Immobilization of copper flotation waste using red mud and clinoptilolite

The flash smelting process has been used in the copper industry for a number of years and has replaced most of the reverberatory applications, known as conventional copper smelting processes. Copper smelters produce large amounts of copper slag or copper flotation waste and the dumping of these quantities of copper slag causes economic, environmental and space problems. The aim of this study was to perform a laboratory investigation to assess the feasibility of immobilizing the heavy metals contained in copper flotation waste. For this purpose, samples of copper flotation waste were immobilized with relatively small proportions of red mud and large proportions of clinoptilolite. The results of laboratory leaching demonstrate that addition of red mud and clinoptilolite to the copper flotation waste drastically reduced the heavy metal content in the effluent and the red mud performed better than clinoptilolite. This study also compared the leaching behaviour of metals in copper flotation waste by short-time extraction tests such as the toxicity characteristic leaching procedure (TCLP), deionized water (DI) and field leach test (FLT). The results of leach tests showed that the results of the FLT and DI methods were close and generally lower than those of the TCLP methods.     

Physicochemical properties of slags produced at various amounts of iron addition in lead smelting

In the process of lead production from lead-bearing materials generated in copper metallurgy, a large amount of hazardous waste in the form of slag is produced. To assess the effect of the slag on the environment, its physicochemical properties were determined. In this study, the following methods were used: wavelength dispersive X-ray fluorescence (WD XRF), X-ray diffraction (XRD), and Bunte-Baum-Reerink method to determine softening and melting points, as well as viscosity examination and leaching tests. The measurements were performed on the slag produced with two different amounts of iron addition to the lead smelting process. The resulting slags, an oxide rich phase slag and a sulfide rich phase slag have different compositions and physicochemical properties. It was found that the increase in iron addition causes an increase in the softening melting point of the oxide rich phase slag by about 100 °C, and a twofold increase in the viscosity of both slag phases. The increase in iron addition also results in the decrease in As leachability and increase in Zn, Fe, and Cu leachability from the slags. Slag produced with increased iron addition has a greater impact on the environment.

     

Treatment of copper industry waste and production of sintered glass-ceramic.

Copper waste is iron-rich hazardous waste containing heavy metals such as Cu, Zn, Co, Pb. The results of leaching tests show that the concentration of these elements exceeds the Turkish and EPA regulatory limits. Consequently, this waste cannot be disposed of in its present form and therefore requires treatment to stabilize it or make it inert prior to disposal. Vitrification was selected as the technology for the treatment of the toxic waste under investigation. During the vitrification process significant amounts of the toxic organic and inorganic chemical compounds could be destroyed, and at the same time, the metal species are immobilized as they become an integral part of the glass matrix. The copper flotation waste samples used in this research were obtained from the Black Sea Copper Works of Samsun, Turkey. The samples were vitrified after being mixed with other inorganic waste and materials. The copper flotation waste and their glass-ceramic products were characterized by X-ray analysis (XRD), scanning electron microscopy and by the toxicity characteristic leaching procedure test. The products showed very good chemical durability. The glass-ceramics fabricated at 850 degrees C/2 h have a large application potential especially as construction and building materials.     

Review on the innovative uses of steel slag for waste minimization

Piles of steel slag, a solid waste generated from the iron and steel industry, could be seen due to no utility found for the past century. Steel slag has now gained much attention because of its new applications. The properties of slag greatly influence its use and thus had got varied applications. The chemical composition of steel slag varies as the mineral composition of raw material such as iron ore and limestone varies. This paper reviews the characteristics of steel slag and its usage. The paper reviews recent developments in well-known applications to the steel slag such as aggregate in bituminous mixes, cement ingredient, concrete aggregate, antiskid aggregate, and rail road ballast. This paper also reviews novel uses such as mechanomutable asphalt binders, building material, green artificial reefs, thermal insulator, catalyst and ceramic Ingredient. The review is also done on utilization of solid waste for waste management by the novel methods like landfill daily cover material, sand capping, carbon sequestration, water treatment and solid waste management. Review also shows recovery of pure calcium carbonate and heavy metals from slag, providing opportunity for revenue generation. Steel slag once traded as free to use by steel industries is now sold in the market at some price. Its utilization is of great economic significance as it also contributes to the reduction of solid waste.     

未知含铜物料固体废物属性鉴别研究

以某未知样品为研究对象,综合样品外观及物理、化学等特性,分析得出样品具有和铜冶炼渣一致的特征,含有特征物相——铁橄榄石,成分与铜精炼炉渣类似,而且其碳含量较高,含有少许金属铜,可以判断样品为铜;台炼渣。经过破碎、研磨、浮选得篓Ⅱ精炼渣（铜精矿）,可作为炼铜原料投入生产。     

UTILIZING THE USED CATALYST FROM REFINERY FCC UNITS AS A SUBSTITUTE FOR KAOLIN IN FORMULATING CERAMIC FRITS

Frits are materials of a vitreous nature which are used for obtaining the glaze used to coat glazed ceramic tiles. One of the raw materials usually employed in preparing frits is kaolin, which provides the aluminium and part of the silicon they contain.This study investigates the possibility of utilizing the used catalyst from the FCC (fluidized catalyst cracking) units involved in petroleum refining, to substitute for kaolin as a raw material in the preparation of ceramic frits. On assessing the aesthetic and technical characteristics (whiteness, gloss, microhardness, etc.) of the glazes obtained from two frits that were prepared by substituting kaolin with the industrial waste mentioned above, no important differences were observed relative to the characteristics of the glazes obtained from the standard frits.     

Processing of copper converter slag for metal reclamation. Part I: Extraction and recovery of copper and cobalt.

Clean processing of copper converter slag to reclaim cobalt and copper could be a challenge. An innovative and environmentally sound approach for recovering valuable metals from such a slag has been developed in the present study. Curing the slag with strong sulphuric acid, without re-smelting or roasting as practiced currently in the industry, render it accessible to leaching, and more than 95% of cobalt and up to 90% of copper was extracted together with iron by water leaching, leaving silica behind in a residue. The copper in the leach liquor was recovered by cementation with iron and the dissolved iron crystallized as ferrous sulphate monohydrate. The cobalt in the mother-liquor rich in iron was recovered by either cementation or sulphide precipitation. Operation variables in the new process were also investigated and optimized.     

Sources of heavy metal contamination in Swedish wood waste used for combustion

In this paper, wood waste (RWW) recovered for heat production in Sweden was studied. Previous research has concluded that RWW contains elevated amounts of heavy metals, causing environmental problems during waste management. This study extends previous work on RWW by analysing which pollution sources cause this contamination. Using existing data on the metal contents in various materials, and the amounts of these materials in RWW, the share of the elevated amounts of metals in RWW that these materials explain was quantified. Six different materials occurring in RWW were studied and the results show that they explain from 70% to 100% of the amounts of arsenic, chromium, lead, copper and zinc in RWW. The most important materials contributing to contamination of RWW are surface-treated wood, industrial preservative-treated wood, plastic and galvanised fastening systems. These findings enable the development and evaluation of strategies aiming to decrease pollution and resource loss from handling RWW. It is argued that source separation and measures taken further downstream from the generation site, such as treatment, need to be combined to substantially decrease the amount of heavy metals in RWW.     

Assessment of the use of spent copper slag for land reclamation.

The shortage of waste landfill space for waste disposal and the high demand for fill materials for land reclamation projects in Singapore have prompted a study on the feasibility of using spent copper slag as fill material in land reclamation. The physical and geotechnical properties of the spent copper slag were first assessed by laboratory tests, including hydraulic conductivity and shear strength tests. The physical and geotechnical properties were compared with those of conventional fill materials such as sands. The potential environmental impacts associated with the use of the spent copper slag for land reclamation were also evaluated by conducting laboratory tests including pH and Eh measurements, batch-leaching tests, acid neutralization capacity determination, and monitoring of long-term dissolution of the material. The spent copper slag was slightly alkaline, with pH 8.4 at a solid : water ratio of 1 : 1. The batch-leaching test results show that the concentrations of the regulated heavy metals leached from the material at pH 5.0 were significantly lower than the maximum concentrations for their toxicity limits referred by US EPA's Toxicity Characteristic Leaching Procedure (TCLP). It was also found that the material is unlikely to cause significant change in the redox condition of the subsurface environment over a long-term period. In terms of physical and geotechnical properties, the spent copper slag is a good fill material. In general, the spent copper slag is suitable to be used as a fill material for land reclamation.     

Utilization of kaolin processing waste for the production of porous ceramic bodies

The kaolin processing industry generates large amounts of waste in producing countries such as Brazil. The aim of this study was to characterize kaolin processing waste and evaluate its suitability as an alternative ceramic raw material for the production of porous technical ceramic bodies. The waste material was physically and chemically characterized and its thermal behaviour is described. Several formulations were prepared and sintered at different temperatures. The sintered samples were characterized to determine their porosity, water absorption, firing shrinkage and mechanical strength. Fired samples were microstructurally analysed by X-ray diffraction and scanning electron microscopy. The results indicated that the waste consisted of quartz, kaolinite, and mica, and that ceramic formulations containing up to 66% of waste can be used for the production of ceramics with porosities higher than 40% and strength of about 70 MPa.     

Physical separation,mechanical enrichment and recycling-oriented characterization of spent NiMH batteries

Nickel–metal hydride (NiMH) batteries contain high amount of industrial metals, especially iron, nickel, cobalt and rare earth elements. Although the battery waste is a considerable secondary source for metal and chemical industries, a recycling process requires a suitable pretreatment method before proceeding with recovery step to reclaim all valuable elements. In this study, AA- and AAA-type spent NiMH batteries were ground and then sieved for size measurement and classification. Chemical composition of the ground battery black mass and sorted six different size fractions were determined by an analytical technique. Crystal structures of the samples were analyzed by X-ray diffraction. Results show that after mechanical treatment, almost 87 wt% of the spent NiMH batteries are suitable for further recycling steps. Size classification by sieving enriched the iron content of the samples in the coarse fraction which is bigger than 0.25 mm. On the other hand, the amounts of nickel and rare earth elements increased by decreasing sample size, and concentrated in the finer fractions. Anode and cathode active materials that are hydrogen storage alloy and nickel hydroxide were mainly collected in finer size fraction of the battery black mass.     

Recovery of copper and cobalt from ancient slag.

About 2.5 million tonnes of copper smelter slag are available in Küre, northern part of Turkey. This slag contains large amounts of metallic values such as copper and cobalt. A representative slag sample containing 0.98% Cu, 0.49% Co and 51.47% Fe was used in the experimental studies. Two different methods, direct acid leaching and acid baking followed by hot water leaching were used for recovering Cu and Co from the slag. The effects of leaching time, temperature and acid concentration on Cu- and Co-dissolving efficiencies were investigated in the direct acid leaching tests. The optimum leaching conditions were found to be a leaching time of 2 h, acid concentration of 120 g L(-1), and temperature of 60 degrees C. Under these conditions, 78% Cu and 90% Co were extracted. In the acid baking + hot water leaching tests, 74% Co was dissolved after 1 h of roasting at 200 degrees C using a 3:1 acid:slag ratio, whereas the Cu-dissolving efficiency was 79% and the total slag weight loss was approximately 50%.     

Prioritising objectives for waste reprocessing: a case study in secondary lead refining

Secondary lead refining produces a sulphidic slag that also contains varying quantities of lead. Initially, the objectives of this project were to treat the slag in order to recover the valuable lead as well as to render the slag environmentally benign. However, in keeping with the principles of clean technology and, specifically, the approach of clean production, the project was redefined with the following priorities: waste characterisation; waste minimisation through process improvement; waste modification; identification of slag treatment methods. Characterisation of the waste facilitated an overall process understanding and aided in identifying process deficiencies. Process improvement was aimed at reducing both the quantity of slag produced as well as the lead loss to the slag. Waste characterisation combined with local hazardous waste regulations enabled desirable waste modifications to be identified. These waste adaptations were implemented through process modification. Lastly, treatment methods for the slag were identified.     

Reactive transport modeling of remedial scenarios to predict cadmium,copper, and zinc in north fork of Clear Creek,Colorado

The North Fork of Clear Creek (NFCC), Colorado, is an acid‐mine‐drainage‐impacted stream typical of many mountain surface waters affected by historic metal mining in the western United States. The stream is devoid of fish primarily because of high metal concentrations in the water (e.g., copper and zinc) and has large amounts of settled iron oxyhydroxide solids that coat the streambed. The NFCC is part of the Central City/Clear Creek Superfund site, and remediation plans are being implemented that include treatment of three of the main point‐source inputs and cleanup of some tailings and waste rock piles. This article examines dissolved (0.45‐μm filterable) concentrations of cadmium, copper, and zinc following several potential remediation scenarios, simulated using a reactive transport model (WASP4/META4). Results from modeling indicate that for cadmium, remediation of the primary point‐source adit discharges should be sufficient to achieve acute and chronic water‐quality standards under both high‐ and low‐flow conditions. To achieve standards for copper and zinc, however, the modeling scenarios suggest that it may be necessary to treat or remove contaminated streambed sediments in downstream reaches, as well as identify and treat nonpoint sources of metals. Recommendations for improvements to the model for metal transport in acid‐mine drainage impacted streams are made. These recommendations are being implemented by the U.S. Environmental Protection Agency. © 2009 Wiley Periodicals, Inc.     

Co-gasification of municipal solid waste and material recovery in a large-scale gasification and melting system

This study evaluates the effects of co-gasification of municipal solid waste with and without the municipal solid waste bottom ash using two large-scale commercial operation plants. From the viewpoint of operation data, there is no significant difference between municipal solid waste treatment with and without the bottom ash. The carbon conversion ratios are as high as 91.7% and 95.3%, respectively and this leads to significantly low PCDD/DFs yields via complete syngas combustion. The gross power generation efficiencies are 18.9% with the bottom ash and 23.0% without municipal solid waste bottom ash, respectively. The effects of the equivalence ratio are also evaluated. With the equivalence ratio increasing, carbon monoxide concentration is decreased, and carbon dioxide and the syngas temperature (top gas temperature) are increased. The carbon conversion ratio is also increased. These tendencies are seen in both modes.Co-gasification using the gasification and melting system (Direct Melting System) has a possibility to recover materials effectively. More than 90% of chlorine is distributed in fly ash. Low-boiling-point heavy metals, such as lead and zinc, are distributed in fly ash at rates of 95.2% and 92.0%, respectively. Most of high-boiling-point heavy metals, such as iron and copper, are distributed in metal. It is also clarified that slag is stable and contains few harmful heavy metals such as lead. Compared with the conventional waste management framework, 85% of the final landfill amount reduction is achieved by co-gasification of municipal solid waste with bottom ash and incombustible residues. These results indicate that the combined production of slag with co-gasification of municipal solid waste with the bottom ash constitutes an ideal approach to environmental conservation and resource recycling.     

氰化钠生产中聚合废料的利用

对氰化钠生产中的聚合废料进行了吸附试验和氰化钠含量分析，试验结果表明，聚合废料中含有２８％左右的氰化钠，其中黑褐色杂质可用活性炭吸附脱除。生产规模试验证明，用聚合废料为原料生产的硫氰酸钠，产品质量可达到装置设计指标，满足腈纶装置的使用要求。     

水淬铜渣技术要求标准研究

面对绿色发展的新形势,我国正在大力推进固废的资源化利用工作,提升标准化水平。论述了编制水淬铜渣标准的意义和作用,介绍了标准研制的原则,以及水淬铜渣的技术要求、试验方法、检验规则等,通过标准的研制与实施,将引领并规范水淬铜渣的应用。     

Application of magnetic separation to steelmaking slags for reclamation

Integrated iron and steel plants generate large amounts of metallurgical slag, which usually contains some quantity of metals or mixtures of oxides that could be treated to be recycled in various applications. The conventional method for disposal of slags is dumping. However, it is possible to process the slags to be used in the production of metallic iron, or as an additive in cement making. In this study, a basic oxygen furnace (BOF) steelwork slag obtained from the Kardemir integrated iron and steel works, Karabuk, Turkey is used. A drum magnetic separator system with pre-engineered crucial processing parameters of drum revolution speed, drum radius, drum flesh thickness, and magnitude of the magnetic field applied is utilized, as these parameters have a competing influence on the results. Subsequently, the effects of slag grain size and the drum-blade gap are investigated in the separation efficiency of magnetic grains. It is found that collection of magnetic grains is improved by decreasing the grain size of slags and moreover, the collection of magnetic grains fraction is increased with an increase in the gap between the blades and drum.     

Metallurgical use of glass fractions from waste electric and electronic equipment (WEEE)

Within the European Union, it is estimated that between 8 and 9 million tonnes of waste electric and electronic equipment (WEEE) arises annually, of which television sets and computers account for an important part. Traditionally, Cathode Ray Tubes (CRT) have been used for TVs and computer monitors, but are rapidly being replaced by flat-screen technology. Only part of the discarded CRT glass is being recycled. Primary smelters use large amounts of silica flux to form iron-silicate slag, and can, in most cases, tolerate lead input. Use of discarded CRT glass in copper smelting is a potential alternative for utilization of the glass.The mineralogical composition of a slag sampled during ordinary slag praxis has been compared with that of a mixture of slag and CRT glass when re-melted and slowly cooled. Slag (iron-silicate slag) from Boliden Mineral AB, Sweden, was used for the experiments. Slag and glass have been mixed in various proportions: pure slag, pure glass, 90% slag-10% glass and 65% slag-35% glass, and heated in an inert atmosphere up to 1400 °C in a Netzsch Thermal Analysis (TA) instrument. The re-melted material has been analyzed using X-ray diffraction (XRD) and scanning electron microscopy (SEM) to determine changes in mineralogical composition after mixing with glass.The results show that the main mineralogical component of the slag is fayalite; the CRT glass is amorphous. The main crystalline phases of the slag do not change with addition of glass. An amorphous phase appears when the addition of glass is increased, which gives the sample a different structure.     

Utilisation of IGCC slag and clay steriles in soft mud bricks (by pressing) for use in building bricks manufacturing

The subject of this study is the application to the construction of soft mud bricks (also known as pressed bricks), both green and heat-treated bodies, built from raw materials from Santa Cruz de Mudela, Ciudad Real, and IGCC slag from the power central of Puertollano (Ciudad Real, Spain). For this purpose, industrial level tests have been performed: the production of these kind of bricks from mixes of waste from ores of construction clays and to significant fraction of different ratios and clay granulometries mixed with IGCC slag. The results of this experimentation suggests that not only can IGCC slag be applied to a ceramic process, but also its use gives several advantages, as water and energy savings, as well as improvements on the final properties of products.