Search Results (52)

This study explores the use of metallurgical slag extracts as a liquid mineral fertilizer for maize cultivation. Slag samples were obtained from the former lead smelter in Shymkent and the Zhezkent Mining and Processing Plant. Elemental analysis identified the slag from the second storage area of the Shymkent smelter as the least contaminated with potentially toxic elements and enriched in macro- and micronutrients. Slag extraction was conducted via chemical leaching using potassium sulfate and ammonia solutions in a hydrogen peroxide medium, yielding Cu²⁺ and Zn²⁺ concentrations of 423.751 mg/L and 86.649 mg/L, respectively. The resulting extracts were diluted with distilled water at a ratio of 1:10 (potassium sulfate extract) and 1:200 (ammonia extract) and applied to assess early seed development and subsequent maize yield. Seed germination rates were comparable to those of the control group (100%). After 90 days of growth, maize plants treated with the ammonia-based extract showed positive effects on root system development, stem growth, and cob formation. The concentration of potentially toxic elements in the dry plant biomass remained within permissible limits. These findings demonstrate the potential for the safe agricultural use of these extracts while ensuring the rational utilization of industrial waste. Full article

Top Submerged Lance (TSL) technology is widely used in non-ferrous smelting, yet in-situ bath dynamics remain challenging to quantify because the process operates in a closed, high-temperature, highly turbulent and optically inaccessible environment. The absence of direct diagnostics limits the ability to relate operating conditions to bubble dynamics, gas penetration and bath agitation and constrains validation of multiphase CFD models under realistic conditions. This study introduces a multimodal sensing framework that combines spectral acoustic analysis with lance-mounted inertial motion sensing to characterize dynamic bath behavior across cold-model, laboratory-scale and pilot-scale systems. Water-glycerin experiments establish repeatable acoustic signatures of individual bubble-collapse events, with dominant emission bands in the 300–900 Hz range and higher-frequency components extending into the kilohertz domain. High-temperature laboratory trials using fayalitic slag reproduce these frequency regions while exhibiting depth-dependent attenuation and clear spectral separation between submerged and non-submerged lance operation. Power Spectral Density (PSD) and cumulative spectral power analyses resolve the influence of gas flow rate and lance submersion depth on acoustic spectral power distribution, while inertial measurements capture corresponding increases in vertical lance acceleration associated with back-pressure fluctuations. Pilot-scale trials at 120 Nm³/h air and 13 L/h diesel confirm that shallow lance submersion substantially increases measured acoustic spectral power below 3 kHz, whereas deeper penetration enhances periodic vertical acceleration response measured by the inertial sensor. The combined acoustic-inertial methodology provides a physically interpretable and cross-scale framework for assessing bubble collapse activity, plume interaction and bath agitation under high-temperature TSL conditions. The approach enables frequency-based diagnostics that can be systematically compared with CFD predictions of plume oscillation and collapse-related dynamics. Once baseline frequency ranges are established for a given slag system, the method can support process monitoring and may provide indirect indicators related to changes in surface agitation or foaming tendency, enabling structured data-driven analysis. The framework thus provides a practical bridge between cold-model experiments, high-temperature measurements, multiphase modeling and industrial TSL operation. Full article

Aluminum is the most used non-ferrous metal, with a well-established recycling procedure, but this process also produces new residues. We recently proposed an integrated laboratory practice based on the recovery of aluminum from the slag generated during its recycling. Now, we expand upon this research by proposing the preparation of a layered material, namely hydrocalumite, from recovered Al³⁺. The synthesis of this solid, its characterization, and the use of the mixed oxides produced after its calcination for the photocatalytic removal of ibuprofen from aqueous solutions are structured as a laboratory practice for students in the last years of Chemistry, Chemical Engineering, Environmental Engineering, Materials Engineering, and related university or masters degrees. In this way, the work integrates material synthesis and characterization procedures with a practical introduction to catalysis photodegradation, incorporating key concepts of the Circular Economy and Sustainable Development Goals, and educating students with respect to the environment. 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

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

Copper slag, a by-product of copper ore and concentrate smelting, is rich in non-ferrous metals; therefore, it has been considered a valuable raw material in recent years. This study aimed to compare the extraction of zinc, copper, and cobalt from two types of copper slag from a dump located near the village of Eliseyna, Bulgaria, which differ in mineralogical composition and chemical content, using indirect bioleaching with a spent medium of Aspergillus niger and Penicillium ochrochloron. Chemical leaching with sulphuric acid revealed that zinc and cobalt existed mainly as an acidic-soluble phase in both types of copper slag. In contrast, it contained 50–75% of the total copper content. Each fungal species was cultivated for one week, and the biomass and the spent medium were separated a week later. Owing to the production of a higher concentration of citric acid, A. niger facilitated more efficient base metal recovery. However, their effective recovery from the acidic-soluble phase required leaching at a 5% pulp density and supplementing the spent medium with sulphuric acid. The temperature played a secondary role. Conclusions: Non-ferrous metal extraction from copper slag exposed to weathering using a spent medium supplemented with sulphuric acid was achieved under milder leaching conditions and with better selectivity. In contrast, slag unaffected by weathering behaved as a refractory due to the worsened results of base metal extraction under similar experimental conditions. Full article

The limited availability of high-quality ore deposits and the environmental hazards of metallurgical wastes highlight the importance of developing resource-efficient metal recovery technologies. Zinc kiln slag (ZKS), also known as Waelz slag, a by-product material enriched in non-ferrous metals, was processed through oxidative HCl leaching with H₂O₂ as an oxidant. Thermodynamic simulation and laboratory experiments were applied to determine optimal leaching conditions to dissolve copper, zinc, and iron. Optimal leaching efficiency was achieved with consumptions of 0.8 g HCl and 0.1 g H₂O₂ per gram of ZKS, a liquid-to-solid (L/S) ratio of 5 mL/g, a temperature of 70 °C, and a duration of 180 min, which resulted in recoveries of 96.3% Cu, 93.6% Fe, and 76.8% Zn. The solid residue with 43.5 wt.% C is promising for reuse as a reductant material in pyrometallurgical processes. Copper and arsenic were separated from the leachate via cementation with iron powder, achieving recovery rates of 98.9% and 91.2%, respectively. A subsequent two-step iron precipitation produced ferric hydroxide with 52.2 wt.% Fe and low levels of impurities. As a result, the developed novel hydrochloric acid oxidative leaching and metal precipitation route for ZKS recycling provides an efficient and sustainable alternative to conventional treatment methods. Full article

Tin slags generated during cassiterite smelting in Brazil contain significant amounts of technologically important metals such as niobium, tantalum, and zirconium. Improper disposal of these materials represents both an environmental concern and the loss of a valuable secondary source of critical elements. This study aimed to characterize a Brazilian tin slag sample to evaluate its composition, morphology, and potential for metal recovery. The material was homogenized and analyzed by laser diffraction (particle size), ICP-OES (chemical composition), X-ray diffraction (mineral phases), differential scanning calorimetry (metallic tin), and scanning electron microscopy with energy-dispersive spectroscopy (morphology). The slag exhibited a heterogeneous particle size distribution (D90 = 0.75 mm, D50 = 0.30 mm, D10 = 0.09 mm) and a complex multiphase structure composed mainly of silica, calcium silicate, and zirconia. The chemical analysis revealed 4.8 wt% Nb and 0.8 wt% Ta, along with high concentrations of Zr (11.1 wt%), confirming the material’s potential as a secondary resource. Thorium (2.7 wt%) and uranium (0.3 wt%) were also detected, indicating the presence of radioactive constituents. The detailed characterization of the slag provides essential insights into its chemical and mineralogical complexity, which directly influence the selection of suitable recovery routes. Understanding the distribution of Nb- and Ta-bearing phases within the refractory silicate–zirconia matrix is fundamental for defining pretreatment and leaching strategies. Therefore, this study establishes a necessary foundation for the design of efficient hydrometallurgical processes aimed at recovering critical metals from Brazilian tin slags. Full article

Highly developed countries generate large volumes of industrial waste, the type and quantity of which are strongly linked to the characteristics of the industries that produce it. Industrial waste can adversely affect the environment, so its disposal and management are a major challenge. Understanding the characteristics of a given waste type (e.g., its chemical and phase composition, technical parameters and likelihood of releasing constituents into aquatic and soil environments) allows its potential economic applications to be determined. A simple application of mineral waste is in the production of artificial aggregates, which are increasingly used as a substitute for natural aggregates. In Poland, artificial aggregates are widely produced from metallurgical waste from steel and non-ferrous metallurgy, which may contain numerous components that are potentially environmentally damaging. Depending on their occurrence form (i.e., mineral composition), these contaminants have varying potential to be released into aquatic and soil environments. This study presents the results of mineral and chemical composition analyses and leachability tests conducted on aggregates produced from metallurgical waste, including slags from blast furnaces, steelmaking, Zn and Pb production, and Ni production. The studied aggregates are characterised by chemical and phase composition differences, resulting from the type of slag from which they originate. The chemical composition of blast furnace slag is dominated by CaO, SiO₂, Fe₂O₃, and MgO; steelmaking slag by CaO, Fe₂O₃, and SiO₂; Zn and Pb production slag by SiO₂, Fe₂O₃, SO₃, and CaO; and Ni production slag by SiO₂, Fe₂O₃, CaO, and Al₂O₃. The phase composition of all the tested aggregates is dominated by silicates resistant to leaching (weathering), which results in low levels of Al, Ca, Cr, Mn, Zn, Pb, Cu, As, Sr and Ni leaching, not exceeding 1.6%. Full article

Using solid waste from the non-ferrous metal industry as non-traditional supplementary cementitious material has attracted increasing attention. In this study, iron-rich slag (IRS) was incorporated into calcium sulfoaluminate cement (CSC) to improve its properties, and its strength development and hydration mechanism were systematically evaluated. Three types of IRS with distinct particle size characteristics were fabricated through mechanical grinding, and their effects on the strength development and hydration heat evolution of CSC-based materials were investigated. Furthermore, several solid-phase analysis methods were employed to characterize the hydration mechanisms and microstructural characteristics of IRS-containing CSC-based materials. The results show that mechanical grinding enhances the reactivity of IRS in CSC-based systems, which in turn facilitates the generation of hydrates like ettringite (AFt), AH₃, and C–S–H gel, thereby improving their strength. The incorporation of IRS effectively decreases the total hydration heat released by CSC-based materials within 24 h. Furthermore, evidence from EDS analysis suggests the possible isomorphic substitution of Al³⁺ by Fe³⁺ in AFt, which, along with the slower reaction kinetics of Fe-AFt, may contribute to the improved late-age strength development of CSC-based materials. This study proposes a sustainable strategy for producing high-performance CSC-based materials and offers a potential approach for the high-value use of non-ferrous metal industry solid waste in construction materials, thereby demonstrating both scientific value and practical engineering significance. Full article

This article focuses on the problem of processing slag waste from non-ferrous metallurgy, in particular, the loss of copper, gold and silver with slag during autogenous smelting in the Vanyukov furnace at the Balkhash Copper Smelter (BMZ). An analysis of factors affecting metal losses, including electrochemical and mechanical components, is presented. This paper offers a comprehensive study of the distribution of Cu, Pb, As, Au and Ag between matte and slag, taking into account the unique characteristics of the raw material and the technological conditions of the copper smelter, which distinguishes it from previous studies. This paper establishes numerical values of dissolved and mechanical losses of valuable metals. It has been established that the most important quantitative result of smelting polymetallic raw materials in a Vanyukov furnace is the proportion of mechanical copper losses in the slag, which is approximately 75–80% of the total copper content in the slag. Mathematical models are proposed to predict the distribution of metals in the process of smelting and loss of copper, gold and silver with slag. It is proposed to integrate model representations into the technology control loop, which will optimize the process of metal recovery. This will lead to an increase in profitability and a reduction in the negative impact on the environment during copper production. Full article

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

The processing of metallurgical slags is an urgent task, as they contain residual amounts of precious and non-ferrous metals such as gold, silver, copper and zinc. The efficiency of extraction of these metals directly depends on the granulometric composition of the processed material, which determines the need for its detailed analysis. The purpose of this study is to analyze the effect of the granulometric composition of slags on the efficiency of extraction of non-ferrous metals using the flotation method. For this purpose, studies were carried out, including granulometric analysis, chemical composition analysis and flotation tests using Na₂S, KAX and 3418A reagents. The analysis showed that the main part of the slag consisted of particles less than 3.36 mm, while the content of copper was 0.60%, zinc was 2.37%, gold was 0.1 g/t and silver was 7.2 g/t. Flotation experiments confirmed that the use of Na₂S and 3418A increased the recoverability of copper and zinc, and reducing the particle size to d80 <10 microns increased the efficiency of copper extraction by 7%. Thus, the optimization of flotation processes and the control of granulometric composition make it possible to increase the efficiency of metallurgical waste processing, reduce losses of valuable metals and reduce the environmental burden. 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