Search Results (41)

The increasing demand for lithium and the limited availability of high-grade resources have accelerated interest in lithium-bearing clays as a promising alternative, despite their relatively lower lithium content. Lithium extraction from such clay minerals typically requires thermal treatment or acid leaching to disrupt the clay crystal lattice and enhance lithium solubility. The enrichment tailings from the Kırka Boron Processing Plant in Türkiye consist predominantly of dolomite-rich clay minerals and contain approximately 900–1200 ppm Li. Considering the substantial quantities of these tailings currently stored on-site, recovering lithium and converting these materials into a valuable resource would be of significant economic importance. However, due to their mineralogical composition, conventional acid leaching of these tailings demands relatively high sulfuric acid consumption (1.5–2.0 M H₂SO₄). This leads to excessively low solution pH and the generation of highly acidic waste streams, while also promoting the co-dissolution of iron (Fe) and aluminum (Al) ions at pH levels below 2, which negatively affects lithium recovery and downstream processing. In this study, mechanical activation was applied to the tailings prior to acid leaching. As a result, the acid requirement to achieve lithium extraction efficiencies of 90% and above was successfully reduced from 1.5 M to 1.0 M H₂SO₄. Moreover, solution pH was maintained near neutral (~7), and the undesirable dissolution of Fe and Al ions was effectively suppressed and kept under control. Full article

This study evaluates coke for iron ore sintering manufactured from Ekibastuz coal fines (fraction 0–3 mm), spent anode material (SAM) from aluminum electrolysis, and coal tar pitch. Laboratory coking was performed at 1000 °C (60 min hold), followed by sintering trials using coke containing 10 wt% and 20 wt% SAM. Microstructural (SEM/EDS) and spectral data indicate an optimal SAM range of 10–20 wt%: higher additions (≥30 wt%) lead to structural degradation of coke, accompanied by reduced mechanical integrity. The produced coke shows C = 85%, S = 0.9–1.1%, ash ≈ 19%, volatiles = 1.5–2.5%, and moisture (Wr) ≤ 1%, which is acceptable for sintering use. In sintering tests, the yield of usable sinter reached 72.4% (10 wt% SAM) and 73.5% (20 wt% SAM); impact strength was 83% and 78%, respectively. XRF of sinter showed Fe_total > 51%, CaO ≈ 5.5–6.8%, SiO₂ ≈ 6.6–7.2%, and S = 0.40–0.45%, meeting technological requirements for blast-furnace practice. Overall, using spent anode material within 10–20 wt% increases fixed-carbon content, enables valorization of aluminum industry waste, and delivers coke for agglomeration performance without compromising key chemical or mechanical indices. Full article

Titanium (Ti) and vanadium (V) are metals critical for the sustainable development of our society. Their growing demand and the depletion of ores rich in these metals along with technological development lead to a reconsideration of sources that were previously considered unpromising. The present work is devoted to the study of an iron (Fe) ore from southeastern Bulgaria, containing Ti and V in low but potentially recoverable concentrations. The aim was to check whether it is possible to obtain an iron concentrate containing Ti and V in concentrations comparable to those in similar market products. The material was examined by optical microscopy, XRD, SEM-EDS, and ICP MS. Magnetic separation was applied with and without predating gravity separation. By applying wet gravity beneficiation followed by a low-intensity magnetic field, an iron concentrate (40%–65% Fe) bearing 3%–5% Ti and 0.4%–0.59% V was obtained. Using only a low-intensity magnetic field, without gravity separation, an iron concentrate (59.4% Fe) containing 3.5% Ti and 0.44% V was obtained. Vanadium was extracted in the highly magnetic material, while a significant amount of Ti was left in the weak magnetic fraction. An additional 1.5% may be recovered by applying a high-intensity magnetic field. The main processing challenge appears to be the recovery, without flotation beneficiation, of magnetite that is oxidized to non-magnetic hematite and maghemite. Using magnetic separation (with or without preliminary wet gravity beneficiation) avoids pollution of the processing waste with reagents. Thus, the waste from the beneficiation of the studied type of ore can be used as a soil improver. As a result, the extraction of critical metals using a practically waste-free technology may be achieved. Full article

Porous acicular mullite was fabricated at 1300 °C starting from Al₂O₃ and mixture of SiO₂ and MoO₃ obtained by previous oxidation of waste MoSi₂. It was found that the presence of MoO₃ favors formation of acicular (prism-like) mullite grains with sharp edges. The effect of addition of Fe₂O₃ (4–12 wt.%) on phase composition, compressive strength, thermal conductivity and microstructure was studied. The addition of Fe₂O₃ improved the compressive strength from approximately 25 MPa in pure mullite to about 76 MPa in samples containing 12 wt.% Fe₂O₃, while the open porosity decreased from 55.4% to 51.8%. The presence of Fe₂O₃ caused a decrease in mullite formation temperature owing to the formation of liquid phase and accelerated diffusion. The solubility of iron oxide in mullite lattice was between 8 and 12 wt.% Fe₂O₃. The incorporated iron ions also promoted the rounding of sharp edges in prismatic mullite grains, leading to a reduced specific surface area of 0.55 m²/g in the sample with 12 wt.% Fe₂O₃. The thermal conductivity of mullite increased with addition of 12 wt.% Fe₂O₃ reaching value of 1.17 W/m·K. Full article

The geopolitical and economic situation impacts raw materials demand. As principal ore deposits reach exhaustion, the study of new sources of raw materials becomes essential. Therefore, mining wastes emerge as alternative sources of raw materials. Their physicochemical properties, such as small particle size or concentration of some metals of interest, enhance reprocessing. A number of critical raw materials (As, Co, Cu, Sb) and base metals (Pb, Zn), as well as precious metals (Ag), were found present in an abandoned tailing deposit composed by finely grounded washed roasted pyrites within the Iberian Pyrite Belt. Copper leaching from a sample of this deposit was investigated. Two hydrometallurgical approaches were studied: acidic leaching with and without activated carbon; and alkaline leaching with glycine solutions. Leaching tests were carried out during 24 h at ambient and moderate temperatures (60 °C). In acidic medium, the maximum copper extraction varied from 88 to 92.5%, while in alkaline medium, the maximum copper extraction was in the range of 71%–76%. Using activated carbon and H₂O₂ seemed to slightly promote the copper extraction with the maximum extraction (92.5%) after 2 h of leaching at 60 °C. Complementarily, above 50% of the zinc and cobalt contained were extracted. In contrast, temperature in alkaline conditions played a key role in reaction speed, but also in precipitation of copper insoluble compounds. In addition, the glycine solution at pH 10–10.5 showed high selectivity for copper over zinc, iron, lead, arsenic, and antimony. Two extra tests at pH above 12 showed arsenic dissolution (up to 51% at pH 12.5). Full article

Constanta port operations involving the handling of bulk minerals often lead to material losses, resulting in mineral waste, containing a mixture of iron ore, bauxite, and coal, amongst others. In order to recover these minerals, a processing plant was built, which successfully separates most of this waste into its constituents. However, a byproduct obtained from this process is a sludge containing fine particles below 0.5 mm, which are deposited in a reservoir that represents definitive tailings. Since this is a “rich” tailing material, which is difficult to be extracted by using conventional methods due to its small size, the selective flocculation procedure was tested as an alternative method. This paper presents the results obtained for standard methods of selective flocculation tests using polyacrylamide A 100 at a pH value of 10.5. SEM-EDS and XRD analyses were performed, and the chemical composition of the sample components was given. According to preliminary tests, using the selective flocculation procedure, the expected results were obtained in terms of separating the overflow between the content of impurities (with a reduced share of Fe in relation to the input) and sediment with an increased content of Fe (with a reduced share of impurities in relation to the entrance). Full article

Leachates from electronic waste, slag dusts generated during the processing of electronic waste, sweeping jewelry, and municipal solid-waste incineration residues contain a myriad of base metals, such as aluminum (Al: 10–2000 mg/L), copper (Cu: 10–1000 mg/L), iron (Fe: 10–500 mg/L), nickel (Ni: 0.1–500 mg/L), lead (Pb: 1–500 mg/L), tin (Sn: 1–100 mg/L), and zinc (Zn: 5–500 mg/L), which are present at much higher quantities than Au (0.01–10 mg/L), which raises several drawbacks to the efficient recycling of Au with high purity using hydrometallurgical strategies. The aim of this work was to study the efficiency and selectivity of two strong basic anion exchange (DOW^TM XZ-91419.00 and Purogold^TM A194) resins to recover Au from a chloride multi-metal solution containing these metals. For both resins, the adsorption kinetic and equilibrium parameters for Au(III), determined at 1.12 mol/L HCl, Eh = 1.1 V, and 25 °C, proceeded according to a pseudo-second order and a Langmuir isotherm (qmax was 0.94 and 1.70 mmol/g for DOW^TM XZ-91419.00 and Purogold^TM A194 resins, respectively), respectively. Continuous adsorption experiments of Au (48 µmol/L; 2.0%) from a chloride multi-metal solution evidenced high Au retention capacity and selectivity to Au over Al, Cu, Fe, Ni, and Zn but low selectivity to Au over Ag and Sn for both resins. Concentrated (>3.3 mmol/L) and pure (>94%) Au eluates were obtained for both resins. Full article

An innovative approach is reported for recovering Fe and Zn resources from hazardous zinc-bearing electric arc furnace dusts (ZBDs) in a sustainable manner. A combination of carbothermal and H₂ reduction were used to overcome challenges associated with the high temperatures of carbothermal reduction and the high costs/limited supplies of hydrogen. In-depth reduction studies were carried out using zinc-rich (17 wt.%), iron-poor (35 wt.%) ZBD; coke oven battery dry quenching dust (CDQD) was used as reductant. Briquettes were prepared by mixing ZBD and CDQD powders in a range of proportions; heat treatments were carried out in flowing H₂ gas at 700 °C–900 °C for 4 h. The reduced products were characterized by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD) and inductively coupled plasma (ICP). The Fe content of the reduced briquettes showed increases between 50 and 150%, depending on composition and reduction temperature; Zn, Pb, Cl, Na, K and S were completely absent. The gaseous elements were collected in cooled traps at the furnace outlet to recover metallic zinc and other phases. The volatile products collected at the outlet (900 °C) contained more than 70% zinc and 6% lead; small amounts of zinc were also present in the metallic phase. The processing temperatures were significantly lower in the combined approach as compared to 100% carbothermal reduction. While reducing energy consumption and limiting the generation of greenhouse gases, this approach has the potential for enhancing the reutilization of hazardous industrial wastes, resource recovery, and economic and environmental sustainability. Full article

The use of reduction leaching in the production of alumina from bauxite by the Bayer process in order to decrease the amount of waste (bauxite residue) by adding elemental iron or aluminum, as well as Fe²⁺ salts and organic compounds in the stage of high-pressure leaching, requires the purchase of relatively expensive reagents in large quantities. The aim of this study was to investigate the possibility of the use of electrolytically reduced bauxite residue (BR) as a substitute for these reagents. Reduced BR was obtained from Al-goethite containing BR using a bulk cathode in alkaline suspension. The degree of deoxidation of Fe³⁺ compounds was 55% after 2 h of electrolysis with a current yield of more than 73%. The addition of reduced BR according to the shrinking core model leads to a change in the limiting stage of the high-pressure boehmitic bauxite leaching from a surface chemical reaction to internal diffusion. The activation energy decreased from 32.9 to 17.2 kJ/mol by adding reduced red mud. It was also shown that the addition of reduced BR increased the rate of thickening of the slurry after leaching by a factor of 1.5 and decreased the Na₂O losses by 15% without the addition of lime. The solid residue was examined by means of X-ray diffraction analysis and scanning electron microscopy to confirm the presence of magnetite and elemental iron. A preliminary techno-economic analysis was carried out to assess the applicability of the proposed process. Full article

Ladle furnace slag (LFS), a by-product of steel refining, shows a promising reuse pathway as an alternative additive or substitute for Portland cement due to its high alkalinity and similar chemical composition to clinkers. However, LFS is often stored in large, open surface areas, leading to many environmental issues. To tackle waste management challenges, LFS can be recycled as supplementary cementitious material (SCM) in many cementitious composites. However, LFS contains some mineral phases that hinder its reactivity (dicalcium silicate (γ-C₂S)) and pose long-term durability issues in the cured cemented final product (free lime (f-CaO) and free magnesia (f-MgO)). Therefore, LFS needs to be adequately treated to enhance its reactivity and ensure long-term durability in the structures of the cementitious materials. This literature review assesses possible LFS treatments to enhance its suitability for valorization. Traditional reviews are often multidisciplinary and explore all types of iron and steel slags, sometimes including the recycling of LFS in the steel industry. As the reuse of industrial by-products requires a knowledge of their characteristics, this paper focuses first on LFS characterization, then on the obstacles to its use, and finally compiles an exhaustive inventory of previously investigated treatments. The main parameters for treatment evaluation are the mineralogical composition of treated LFS and the unconfined compressive strength (UCS) of the final geo-composite in the short and long term. This review indicates that the treatment of LFS using rapid air/water quenching at the end-of-refining process is most appropriate, allowing a nearly amorphous slag to be obtained, which is therefore suitable for use as a SCM. Moreover, the open-air watering treatment leads to an optimal content of treated LFS. Recycling LFS in this manner can reduce OPC consumption, solve the problem of limited availability of blast furnace slag (GGBFS) by partially replacing this material, conserve natural resources, and reduce the carbon footprint of cementitious material operations. Full article

The study is the first to examine the combined use of blast-furnace sludge as a source of microelements and converter slag as a soil-deoxidizing agent in oat (Avena sativa L.) cultivation in sod-podzolic soils. It has been established that blast-furnace sludge is a highly dispersed waste, which contains about 50% iron, 7% zinc, and a small amount of calcium, silicon, magnesium, aluminum, and sulfur. Hazardous components such as lead, arsenic, etc., are not detected. Converter slag comprises porous granules up to 3 mm in size, consisting mainly of calcium compounds (CaO, Ca(CO)₃, CaSiO₃, CaFe₂O₄) and a small amount of Mn, Al, and Mg trace elements. In a laboratory experiment, blast-furnace sludge increased the germination of oats by 5–10%, regardless of the addition of a deoxidizer (slag), but at the same time suppressed the growth of stem length by a maximum of 18% at 1 g∙kg⁻¹. The addition of slag raised substrate pH and increased the index by 8% at a sludge concentration of 0.1 g∙kg⁻¹. Root length in deoxidizer-free variants increased by 50–60% and with the addition of slag by 27–47%. Root dry mass also increased under the addition of sludge by 85–98%; however, the addition of slag reduced the indicator to the control level. In a field experiment with the combined application of waste, an increase in yield by more than 30% was shown. When soil was treated with slag and sludge, the height of plants increased by an average of 18%. It should be noted that the introduction of waste did not affect the quality of the grain. The use of slag increased the lead content in the soil, which is probably due to the sorption properties of calcium compounds in the slag, since lead was not found in the analyzed waste. Presumably, lead is sorbed by slag from the lower soil horizons, concentrating and immobilizing it in the upper layer. This version is supported by the absence of lead accumulation in straw and oat grain. The zinc-containing sludge increased the content of this element by 33% in the soil, as well as by 6% in straw and by 14% in grain. Thus, we found that the studied metallurgical wastes can be used as nutrients for agriculture, both individually and jointly. Overall, the proposed approach will contribute both to reducing the amount of accumulated waste and to improving the efficiency and sustainability of agricultural production and CO₂ sequestration. However, the features of the accumulation of heavy metals in soil and plants under the influence of the analyzed types of waste require more in-depth study, including within the framework of long-term field experiments. Full article

Slags from the Silesia–Cracow Upland (Poland), including ten historical slags (deposited in waste dumps) and four contemporary slags (from current production), were examined to compare their chemical and mineralogical properties as well as to assess their potential for the recovery of selected metals and critical raw materials. The historical slags associated with the smelting of polymetallic ores originating from Mississippi Valley-type (MVT) deposits consisted primarily of gypsum. The contemporary slags, obtained from industrial waste rich in zinc and lead, were predominantly spinels (magnesium-aluminate and ferric) that exhibited higher iron content (up to 46.6 wt% of Fe₂O₃) compared to the historical slags (up to 26.1 wt% of Fe₂O₃). The zinc content was similar for both the slag types (3.5 wt% Zn). The average titanium and arsenic contents in the old and contemporary slags were at the same level as well, with 0.21 wt% (Ti) and 0.13 wt% (As), respectively. The contemporary slags contained higher levels of critical raw materials, such as cobalt, nickel, copper, and manganese, compared to the historical slags. Rare earth elements (REEs) were also more abundant in the contemporary slags, with an average content of 212 ppm, while the historical slags averaged 124 ppm. These findings underscore the potential for recovering valuable metals and critical raw materials from such slags, presenting opportunities for resource optimisation and environmental management. Full article

Ferronickel slag (FNS) is a byproduct produced during ferronickel alloy manufacturing, primarily used in the manufacturing of stainless steel and iron alloys. This material is produced by cooling molten slag with water or air, posing significant disposal challenges, as improper storage in industrial yards can lead to environmental contamination. This study investigates the chemical and mineralogical characteristics of reduction ferronickel slag (RFNS) and its potential use as an alternative aggregate in hot mix asphalt (HMA). The research is based on the practical application of HMA containing RFNS in an experimental area, specifically the parking lot used by buses transporting employees of Anglo American, located at the Codemin Industrial Unit in Niquelândia, Goiás, Central Brazil. Chemical analysis revealed that RFNS primarily consists of MgO, Fe₂O₃, and SiO₂, which are elements with minimal environmental impact. The lack of significant calcium content minimizes concerns about expansion issues commonly associated with calcium-rich slags. The X-ray diffractogram indicates a predominantly crystalline structure with minerals like Laihunite and Magnetite, which enhances wear and abrasion resistance. HMA containing 40% RFNS was tested using the Marshall methodology, and a small experimental area was subsequently constructed. The HMA containing RFNS met regulatory specifications and technological controls, achieving an average resilient modulus value of 6323 MPa. Visual inspections conducted four years later confirmed that the pavement remained in excellent condition, validating RFNS as a durable and effective alternative aggregate for asphalt mixtures. The successful application of RFNS not only demonstrates its potential for local road paving near industrial areas but also underscores the importance of sustainable waste management solutions. This research highlights the value of academia–industry collaboration in advancing environmentally responsible practices and reinforces the contribution of RFNS to enhancing local infrastructure and promoting a more sustainable future. Full article

Mixed plastic packaging waste sorting residue (MPO323) was treated by thermal pyrolysis to utilize pyrolysis oil and char. The pyrolysis oil was found to contain aromatic and aliphatic hydrocarbons. The chlorine and bromine contents were as high as 40,000 mg/kg and 200 mg/kg, respectively. Additionally, other elements like sulfur, phosphorous, iron, aluminum, and lead were detected, which can be interpreted as impurities relating to the utilization of oils for chemical recycling. The pyrolysis char showed high contents of potentially active species like silicon, calcium, aluminum, iron, and others. To enhance the content of aromatic hydrocarbons and to reduce the level of contaminants, pyrolysis oil was reformed with the corresponding pyrolysis char to act as an active material in a fixed bed. The temperature of the reactor and the flow rate of the pyrolysis oil feed were varied to gain insights on the cracking and reforming reactions, as well as on performance with regard to decontamination. Full article

This paper presents the results of a study of the mineralogical and chemical composition of zinc and lead metallurgical slags. These slags contain numerous elements, including toxic metals, which form conglomerates or multiphase intergrowths. The phase composition of slags is one of the main factors that determine their behaviour in weathering environments, that is, their ability to release metals when exposed to atmospheric factors. In this paper, the release of elements from slags and their mobility in a hypergenic environment is determined based on the results of leachability tests and on geochemical modelling, thus assessing the environmental impact of landfilled slags. The elements released from slags in the largest quantities are zinc and lead. Zn is leached out over a long period of time. It was found that after 12 years, the concentration of Zn in the eluate exceeds by 40 times the permissible value of 200 mg/kg for hazardous waste. The degree of leaching of lead from slags as a function of time (after 12 years), despite its significant solubility in water, is much lower than the degree of leaching of zinc. The most mobile phase components of slags in the studied hypergenic environment are the lead phases (anglesite and galena) and, to a lesser extent, the zinc phases (sphalerite and willemite). Anglesite and galena in almost the entire Eh-pH range, along with admixtures of elements, decompose into ionic forms: PbCl₄²⁻, Pb²⁺, and PbOH⁺. Sphalerite in the soil and water environment (oxidizing and acidic conditions) will decompose into the mobile ionic form Zn²⁺. Willemite, which is resistant to weathering, will undergo similar decomposition. It can therefore be assumed that the carriers of toxic metals are primarily lead sulphides and sulphates, zinc sulphides, and, less frequently, zinc, lead, and iron oxides. Full article