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Hydrometallurgy
j o u r n a l h o m e p a g e : w w w. e l s ev i e r. c o m / l o c a t e / h yd r o m e t
Treatment of copper ash smelter ue dusts for copper and zinc extraction and
arsenic stabilization
A. Morales a, M. Cruells b, A. Roca b,, R. Berg b
a
b
a r t i c l e
i n f o
Article history:
Received 14 June 2010
Received in revised form 2 September 2010
Accepted 2 September 2010
Available online 9 September 2010
Keywords:
Copper smelter dusts
Arsenic stabilization
Copper and zinc extraction
a b s t r a c t
A ue dust sample of copper from ash smelting furnace has been extensively characterized. The main phases
of the dusts are magnetite, cuprospinel, chalcocyanite, zincosite, dolerophanite, and claudetite. As minor
phases, tenorite, arsenolite, delafossite and enargite were detected. In the sample studied, particles were
mainly spherical and less than 60 m. The leaching of ue dust sample with water dissolved copper sulfates
and zinc sulfates and, partially, arsenic oxides, in an exothermic process. The leaching of the residue after
water leaching in several acid media increased the dissolution of copper and arsenic oxides and small
amounts of zinc. A preliminary study by hydrocyclone classication was carried out with the objective of to
obtain two fractions: a coarse fraction rich in copper and a ne fraction rich in arsenic. However, results
obtained in this sample were not very successful. In the stabilization study, the residue obtained after leaching
the copper ash smelter ue dust with sulfuric acid was mixed with sludge from a paper factory (coinertization process). The smaller size fraction (N 12 m) obtained in the hydrocyclone was also mixed with
this sludge. Results obtained derived of the application of a standard leaching test over these residues indicate
that they were stabilized. Thus, the resulting mixtures should be dumped without generating major
environmental problems.
2010 Elsevier B.V. All rights reserved.
1. Introduction
Copper smelter ue dusts are generated in the pyrometallurgical
process of copper extraction. The constituent elements, and their
concentrations, depend on: the characteristics of the sulfurated ores
that are processed, the species and their concentration, the reactortype used in the different stages of the process and the conditions
under which these stages operate. All these factors affect the chemical
and mineralogical characteristics of the smelting dusts, thus explaining their variability and, consequently, the processes chosen for their
treatment, which is based on the recovery of valuable elements and
the stabilization of undesirable elements present in the dusts (Biswas
and Davenport, 1976).
The treatment of ue dusts has been extensively studied by several
authors. The processes put forward or implemented at the pilot and/
or industrial scale, according to the reasons indicated, include:
roasting of the dusts and leaching (Sumitomo Metal Mining, 1982;
Yin et al., 1992; Mulale et al., 1999; Gorai et al., 2002), smelting and
leaching (Hanks et al., 1979; Smirnov et al., 1984; Zhang et al., 1992),
roasting (Carter et al., 1994; Fu et al., 2000), and smelting (Ermakov,
1979; Yu, 1987; Mochida and Iida, 1988). However, most studies focus
Corresponding author.
E-mail address: roca@ub.edu (A. Roca).
0304-386X/$ see front matter 2010 Elsevier B.V. All rights reserved.
doi:10.1016/j.hydromet.2010.09.001
149
Table 1
Chemical composition of the sample (XRF).
Element
Cu
Fe
As
Zn
Pb
Mo
Bi
Cd
Ca
% weight
27
11
7.5
13
5.8
1.5
0.54
0.21
0.16
0.52
The moisture of the sample as received was less than 0.5%. Table 1
shows the characterization by XRF of this material. The major
elements were copper, iron, sulfur, zinc and arsenic.
The XRD characterization of the ue dust sample is shown in
Table 2 and Fig. 1. These results show the complexity of copper ue
dusts. They consist mainly of oxidized species and a few sulde
species. The sample showed a background that indicates the presence
of amorphous species, which were not identiable by XRD.
In the copper ue dust sample, spherical-shaped particles and
other irregular ones with particle sizes from tens of micrometers to
one micrometer are found (SEM-SE). Fig. 2 shows SEM images of a
complex particle (50 m size); image (A) was obtained with SEM-SE
and image (B) with SEM-BSE (backscattered electrons).
In the BSE image (Fig. 2B), the darkest part of the particle
corresponds to a cuprospinel phase. According to several EDS analysis
carried out, the spinel phase contains variable amounts of zinc. The
bright particles in the zone of cuprospinel crystals are copper oxides
(EDS analysis). The particles of sizes between 12 m were also
analyzed by SEM-EDS. Some of the particles analyzed are arsenic-rich
particles.
A complex particle ( 60 m size) is shown in Fig. 3. Image (A) was
obtained with SEM-SE and image (B) with SEM-BSE. According to the
analyses carried out by SEM-EDS, the upper part of the particle (1)
consists of a copper sulde, and the lower part (2), of iron and oxygen,
probably magnetite. Between the magnetite crystals, a vitreous iron
silicate phase appears.
3.2. Water leaching of the copper smelter ue dust sample
The water leaching process of copper smelter ue dust was carried
out at a solid-liquid ratio of 1/5 (weight/volume) for 1 h and at a
stirring rate of 700 min1. Table 3 shows the changes in acidity and
temperature during leaching with water.
The amount of dusts dissolved was of 54 wt.%. Preliminary
experiments indicated that the main part of the solids dissolved
were in the rst 5 min, that corresponds to the copper and zinc sulfate
dissolution. pH diminishes from the initial value of 6.10 to 2.80. The
process was exothermic, increasing the temperature by 9 C. Table 4
Table 2
Mineralogical characterization of the copper smelter ue dust (XRD).
Main components
Minor components
Magnetite Fe3O4
Cuprospinel CuFe2O4
Chalcocyanite CuSO4
Zincosite ZnSO4
Dolerofanite CuOCuSO4
Claudetite As4O6
Tenorite CuO
Arsenolite As4O6
Enargite Cu3AsS4
Delafossite CuFeO2
150
Fig. 1. X-ray diffractogram of copper smelter ue dust: (1) cuprospinel, (2) chalcocyanite, (3) dolerofanite, (4) delafossite, (5) zincosite, (6) claudetite, (7) arsenolite, (8) tenorite,
(9) enargite.
151
Table 5
Chemical composition of the precipitates formed in ltrate after leaching with water.
Time (min)
pH
T(C)
Precipitate
0
0.5
15
30
45
60
6.10
3.15
2.98
2.91
2.80
26
35
31
29
27
25
Amorphous
Crystals
Fe
As
Zn
Pb
Mo
Bi
R (%)
S (gL1)
17
27
20
1.0
0.20
17
19
1.4
5.1
4.7
2.5
0.013
0.82
0.38
Fe
Cu
As
Ca
100
80
60
40
20
0
Mass
Elements
29.70.9
Distribution (%)
Lead also remains in the residue. The copper dissolved is in the form of
copper sulfate and dolerofanite. Copper also appears in the residue as
cuprospinel, some residual suldes and copper oxides. Zinc sulfate
was dissolved, partially remaining in the residue as spinel. Arsenic
was partially dissolved from arsenic oxides. A lot of sulfur is in the
form of soluble sulfates, shown by sulfur dissolving to a high degree.
The presence of different species in the residues was conrmed by
XRD, Fig. 5.
% O
Cu
Fe
Zn
residue
As
solution
Pb
152
Fig. 5. X-ray diffractogram of residue after water leaching: (1) cuprospinel, (2) arsenolite, (3) claudetite, (4) scorodite, (5) enargite.
Extraction (%)
70
60
50
40
30
20
10
0
Cu
Fe
water
Zn
nitric acid
As
sulfuric acid
Pb
hydrochloric acid
Composition (%weight)
Cyclosizer distribution
30
residue with sulfuric acid (0.1 M) additionally dissolved 2.9, 1.5 and
0.2 g L1 of these elements, respectively.
Concentration of copper in coarse fractions by hydrocyclone was not
well achieved. This is different to the behavior detected in a previous
work (Morales et al., 2007). There was not detected signicant
amounts of residual suldes in the coarse fraction of the dusts
generated in the ash furnace, as was previously detected in ue
dusts from the continuous furnace; and probably due to the
different furnaces used in both cases and the corresponding
operating conditions.
Mixtures of residues from the treatment of copper smelter ue dust
with sludge from a paper factory subjected to the standard leaching
test, released between 1.43.5 ppm Cu, less than 0.50 ppm As, and
less than 0.20 ppm Zn, whereas the residue from sulfuric acid
leaching released 1.7 ppm Cu, 19 ppm As and b 0.20 ppm Zn.
Consequently, the process to be proposed for the treatment of
copper ash smelter ue dusts can include the following steps:
1) Leaching the dusts with sulfuric acid 0.1 M (63% solids are
dissolved). From the solutions generated, copper can be
recovered by cementation. However, to prevent possible
problems of arsine formation during this step, solvent
extraction followed by electrowining is an alternative method
for recovering copper and zinc, leaving arsenic in solution.
After this, dissolved arsenic can be precipitated from the
resulting solutions by one of several well-established systems,
such as precipitation of crystalline or amorphous iron
arsenate (Dutrizac and Jambor, 1988; Vircikova et al., 1995)
or processes such as arsenic precipitation as beudantite or
alunite structures (Vials et al., 2010; Dutrizac et al., 1987;
Dutrizac & Jambor, 1987; Twidwell and Mehta, 1985). After
this, zinc can be recovered by precipitation.
25
Table 6
Distribution of the different size fractions obtained by cyclosizer.
20
15
10
5
0
> 44 > > 33 > > 23 >
>6>
> 12 >
Global
Fractions (micrometer)
Cu
Fe
Zn As
Fig. 7. Chemical composition of the different size fractions obtained by cyclosizer (XRF).
Mass
Fe
Cu
Zn
As
T1+
T1-
T2+
T2-
T3+
T3-
T4+
T4-
T5+
T6
N 44
b 44
N 33
b 33
N 23
b23
N16
b16
N12
b12
9
9
8
7
7
91
91
92
93
93
13
14
11
10
9
87
86
89
90
91
19
20
16
16
13
81
80
84
84
87
27
30
24
26
18
73
70
76
74
82
34
39
32
35
23
66
61
68
65
77
153
Table 7
DIN 38414-S4 test conditions applied to the samples R1, R2, R3, and R4.
Sample
R1
R2
R3 (60/40)
R4 (80/20)
pH
( N 2 mm)
( b 0.1 mm)
( N 2 mm)
( b 0.1 mm)
7.10
7.43
7.40
7.35
7.80
7.70
Conductivity
(mS m1)
0.680
0.600
0.600
0.625
0.210
0.250
Cu
Pb
Zn
Ni
As
Cr
b0.040
b0.040
b0.040
b0.040
b0.040
b0.040
1.7
3.0
3.2
3.5
1.4
2.1
0.80
b0.40
b0.40
b0.40
b0.40
b0.40
b 0.25
b 0.25
b 0.25
b 0.25
b 0.25
0.13
b 0.10
b 0.10
b 0.10
b 0.10
b 0.10
0.10
19
b 0.20
0.20
b 0.20
0.40
0.55
b0.020
b0.020
b0.020
b0.020
b0.020
b0.020
4. Conclusions
The copper ue dust sample consists mainly of oxidized species
and a few sulde species. The main components are magnetite,
cuprospinel, chalcocyanite, zincosite, dolerofanite and claudetite. The
minor components are tenorite, delafossite, arsenolite and enargite.
The amount of dusts dissolved in water was 54%. Almost all the
iron remains in the residue (like magnetite and cuprospinel). Copper
dissolves as copper sulfate and dolerofanite, and remains in the
residue as cuprospinel, some residual suldes and copper oxides. Zinc
sulfate was dissolved, with zinc remaining in the residue as spinel.
Arsenic was partially dissolved from arsenic oxides. Almost all the
sulfur dissolved is as soluble sulfates.
Treatments of the residues after leaching with water in various
acid media, increases the extraction of copper and arsenic, slightly
increases the extraction of zinc, while almost all the iron remains in
the residue. Dissolution of copper corresponds to its oxides and
perhaps additional amounts of copper basic sulfates; therefore,
additional amounts of arsenic oxides were dissolved. Residues
generated after acid treatments consist basically of magnetite and
cuprospinel.
In the cyclosizer experiments, copper composition is homogeneous in almost all the fractions (17% Cu), iron and arsenic are also
homogeneous in all the fractions ( 25% Fe, 19% As) except in the
nest fraction (19% Fe, 26% As), and zinc is concentrated in the middle
fractions (6.46.8% Zn).
The leaching DIN 38414-S4 test over the residue after sulfuric acid
leaching indicated low elements dissolution, with the exception of
arsenic (19 ppm). The mixture of the former residue and sludge
shows a good stabilization. Samples b 12 from hydrocyclone mixed
with sludge at different proportions also indicates a good stabilization,
and this process can be considered chemical in nature because the
results obtained in the fractions N2 mm and b0.1 mm were almost the
same. All these materials could be dumped without generating major
environmental problems.
Acknowledgments
We are grateful to the Serveis Cienticotcnics de la Universitat
de Barcelona for their assistance in the characterization studies
developed in this work. Thanks are also due to Ms. Esther Vilalta and
Ms. Gemma Garcia for their assistance with the microscopy studies.
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