Search Results (17)

The metallurgical industry is integral to industrial development. As technology advances and industrial demand grows, the annual output of metallurgical waste slag continues to rise. Combined with the substantial historical stockpile, this has made the utilization of metallurgical slag a new research focus. This study comprehensively sums up the composition and fundamental characteristics of metallurgical waste slag. It delves into the application potential of non-ferrous metal smelting waste slag, such as copper slag, nickel slag, and lead slag, in both sensible and latent heat storage. In sensible heat storage, copper slag, with its low cost and high thermal stability, is suitable as a storage material. After appropriate treatment, it can be combined with other materials to produce composite phase change energy storage materials, thus expanding its role into latent heat storage. Nickel slag, currently mainly used in infrastructure materials, still needs in-depth research to confirm its suitability for sensible heat storage. Nevertheless, in latent heat storage, it has been utilized in making the support framework of composite phase change materials. While there are no current examples of lead slag being used in sensible heat storage, the low leaching concentration of lead and zinc in lead slag concrete under alkaline conditions offers new utilization ideas. Given the strong nucleation effect of iron and impurities in lead slag, it is expected to be used in the skeleton preparation of composite phase change materials. Besides the aforementioned waste slags, other industrial waste slags also show potential as sensible heat storage materials. This paper aims to evaluate the feasibility of non-ferrous metal waste slag as energy storage materials. It analyses the pros and cons of their practical applications, elaborates on relevant research progress, technical hurdles, and future directions, all with the goal of enhancing their effective use in heat storage. Full article

To address the issues of low solid–liquid mixing and mass transfer efficiency and difficult real-time regulation in the resource utilization of non-ferrous metal smelting slag, this study constructs a research framework integrating Computational Fluid Dynamics-Discrete Element Method (CFD-DEM) coupling models and machine learning. The framework systematically investigates particle motion characteristics and mass transfer laws in stirred tanks and enables an intelligent prediction of key parameters. Through a CFD-DEM two-way coupling simulation, the study quantifies particle dispersion characteristics using relative standard deviation (RSD) and calculates the mass transfer coefficient (k) based on the Hughmark model, revealing the effects of particle size and impeller speed on mixing and mass transfer efficiency. For parameter prediction, particle motion and mass transfer data are used to train a multi-model prediction library, with model performance evaluated through comparative experiments. The results show that increasing the rotational speed shortens the particle mixing time, reduces RSD values by 25–40%, increases the coupling force, and decreases stability during the circulation phase. Different machine learning (ML) algorithms exhibit varying performances in the time-series prediction of particle motion characteristics and real-time prediction of mass transfer coefficients. Notably, GA-BP achieves a fitting degree R of 0.99 in both predictions, meeting the requirements for the structural optimization and intelligent regulation of stirred tanks. This research provides theoretical support and technical pathways for the structural optimization and intelligent control of stirred tanks, offering engineering application value in fields such as hydrometallurgy and solid waste resource utilization. Full article

The historical industrial waste deposit Gater was used to dispose of different metallurgy wastes from lead and zinc production. The metallurgical waste deposit was situated in the open space, between the tailing waste deposit Žitkovac and river Ibar flow. Large amounts of lead-containing wastes are produced in the non-ferrous metallurgical industry, such as lead ash and lead slag generated in Pb smelting, lead anode slime, and lead sludge produced in the raw lead refining process. In addition to the lead concentration, numerous valuable components are found in the lead refinery waste from the group of Critical Raw Materials, such as antimony, arsenic, bismuth, copper, nickel, magnesium, scandium, as well as Rare-Earth Elements. Samples with eight characteristic points were taken to obtain relevant data indicating a possible recycling method. The chemical composition analysis was conducted using ICP; the scanning was completed using SEM-EDS. The mineralogical composition was determined by using XRD. The chemical analysis showed a wide range of valuable metal concentrations, from Ag (in the range from 14.2 to 214.6, with an average 86.25 mg/kg) to heavy metals such as Cu (in the range from 282.7 to 28,298, with an average 10,683.7 mg/kg or 1.0683% that corresponds to some active mines), Ni and Zn (in the range from 1.259 to 69,853.4, with an average 14,304.81 mg/kg), Sc (in the range from 2.4 to 75.3, with an average 33.61 mg/kg), Pb (in the range from 862.6 to 154,027.5, with an average 45,046 mg/kg), Sb (in the range from 51.7 to 18,514.7, with an average 2267.8 mg/kg), Ca (in the range from 167.5 to 63,963, with an average 19,880 mg/kg), Mg (in the range from 668.3 to 76,824.5, with an average 31,670 mg/kg), and As (in the range from 62.9 to 24,328.1, with an average 5829.53 mg/kg). The mineralogy analysis shows that all metals are in the form of oxides, but in the case of As and Fe, SEM-EDS shows some portion of elemental lead, pyrite, and silica-magnesium-calcium oxides as slag and tailing waste residues. The proposed recovery process should start with leaching, and further investigation should decide on the type of leaching procedure and agents, considering the waste’s heterogeneous nature and acidity and toxicity. Full article

In pursuing sustainable environmental solutions, the concept of ‘waste to treasure’ has emerged as a promising approach. In this study, a new process is proposed to combine solid copper slag with hydrogen peroxide (H₂O₂) to remove nitrogen oxides (NOx) from acidic exhaust gases, thus effectively utilizing waste materials. Firstly, different smelting slags were screened to determine the catalytic potential of copper slag for hydrogen peroxide. Subsequently, the catalytic activity of the copper slags at various stages of the copper smelting process was thoroughly evaluated and optimized. In addition, a multifactorial evaluation of slow-cooled copper slag catalysts for removing NOx was carried out. Preliminary indications are that the iron phase in the copper slag is identified as the main source of catalytic activity sites. The results suggest that Fe²⁺/Fe³⁺ sites on the surface of the Fe phase in the slow-cooled copper slag may be crucial in improving the NOx removal efficiency. The main reactive oxygen species detected in the system were ·OH, ·O₂⁻, and ¹O₂. In addition, the transformation products, formation pathways, and reaction mechanisms of NO in the liquid phase were initially investigated and determined. This study provides a green and sustainable path for the utilization of solid waste and management of atmospheric fumes in the non-ferrous metal industry and offers new perspectives to address environmental challenges in industrial processes. Full article

Jarosite residue (JR), a hazardous solid waste generated in non-ferrous metallurgy, poses significant environmental challenges due to its large volume and poor storage stability. However, its high content of valuable metals (such as iron, zinc, gallium, indium, silver, …) makes its efficient recovery and comprehensive utilization highly significant. This study investigates the “oxidative roasting–reductive smelting” process for JR treatment. The reduction thermodynamics of JR-R (roasted JR) were analyzed, and the effects of smelting temperature, time, and slag basicity on the reduction and smelting process were examined. The results indicate that increasing slag basicity and temperature generally decreases slag viscosity. Thermodynamic calculations demonstrate that reductive smelting effectively enriches valuable metals (>1039 °C). The optimal conditions for reductive smelting of JR were determined to be as follows: smelting temperature of 1550 °C, smelting time of 60 min, and slag basicity of 0.9. Under these conditions, the process achieved an Fe grade of 92.87% in pig iron with a recovery rate of 90.66%, a Ga grade of 377 g/t with a recovery rate of 94.91%, and Zn and In volatilization rates of 99.91% and 83.36%, respectively. This study provides a feasible approach for the comprehensive recovery of valuable metals such as Ga, Fe, Zn, and In from JR, offering promising economic and social benefits. Full article

Aluminum is one of the most in-demand nonferrous metals in the world. The secondary aluminum dross (SAD) produced during aluminum smelting is a type of solid waste that urgently requires disposal. SAD, municipal solid waste incineration fly ash, and bottom slag were used as raw materials to prepare porous ceramsite in a laboratory in this study. Multi-factor design experiments were then used to explore the influence of the sintering condition on the compressive strength to provide a basis for ceramsite preparation using SAD. The results showed that, within a certain variation range, the levels of each factor showed overall positive correlations with the ceramsite compressive strength. The contributions of the ceramsite particle size, the silicon–aluminum ratio (Si/Al), the sintering temperature, and the sintering time to the compressive strength of the porous ceramsite then decreased. The factors had a synergistic effect. The interactive effect of multiple factors on the porous ceramsite compressive strength rose with an increase in the particle size and Si/Al ratio. The average compressive strength of the porous ceramsite prepared in this study was 4.06 ± 3.71 MPa, and the maximum compressive strength was 14.13 MPa. The highest ceramsite compressive strength was achieved under a sintering temperature of 1270 °C, a particle size of 2 cm, a sintering time of 30 min, and a silicon–aluminum ratio of 1.5. In addition, there was a reaction relationship between the multiple factors involved in the sintering of the SAD-based porous ceramsite. Pilot or industrial tests should be conducted in the future based on these experiments and the intended ceramsite use. Full article

The study object was slag from the Balkhash copper smelter, obtained by re-melting anode mud containing nonferrous metals. The process flow for processing these slags includes sintering with Na₂SO₄, Na₂CO₃, and coal, followed by soda-alkaline leaching of the sinter and extraction of metals from the solution into marketable products. Since sintering is the main operation providing high selectivity, the composition of the products of this process was studied. The main transformations during sintering were determined, and the optimal parameters were identified. The structures of slags and sintered materials obtained during the experiments were studied by electron-probe microanalysis. Sintering was performed at 600–800 °C. The best results for sulphidization of slag components were obtained at 800 °C; a further increase in temperature leads to the smelting of sinter particles and slows down sulphidization. The optimal quantities of additives, based on the weight of the slag, are Na₂SO₄—45%, Na₂CO₃—15%, and reducing agent—41%, with a sintering time of 2 h. These conditions enable the sulphidization of non-ferrous metals in the slag to the entire depth of the polymetallic globules. The distinct concentration of harmful impurities (Ni, As, and Sb) was observed in the fine structure of the polymetallic globules. Full article

The technosphere consists of material stocks accumulated by human activities, which can include processing residue, such as slag. Various smelting processes generate slag, and some valuable elements are concentrated in this by-product. In this review, the extraction of critical and strategic metals from non-ferrous slags is discussed. Critical and strategic metals are materials that are vital for the nation’s economy and defence, as well as its industries, and have common features, such as expected shortfalls, increasing demand, and few substitutions. There are several definitions, methods, and classifications of critical and strategic elements by different organisations. In this study, reports from seven institutions around the world are summarised, and a list of recommended critical and strategic metals is presented. Non-ferrous slags contain a considerable amount of critical and strategic elements, and research on technology and process development using both pyro- and hydrometallurgical methods is very attractive. When it comes to the extraction of values from slag and the development of technology, it is not only important to consider the economic aspect but also to ensure the processes are low in emissions and energy consumption but high in efficiency and recycling. 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

In Part II of this series of review papers, the reaction mechanisms, thermodynamics, slag chemistry and process flowsheets are analyzed concerning cases where the TSL bath smelter has found its application. These include the primary and secondary production routes of five non-ferrous metals (tin, copper, lead, nickel, zinc), ironmaking and two waste-processing applications (spent pot lining and municipal solid waste/related ash treatment). Thereby, chemistry and processing aspects of these processes are concisely reviewed here, allowing for clear and in-depth overview of related aspects. In contrast to Part I, the focus lies on a holistic analysis of the metallurgical processes themselves, especially the particularities induced by carrying them out in a TSL reactor rather than on the respective equipment and auxiliaries. The methodology employed per metal/application is presented briefly. Firstly, the feed type and associated statistical information are introduced, along with relevant process goals, e.g., the secondary metallurgy of copper involves the recovery of platinum group metals (PGMs) from waste from electrical and electronic equipment (WEEE). Subsequently, associated chemistry is discussed, including respective chemical equations, analysis of the reaction mechanisms and phase diagrams (especially of associated slag systems); these are redrawn using FactSage 8.1 (databases used: FactPS, FToxid, FTmisc, FTsalt and FTOxCN) and validated by comparing them with the literature. Then, based on the above understanding of chemistry and thermodynamics, the flowsheets of several industrial TSL plants are introduced and discussed while providing key figures associated with process conditions and input/output streams. Finally, this article culminates by providing a concise overview of the simulation and digitization efforts on TSL technology. In light of the foregoing discourse, this paper encapsulates basic principles and operational details, specifically those pertaining to TSL bath smelting operations within the non-ferrous industry, thereby offering valuable insights intended to benefit both scholarly researchers and industry professionals. Full article

Vis-NIR and XRF spectroscopy are widely used in monitoring heavy metals in soil due to their advantages of being fast, non-destructive, cost-effective, and non-polluting. However, when used individually, XRF and vis-NIR may not meet the accuracy requirements for Cd determination. In this study, we focused on the impact area of a non-ferrous metal smelting slag site in Gejiu City, Yunnan Province, fused the pre-selected vis-NIR and XRF spectra using the Pearson correlation coefficient (PCC), and identified the characteristic spectra using the competitive adaptive reweighted sampling (CARS) method. Based on this, a quantitative model for soil Cd concentration was established using partial least squares regression (PLSR). The results showed that among the four fusion spectral quantitative models constructed, the model combining vis-NIR spectral second-order derivative transformation and XRF spectral first-order derivative transformation (D2(vis-NIR) + D1(XRF)) had the highest coefficient of determination (R² = 0.9505) and the smallest root mean square error (RMSE = 0.1174). Compared to the estimation models built using vis-NIR and XRF spectra alone, the average computational time of the fusion models was reduced by 68.19% and 63.92%, respectively. This study provides important technical means for real-time and large-scale on-site rapid estimation of Cd content using multi-source spectral fusion. Full article

To explore the source of Pb in Bronze Age artefacts from the Central Plains (Zhongyuan) in China, we investigated non-ferrous minerals from the Qingyuan archaeological site in Yuanqu County near the Zhongtiao Mountains. Fragments of smelting slag from the Erlitou cultural layer were collected. The smelting slag was investigated by scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS), X-ray diffraction (XRD), and lead isotope analysis. The SEM and EDS results confirmed that the slag contained Pb, Pb–As, and Cu–Pb–Sn inclusions and non-metal impurities such as low-Zn spinels. The XRD results signified that the bulk of the slag comprised Fe–Mn–Si phases. The chemical state of Pb was mainly Pb–O with some metallic Pb, as identified by XPS. The theoretical melting point was calculated using FactSage7.1 based on the composition and phase characterisation. The calculated temperature was 1100–1200 °C, which agreed well with the actual melting point of 1114–1354 °C. The slag composition and inclusion phases indicated that Pb–Zn–O ores with Mn and As were added during reduction smelting in Qingyuan. The raw materials of smelting included crude Pb with minor amounts of Cu, As, and Sn. Lead isotope analysis revealed that the lead materials produced in Qingyuan were likely transferred to Yanshi City in the Shang Dynasty. The findings of this study provide significant clues for exploring lead mineral production in the Central Plains during the Early Bronze Age. Full article

In situ treatment of acidic arsenic-containing wastewater from the non-ferrous metal smelting industry has been a great challenge for cleaner production in smelters. Scorodite and iron arsenate have been proved to be good arsenic-fixing minerals; thus, we used lead slag as an iron source to remove arsenic from wastewater by forming iron arsenate and scorodite. As the main contaminant in wastewater, As(III) was oxidized to As(V) by H₂O₂, which was further mineralized to low-crystalline iron arsenate by Fe(III) and Fe(II) released by lead slag (in situ generated). The calcium ions released from the dissolved lead slag combined with sulfate to form well-crystallized gypsum, which co-precipitated with iron arsenate and provided attachment sites for iron arsenate. In addition, a silicate colloid was generated from dissolved silicate minerals wrapped around the As-bearing precipitate particles, which reduced the arsenic-leaching toxicity. A 99.95% removal efficiency of arsenic with initial concentration of 6500 mg/L was reached when the solid–liquid ratio was 1:10 and after 12 h of reaction at room temperature. Moreover, the leaching toxicity of As-bearing precipitate was 3.36 mg/L (As) and 2.93 mg/L (Pb), lower than the leaching threshold (5 mg/L). This work can promote the joint treatment of slag and wastewater in smelters, which is conducive to the long-term development of resource utilization and clean production. Full article

Atmospheric emission of heavy metals from different anthropogenic sources is a great concern to human beings due to their toxicities. In order to disclose the emission levels and the distribution patterns of zinc (Zn) in the modern cement industry with respect to its low boiling point (~900 °C) comparing to the high-temperature (1450 °C) clinker production process, solid samples representing the input and output flow of Zn during the entire production process in two preheater–precalciner cement plants (CPs) were collected and analyzed. For the first time, it was found that the behaviour of Zn inside different precalciner CPs was similar despite a huge difference in the Zn inputs to the CPs; namely, almost all the Zn input was output in clinker, which was then mixed with different additives and retarder to make cement products. The high-temperature clinkerisation process would incorporate Zn into the aluminosilicate of clinker. As a result, there was no enrichment of Zn during clinker production and the atmospheric emission factor was relatively low at 0.002%, or 1.28–9.39 mg Zn·t⁻¹ clinker. Our result for the atmospheric Zn emissions from CPs was much lower than most previous reports, implying the CPs were not a crucial Zn emission source. However, the higher load of Zn in some raw/alternative materials—like nonferrous smelting slag with a Zn content of ~2%—could greatly increase the content of Zn in clinker and cement products. Therefore, further investigation on the environmental stability of Zn in such Zn-laden cement and concrete should be carried out. Full article

The depleting and increasingly complex mineral resources bring challenges into the area of metal production, bringing new boundary conditions to the smelting and refining processes. Thermodynamics of phases and equilibria are the key to the analysis of pyrometallurgical processes, enabling descriptions of their limiting boundary conditions. The raw material basis of non-ferrous metals needs an effective control of iron oxide fluxing due to the challenging fact that the targeted metal values of, e.g., copper, nickel, lead, and tin will exist as minority components in the smelter feeds compared to iron sulphides, gangue, and many harmful elements. This means more complex slag compositions and the amount of produced slag being several times that of the metal production. This feature severely impacts the heat balance of the smelting vessels where autogenous operation without external fuels becomes more and more difficult to maintain. Full article