Reductive smelting of spent lead-acid battery colloid sludge in a molten Na2CO3 salt

Lead extraction from spent lead–acid battery paste in a molten Na2CO3 salt containing ZnO as a sulfur-fixing agent was studied. Some influencing factors, including smelting temperature, reaction time, ZnO and salt dosages, were investigated in detail using single-factor experiments. The optimum conditions were determined as follows:T = 880°C;t = 60 min; Na2CO3/paste mass ratio = 2.8:1; and the ZnO dosage is equal to the stoichiometric requirement. Under the optimum conditions, the direct recovery rate of lead reached 98.14%. The re-sults suggested that increases in temperature and salt dosage improved the direct recovery rate of lead. XRD results and thermodynamic cal-culations indicated that the reaction approaches of lead and sulfur were PbSO4→Pb and PbSO4→ZnS, respectively. Sulfur was fixed in the form of ZnS, whereas the molten salt did not react with other components, serving only as a reaction medium.     

Comprehensive recovery of lead,zinc, and iron from hazardous jarosite residues using direct reduction followed by magnetic separation

Lead, zinc, and iron were recovered from jarosite residues using direct reduction followed by magnetic separation. The influence of the coal dosage, reduction temperature, and reduction time on the volatilization rates of lead and zinc and the metallization rate of iron were investigated. The results show that the volatilization rates of lead and zinc were 96.97% and 99.89%, respectively, and the iron metallization rate was 91.97% under the optimal reduction roasting conditions of a coal dosage of 25.0wt% and reduction roasting at 1250℃ for 60 min. The magnetic concentrate with an iron content of 90.59wt% and an iron recovery rate of 50.87% was obtained under the optimum conditions in which 96.56% of the reduction product particles were smaller than 37 μm and the magnetic field strength was 24 kA/m. Therefore, the results of this study demonstrate that recovering valuable metals such as lead, zinc, and iron from jarosite residues is feasible using the developed approach.     

Comprehensive recovery of lead,zinc, and iron from hazardous jarosite residues using direct reduction followed by magnetic separation

Lead, zinc, and iron were recovered from jarosite residues using direct reduction followed by magnetic separation. The influence of the coal dosage, reduction temperature, and reduction time on the volatilization rates of lead and zinc and the metallization rate of iron were investigated. The results show that the volatilization rates of lead and zinc were 96.97% and 99.89%, respectively, and the iron metallization rate was 91.97% under the optimal reduction roasting conditions of a coal dosage of 25.0 wt% and reduction roasting at 1250°C for 60 min. The magnetic concentrate with an iron content of 90.59 wt% and an iron recovery rate of 50.87% was obtained under the optimum conditions in which 96.56% of the reduction product particles were smaller than 37 μm and the magnetic field strength was 24 k A/m. Therefore, the results of this study demonstrate that recovering valuable metals such as lead, zinc, and iron from jarosite residues is feasible using the developed approach.     

Leaching of lead from zinc leach residue in acidic calcium chloride aqueous solution

A process with potentially reduced environmental impacts and occupational hazards of lead-bearing zinc plant residue was studied to achieve a higher recovery of lead via a cost-effective and environmentally friendly process. This paper describes an optimization study on the leaching of lead from zinc leach residue using acidic calcium chloride aqueous solution. Six main process conditions, i.e., the solution pH value, stirring rate, concentration of CaCl₂ aqueous solution, liquid-to-solid (L/S) ratio, leaching temperature, and leaching time, were investigated. The microstructure and components of the residue and tailing were characterized using scanning electron microscopy (SEM) and X-ray diffraction (XRD). On the basis of experimental results, the optimum reaction conditions were determined to be a solution pH value of 1, a stirring rate of 500 r·min-1, a CaCl₂ aqueous solution concentration of 400 g·L-1, a liquid-to-solid mass ratio of 7:1, a leaching temperature of 80℃, and a leaching time of 45 min. The leaching rate of lead under these conditions reached 93.79%, with an iron dissolution rate of 19.28%. Silica did not take part in the chemical reaction during the leaching process and was accumulated in the residue.     

Effect of reductant type on the embedding direct reduction of beach titanomagnetite concentrate

Iron and titanium were recovered from beach titanomagnetite(TTM) concentrate by embedding direct reduction and magnetic separation. The reduction products and the effects of the reductant type and reduction temperature on the reduction behavior were investigated. The results showed that the reduction of TTM concentrate was strongly related to the gasification reactivity of the reductant. Bitumite presented a better product index than wheat-straw biochar and coke, mainly because the gasification reactivity of bitumite was better than that of the other reductants. In addition, high temperatures were not beneficial to embedding direct reduction because of the emergence of a molten phase and iron-joined crystals, which in turn reduced the diffusion rate of the reducing gas and impeded the reduction reaction in the central area of the roasted briquette. The use of bitumite as the reductant at a C/Fe molar ratio of 1.4 and a reduction temperature of 1200°C for 120 min resulted in direct-reduction iron powder assaying 90.28 wt% TFe and 0.91 wt% TiO_2 with an iron recovery of 91.83% and titanium concentrate assaying 46.01 wt% TiO_2 with a TiO_2 recovery of 91.19%. Titanium existed mainly in the form of anosovite and ilmenite in the titanium concentrate.     

A novel process for Fe recovery and Zn,Pb removal from a low-grade pyrite cinder with high Zn and Pb contents

Comprehensive utilization of pyrite cinders is increasingly important because of their huge annual outputs and potential valuable metals recovery to cope with the gradual depletion of high-grade mineral resources. In this work, a new process, i.e., a high-temperature chlorination–magnetizing roasting–magnetic separation process, was proposed for recovering Fe and removing Zn, Pb from a low-grade pyrite cinder containing 49.90 wt% Fe, 1.23 wt% Zn, and 0.29 wt% Pb. Various parameters, including the chlorinating conditions(dosage of Ca Cl2, temperature, and time) and the magnetization roasting conditions(amount of coal, temperature, and time) were investigated. The results indicate that the proposed process is effective for Fe recovery and Zn, Pb removal from the pyrite cinder. Through this process, 97.06% Zn, 96.82% Pb, and approximately 90% S can be removed, and 89.74% Fe is recovered as magnetite into the final product under optimal conditions. A purified magnetite concentrate containing 63.07 wt% Fe, 0.16 wt% P, 0.26 wt% S, and trace amounts of nonferrous metals(0.005 wt% Cu, 0.013 wt% Pb, and 0.051 wt% Zn) was obtained. The concentrate can be potentially used as a high-quality feed material for producing oxidized pellets by blending with other high-grade iron ore concentrates.     

A novel process for Fe recovery and Zn,Pb removal from a low-grade pyrite cinder with high Zn and Pb contents

Comprehensive utilization of pyrite cinders is increasingly important because of their huge annual outputs and potential valuable metals recovery to cope with the gradual depletion of high-grade mineral resources. In this work, a new process, i.e., a high-temperature chlorination-magnetizing roasting-magnetic separation process, was proposed for recovering Fe and removing Zn, Pb from a low-grade pyrite cinder containing 49.90wt% Fe, 1.23wt% Zn, and 0.29wt% Pb. Various parameters, including the chlorinating conditions (dosage of CaCl₂, temperature, and time) and the magnetization roasting conditions (amount of coal, temperature, and time) were investigated. The results indicate that the proposed process is effective for Fe recovery and Zn, Pb removal from the pyrite cinder. Through this process, 97.06% Zn, 96.82% Pb, and approximately 90% S can be removed, and 89.74% Fe is recovered as magnetite into the final product under optimal conditions. A purified magnetite concentrate containing 63.07wt% Fe, 0.16wt% P, 0.26wt% S, and trace amounts of nonferrous metals (0.005wt% Cu, 0.013wt% Pb, and 0.051wt% Zn) was obtained. The concentrate can be potentially used as a high-quality feed material for producing oxidized pellets by blending with other high-grade iron ore concentrates.     

Comparative studies on the hot corrosion behavior of air plasma spray and high velocity oxygen fuel coated Co-based L605 superalloys in a gas turbine environment

An improvement in the corrosion resistance of alloys at elevated temperature is a factor for their potential use in gas turbines. In this study, Co Ni Cr Al Y has been coated on the L605 alloy using air plasma spray(APS) and high-velocity oxygen fuel(HVOF) coating techniques to enhance its corrosion resistance. Hot corrosion studies were conducted on uncoated and coated samples in a molten salt environment at 850°C under cyclic conditions. Thermogravimetric analysis was used to determine the corrosion kinetics. The samples were subjected to scanning electron microscopy, energy-dispersive spectroscopy, and X-ray diffraction for further investigation. In coated samples, the formation of Al2O3 and Cr2O3 in the coating acts as a diffusion barrier that could resists the inward movement of the corrosive species present in the molten salt. Coated samples showed very less spallation, lower weight gain, less porosity, and internal oxidation as compared to uncoated sample.HVOF-coated sample showed greater corrosion resistance and inferred that this is the best technique under these conditions.     

Deep cleaning of a metallurgical zinc leaching residue and recovery of valuable metals

Huge quantities of zinc leaching residues (ZLRs) generated from zinc production are dumped continuously around the world and pose a potential environmental threat because of their considerable amounts of entrained heavy metals (mainly lead). Most ZLRs have not been properly treated and the valuable metals in them have not yet been effectively recovered. Herein, the deep cleaning of a ZLR and recovery of valuable metals via a hydrometallurgical route were investigated. The cleaning process consists of two essential stages:acid leaching followed by calcium chloride leaching. The optimum conditions for extracting zinc, copper, and indium by acid leaching were a sulfuric acid concentration of 200 g·L-1, a liquid/solid ratio of 4:1 (mL/g), a leaching time of 2 h, and a temperature of 90℃. For lead and silver extractions, the optimum conditions were a calcium chloride concentration of 400 g·L-1, a pH value of 1.0, a leaching time of 1 h, and a temperature of 30℃. After calcium chloride leaching, silver and lead were extracted out and the lead was finally recovered as electrolytic lead by electrowinning. The anglesite phase, which poses the greatest potential environmental hazard, was removed from the ZLR after deep cleaning, thus reducing the cost of environmental management of ZLRs. The treatment of chlorine and spent electrolyte generated in the process was discussed.     

Recovery of iron from copper tailings via low-temperature direct reduction and magnetic separation: process optimization and mineralogical study

Currently, the majority of copper tailings are not effectively developed. Worldwide, large amounts of copper tailings generated from copper production are continuously dumped, posing a potential environmental threat. Herein, the recovery of iron from copper tailings via low-temperature direct reduction and magnetic separation was conducted; process optimization was carried out, and the corresponding mineralogy was investigated. The reduction time, reduction temperature, reducing agent (coal), calcium chloride additive, grinding time, and magnetic field intensity were examined for process optimization. Mineralogical analyses of the sample, reduced pellets, and magnetic concentrate under various conditions were performed by X-ray diffraction, optical microscopy, and scanning electron microscopy-energy-dispersive X-ray spectrometry to elucidate the iron reduction and growth mechanisms. The results indicated that the optimum parameters of iron recovery include a reduction temperature of 1150℃, a reduction time of 120 min, a coal dosage of 25%, a calcium chloride dosage of 2.5%, a magnetic field intensity of 100 mT, and a grinding time of 1 min. Under these conditions, the iron grade in the magnetic concentrate was greater than 90%, with an iron recovery ratio greater than 95%.     

Chlorination roasting-coupled water leaching process for potash recovery from waste mica scrap using dry marble sludge powder and sodium chloride

The present paper reports the effective utilization of marble sludge powder(MSP) for the recovery of potash values from waste mica scrap using chlorination roasting–water leaching method. Characterization studies indicated the presence of dolomite as the major mineral phase in MSP, whereas muscovite and quartz were observed in the mica sample. The acid leaching studies suggest a maximum of 22% potash recovery under conditions: 4 M H_2SO_4 acid, particle size of ～100 μm, stirring speed of 600 r/min, leaching temperature of 75℃, and leaching time of 90 min. The chlorination roasting–water leaching process was adopted to achieve the lowest level of 80%–90% potash recovery. The optimum conditions for the recovery of ～93% potash from mica(～8.6 wt% K_2O) requires 900℃ roasting temperature, 30 min roasting time,and 1:1:0.75 mass ratio of mica : MSP : Na Cl. The roasting temperature and amount of Na Cl are found to be the most important factors for the recovery process. The reaction mechanism suggests the formation of different mineral phases, including sylvite(KCl), wollastonite, kyanite,and enstatite, during roasting, which were confirmed by X-ray diffraction(XRD) analyses and scanning electron microscopy(SEM) morphologies. The MSP-blended Na Cl additive is more effective for potash recovery compared with the other reported commercial roasting additives.     

Alkaline pressure oxidative leaching of bismuth-rich and arsenic-rich lead anode slime

A new alkaline pressure oxidative leaching process(with NaNO3 as the oxidant and NaOH as the alkaline reagent)is proposed herein to remove arsenic,antimony,and lead from bismuth-rich and arsenic-rich lead anode slime for bismuth,gold,and silver enrichment.The effects of the temperature,liquid-to-solid ratio,leaching time,and reagent concentration on the leaching ratios of arsenic,antimony,and lead were investigated to identify the optimum leaching conditions.The experimental results under optimized conditions indicate that the average leaching ratios of arsenic,antimony and lead are 95.36%,79.98%,63.08%,respectively.X-ray diffraction analysis indicated that the leaching residue is composed of Bi,Bi2O3,Pb2Sb2O7,and trace amounts of NaSb(OH)6.Arsenic,antimony,and lead are thus separated from lead anode slime as Na3AsO4·10H2O and Pb2Sb2O7.Scanning electron microscopy and energy-dispersive spectrometry imaging revealed that the samples undergo appreciable changes in their surface morphology during leaching and that the majority of arsenic,lead,and antimony is removed.X-ray photoelectron spectroscopy was used to demonstrate the variation in the valence states of the arsenic,lead,and antimony.The Pb(IV)and Sb(V)content was found to increase substantially with the addition of NaNO3.     

Effect of curing humidity on performance of cemented paste backfill

Cemented paste backfill(CPB), a mixture of tailings, binder, and water, is widely and extensively used for the recovery of mineral resources, the prevention of ground subsidence, and the management of mine waste. When installed, the CPB is subjected to complex environmental conditions such as water content, temperature, and power, which have a significant impact on its efficiency. Thus, this study conducts a series of laboratory programs, including investigation of moisture, temperature, stress–strain relation, and microstructure to show the effect of curing humidity on the CPB behaviors. The results obtained indicate that ambient humidity can have a dramatic effect on CPB in terms of its macro performance of internal relative humidity, temperature and strength, as well as the micro expression. Typical examples of these effects on CPB include an increase in curing humidity, which favors binder hydration, and then an increase in hydration materials, temperature and peak stress in the CPB. The results obtained will lead to a better understanding of CPB's responses to various environmental conditions.     

养护湿度对充填体性能的影响规律

Cemented paste backfill (CPB), a mixture of tailings, binder, and water, is widely and extensively used for the recovery of mineral resources, the prevention of ground subsidence, and the management of mine waste. When installed, the CPB is subjected to complex environmental conditions such as water content, temperature, and power, which have a significant impact on its efficiency. Thus, this study conducts a series of laboratory programs, including investigation of moisture, temperature, stress–strain relation, and microstructure to show the effect of curing humidity on the CPB behaviors. The results obtained indicate that ambient humidity can have a dramatic effect on CPB in terms of its macro performance of internal relative humidity, temperature and strength, as well as the micro expression. Typical examples of these effects on CPB include an increase in curing humidity, which favors binder hydration, and then an increase in hydration materials, temperature and peak stress in the CPB. The results obtained will lead to a better understanding of CPB’s responses to various environmental conditions.     

Reaction kinetics modeling for lithium and cobalt recovery from spent lithium-ion batteries using acetic acid

Lithium and cobalt recovery from spent lithium-ion batteries(LIBs) is a major focus because of their increased production and usage. The conventional method for recycling spent LIBs using inorganic acids produces harmful byproducts. In this work, the leaching agent was substituted with a less expensive and more environmentally friendly alternative—acetic acid—and a mathematical model was developed to describe the kinetics of the recovery process. The variables used were the pH value, temperature, H_2O_2 concentration, and the solid-to-liquid(S/L) ratio. The mathematical model used was the shrinking core model, which was modified to accommodate an equilibrium reaction. The experimental results show that the rate of recovery of Li and Co over time was only affected by temperature. The leaching behaviors of Li and Co were found to oppose each other. An increase in temperature resulted in increased recovery of Li but decreased recovery of Co because of the product-favoring endothermic reaction of Li and the reactant-favoring exothermic reaction of Co. The product of Li has a lower entropy value than the reactant as a free-moving ion, whereas the product of Co leaching has a higher entropy value as a stiff crystal complex. Thus, temperature conditioning is a pivotal factor in the leaching of spent LIBs.     

Investigation on microwave heating for direct leaching of chalcopyrite ores and concentrates

The use of microwave energy in materials processing is a relatively new development presenting numerous advantages because of the rapid heating feature. Microwave technology has great potential to improve the extraction efficiency of metals in terms of both a reduction in required leaching time and an increase in the recovery of valuable metals. This method is especially pertinent in view of the increased demand for environment-friendly processes. In the present study, the influence of microwave heating on the direct leaching of chalcopyrite ores and concentrates were investigated. The results of microwave leaching experiments were compared with those obtained under conventional conditions. During these processes, parameters such as leaching media, temperature, and time have been worked to determine the optimum conditions for proper copper dissolution. Experimental results show that microwave leaching is more efficient than conventional leaching. The optimum leaching conditions for microwave leaching are the solid-to-liquid ratio of 1:100 g/mL, the temperature of 140℃, the solution of 0.5 M H₂SO₄ + 0.05 M Fe₂(SO₄)₃, and the time of 1 h.     

Thermodynamics and kinetics of extracting zinc from zinc oxide ore by the ammonium sulfate roasting method

Thermodynamic analyses and kinetic studies were performed on zinc oxide ore treatment by (NH₄)₂SO₄ roasting technology. The results show that it is theoretically feasible to realize a roasting reaction between the zinc oxide ore and (NH₄)₂SO₄ in a temperature range of 573-723 K. The effects of reaction temperature and particle size on the extraction rate of zinc were also examined. It is found that a surface chemical reaction is the rate-controlling step in roasting kinetics. The calculated activation energy of this process is about 45.57 kJ/mol, and the kinetic model can be expressed as follows:1-(1-α)1/3=30.85 exp(-45.57/RT)·t. An extraction ratio of zinc as high as 92% could be achieved under the optimum conditions.     

Comparative studies on the hot corrosion behavior of air plasma spray and high velocity oxygen fuel coated Co-based L605 superalloys in a gas turbine environment

An improvement in the corrosion resistance of alloys at elevated temperature is a factor for their potential use in gas turbines. In this study, Co Ni Cr Al Y has been coated on the L605 alloy using air plasma spray(APS) and high-velocity oxygen fuel(HVOF) coating techniques to enhance its corrosion resistance. Hot corrosion studies were conducted on uncoated and coated samples in a molten salt environment at 850°C under cyclic conditions. Thermogravimetric analysis was used to determine the corrosion kinetics. The samples were subjected to scanning electron microscopy, energy-dispersive spectroscopy, and X-ray diffraction for further investigation. In coated samples, the formation of Al_2O_3 and Cr_2O_3 in the coating acts as a diffusion barrier that could resists the inward movement of the corrosive species present in the molten salt. Coated samples showed very less spallation, lower weight gain, less porosity, and internal oxidation as compared to uncoated sample.HVOF-coated sample showed greater corrosion resistance and inferred that this is the best technique under these conditions.     

Prediction of operational parameters effect on coal flotation using artificial neural network

Artificial neural network procedures were used to predict the combustible value (i.e. 100-Ash) and combustible recovery of coal flotation concentrate in different operational conditions. The pulp density,pH,rotation rate,coal particle size,dosage of collector,frother and conditioner were used as inputs to the network. Feed-forward artificial neural networks with 5-30-2-1 and 7-10-3-1 arrangements were capable to estimate the combustible value and combustible recovery of coal flotation concentrate respectively as the outputs. Quite satisfactory correlations of 1 and 0.91 in training and testing stages for combustible value and of 1 and 0.95 in training and testing stages for combustible recovery prediction were achieved. The proposed neural network models can be used to determine the most advantageous operational conditions for the expected concentrate assay and recovery in the coal flotation process.     

用离心法代替浮选提纯镜铁矿制备氧化铁红色素

This study used specularite, a high-gradient magnetic separation concentrate, as a raw material in reverse flotation. An iron concentrate with a grade of 65.1wt% and a recovery rate of 75.31% were obtained. A centrifugal concentrator served as the deep purification equipment for the preparation of iron oxide red pigments, and its optimal rotating drum speed, feed concentration, and other conditions were determined. Under optimal conditions, a high-purity iron oxide concentrate with a grade of 69.38wt% and a recovery rate of 80.89% were obtained and used as a raw material for preparing iron oxide red pigment. Calcining with sulfuric acid produced iron red pigments with different hues. Simultaneously, middlings with a grade of 60.20wt% and a recovery rate of 17.51% were obtained and could be used in blast furnace ironmaking. High-value utilization of specularite beneficiation products was thus achieved.