and the underutilization of iron resources in copper slag, this study proposes a synergistic smelting approach using copper slag and waste MoSi₂, aiming to realize the coordinated treatment of these two solid wastes and the simultaneous, efficient recovery of valuable metals (Mo and Fe). Under non-isothermal conditions, this work elucidates the phase evolution of copper slag and the decomposition–reduction behavior of MoSi₂; clarifies the dual role of coke as the primary reductant at the initial reaction stage and as a maintainer of a reducing atmosphere during smelting; and systematically investigates the effects of smelting temperature, slag basicity, and coke dosage on metal recovery. The results demonstrate that, under optimized process conditions, the recovery efficiencies of molybdenum and iron can reach 98.97% and 98.46%, respectively. This study provides a new strategy for the enrichment and extraction of metallic elements from waste MoSi₂ and copper slag. Full article

This study addresses the ongoing challenge of mitigating the environmental risks posed by metal tailings storage facilities while simultaneously offering a novel and sustainable alternative to conventional construction materials. This study examined the utility of copper tailings and slag, two main byproducts of the mining industry, through the formulation of concrete that incorporates over 80% of these materials by weight. Comprehensive physical, chemical, and mineralogical analyses were performed following the Chilean and international standards. These assessments confirmed the presence of potentially hazardous elements and demonstrated the effectiveness of passivation treatments that make these materials suitable for reuse. Three experimental concrete mixtures were designed and tested under optimum laboratory conditions. The results showed that the compressive strengths exceeded 25 MPa within 7 days, whereas conventional concrete typically requires 28 days to achieve a comparable performance. The mixes also demonstrated effective immobilization of acidic and metallic components, ensuring compliance with the Chilean national regulations governing aggregates and construction materials. An economic evaluation highlighted the strong competitiveness of this approach. Production costs decreased by approximately 74% compared to traditional Portland cement concrete, primarily because of the lower raw material costs of tailings and slag. This research presents a technically feasible, economically viable, and environmentally beneficial solution that supports circular economy models in Chile, thereby providing a replicable framework for international applications. Full article

Mining activities generate vast quantities of waste each year, including mine tailings, bauxite residue, waste rock, and various metallurgical slags. Although these materials have traditionally been regarded as environmental liabilities, many possess physical and chemical properties that make them promising candidates for use in construction. This review synthesizes recent research on the utilization of major mining waste streams, with particular emphasis on pavement applications and other construction materials. The findings indicate that bauxite residue exhibits both pozzolanic and filler characteristics, demonstrating potential in asphalt mastics, asphalt mixtures, and other construction products. Nonetheless, its widespread adoption is constrained by issues such as high alkalinity, leaching risks, and concerns related to naturally occurring radioactivity. Mine tailings can be a substitute for fine aggregates and cement in a range of mixtures, though challenges, including pronounced material variability and environmental risks, persist. Waste rock offers favorable geotechnical properties for use in road bases and embankments, while metallurgical slags (e.g., copper, nickel, and lithium slags) provide functional pozzolanic activity and suitable aggregate qualities. Across all waste types, their incorporation into construction materials can conserve natural resources, reduce material costs, and support circular-economy and low-carbon development objectives. However, progress remains contingent upon advancements in material standards, pretreatment technologies, environmental protection measures, and large-scale field validation. Overall, this review underscores both the significant potential and the practical challenges associated with transforming mining waste into valuable and sustainable construction resources. Full article

Copper slag was introduced as a second phase into Cr₃C₂–NiCr coating to improve corrosion resistance and reduce material cost. Composite coatings with different copper slag/Cr₃C₂–NiCr ratios were prepared by high-velocity oxygen fuel (HVOF) spraying. The corrosion behavior was evaluated through electrochemical tests and immersion experiments, and the effect of coating composition on corrosion resistance was elucidated by microstructural and compositional analysis. To increase the addition of copper slag, the open-circuit potential of the coatings shifted positively, the corrosion current density decreased significantly, and both the polarization resistance and charge-transfer resistance increased markedly, leading to a notable reduction in corrosion rate. The coating with a copper slag-to-Cr₃C₂–NiCr mass ratio of 3:7 exhibited the best corrosion resistance. The improvement can be attributed to the reduced porosity and more compact structure resulting from the copper slag addition, as well as the homogeneous distribution of copper slag, which enhances the stability of the surface passivation layer. Full article

The circular economy represents a significant opportunity to enhance the mechanical properties of bituminous mixtures, thereby contributing to sustainable development. This research compares the behaviour of traditional bituminous mixtures with sustainable ones that reuse recycled materials, industrial waste products, or additives that improve mechanical or rheological properties. The methodology employed comprised the acquisition of fatigue resistance laws from 4-point bending tests on prismatic specimens. This facilitated the analytical determination of the number of axles of 13 tons that the section of pavement with sustainable material can support for comparison with the axles supported in the conventional mix. The findings corroborate the utilization of sustainable bituminous mixtures in pavement sections, employing the maximum circularity criterion. The fatigue laws calculated must permit the use of different calculation methods or other applications in green infrastructures, such as cycling lanes or pedestrian areas. On sections with an AADT of between 800 and 25 HV/day, all of the analyzed bituminous mixtures with sustainable materials prolong the service life of the road. There were increases in service life of between 25.5% and 6.6%, respectively, which satisfactorily achieved an increase in pavement service life based on the criterion of maximum circularity. Full article

Aluminothermic reduction is gaining renewed interest as an alternative processing route for the circular economy. A unique Na₂O-fluxed MnO₂ ore formulation with a small quantity of carbon reductant was applied to ensure rapid pre-reduction to MnO. This approach negates the pre-roasting step. The Na₂O flux enables the formation of the water-soluble compound, NaAlO₂, which enables recycling of Al₂O₃ for aluminium production. The addition of copper as a collector metal improved the overall alloy yield from 43% to 57%, which includes a 6% increase in Mn recovery to the alloy. The product alloy is a medium-carbon Fe–Mn–Si–Al–Cu complex ferroalloy that can be used as a steelmaking ferroalloy additive. The ferroalloy consists of 54% Mn, 19% Fe, 2.1% Si, 2.6% Al, 21% Cu, and 1.2% C. This carbon content is modulated by low-carbon solubility copper, despite the use of a graphite crucible. The formulated slag exhibits high Al₂O₃ solubility, enabling effective alloy–slag separation from the high Al₂O₃ content slag of 52% Al₂O₃. Gas–slag–metal equilibrium calculations for 1650 °C–1950 °C overlap with the experimentally produced alloy chemistry in %C and %Si, but not the %Al, as the uptake of aluminium exceeds the equilibrium calculation at 0.03–0.17%. Full article

Cu and Cr are the essential alloying elements for low-Ni stainless steels. An effective and economical method has been developed for the direct production of Cu-Cr-Fe master alloys through the synergistic reduction of chromite and copper smelting slag. The smelting conditions for synergy reduction were systematically investigated by combining thermodynamic calculations and high-temperature experiments. The results indicate that synergistic reduction drives the reactions of Cr₂O₃, FeO, and Cu₂O with carbon in a positive direction, which can increase their recovery and decrease the flux and fuel costs. The optimum slag composition was identified to control the (CaO + MgO)/(SiO₂ + Al₂O₃) ratio between 0.62 and 0.72, where the slag is fully liquid, resulting in an efficient separation of the alloy from the slag. At 1550 °C, with 50 wt% chromite and 50 wt% copper smelting slag as raw materials, a Cu-Cr-Fe alloy containing 5.2 wt% Cu, 28.6 wt% Cr and 57.9 wt% Fe was produced, while the contents of FeO, Cu₂O, and Cr₂O₃ in the final slag were 0.057 wt%, 0.059 wt%, and 0.23 wt%, respectively. Full article

The depletion of the mineral resource base is inevitable. Therefore, it is necessary to adapt and expand the resource base by incorporating non-traditional copper sources in production. Slag samples from the Balkhash Copper Smelting Plant (Kazakhstan) were analyzed for phase composition, microstructure, and metal distribution using X-ray diffraction (XRD), scanning electron microscopy (SEM), and chemical and granulometric methods. The slags are characterized by a fayalite structure with a high content of FeO (35–45%) and SiO₂ (25–35%). Sample composition was determined as 0.7–0.8% Cu, 0.39–0.43% Pb, 2.53% Zn, 0.075 g/t Au, and 2.6 g/t Ag. Mineralogical and granulometric analysis revealed a uniform distribution of iron and slag-forming components (SiO₂, Al₂O₃, etc.) across the fractions. In contrast, non-ferrous and precious metals concentrated in the fine classes. Laboratory tests confirmed that the fine dissemination of valuable components led to low efficiency in magnetic and gravity separation, necessitating specific preliminary slag preparation to improve recovery. Flotation tests showed improved recovery, yielding copper concentrates with 4.57% copper content when the material was crushed to 80–90% of the −0.074 mm class. The research creates a basis for the development of environmentally safe and resource-saving technologies and provides initial data for future recovery technologies. Full article