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

A Review of the Influence of Copper Slag on the Properties of Cement-Based Materials

Global copper slag (CS) emissions reached 57.2 million tons in 2021. Despite the increasing reuse of CS, the treatment of CS is still dominated by landfill so far, which not only occupies land resources but also causes damage to the environment. The application of CS to cement-based materials (CBMs) is one of the main approaches to its comprehensive utilization and has important economic and social implications. This article reviews the physicochemical properties, activity excitation, and heavy metal leaching properties of CS and summarizes the effect of CS on the working properties, mechanical properties, and durability of CBMs. At the end of the article, the existing problems in the research are analyzed, and the development trend is proposed, which provides technical guidance and reference for further research and application of CS in CBMs in the future.

Reduction Kinetics of Copper Slag by H2

In order to maximize the utilization value of copper slag, a process of smelting copper–iron alloy with copper slag is proposed here. The reduction kinetics of copper slag by H2 are studied in this paper. The main phases of the copper slag were Fe2SiO4 and Fe3O4. The suitable conditions of reduction were a temperature of 1373.15 K, a H2 partial pressure of 40%, and a calcium oxide addition amount of 30%. In these conditions, the metal reduction ratio was 85.12%. The copper slag, after reduction, was heated to 1773.15 K for 4 h. The content of iron in the metal was 85.11%, and the copper content was 10.40%. According to the unreacted nuclear model, the reduction process of copper slag is controlled by internal diffusion and chemical reaction. With the increase of the reduction ratio, internal diffusion is the main influencing factor. The activation energy of H2 reduction copper slag is 29.107~36.082 kJ/mol, which decreases gradually with the H2 partial pressure’s increase. The metal obtained by copper slag reduction contains a certain amount of sulfur, and a desulfurization process is required before it is used.

Value-added strategies for the sustainable handling, disposal, or value-added use of copper smelter and refinery wastes

Metallurgical plants constituting of smelters and refineries recover metals (i.e., copper) from mineral deposits. Copper production generates several waste streams of which slag, sludge and dust are generated in the largest quantities. The need to eliminate or at least reduce their adverse effects on the environment call for developing methods for recovering valuable components such as copper, zinc and iron through their selective separation from toxic components present in the waste (mainly arsenic and lead). This can be achieved through hydrometallurgical methods (leaching with organic and inorganic media), techniques facilitating mobility of elements (roasting with leaching) and biological processes (bioleaching). The valorization of metallurgical waste as a source of fertilizer micronutrients can be a sustainable and value-added direction of its management. This review presents ways of useful-metals recovery from the copper smelter and refinery wastes, including selective separation of valuable metals. The novelty of this review is a demonstration of the application potential of recovered components from metallurgical waste in the agricultural sector.

The Fabrication of Calcium Alginate Beads as a Green Sorbent for Selective Recovery of Cu(Ⅱ) from Metal Mixtures

Calcium alginate (CA) beads as a green sorbent were easily fabricated in this study using sodium alginate crosslinking with CaCl2, and the crosslinking pathway was the exchange between the sodium ion of α-L-guluronic acid and Ca(II). The experimental study was conducted on Cu(II), Cd(II), Ni(II) and Zn(II) as the model heavy metals and the concentration was determined by inductively coupled plasma optical emission spectrometry (ICP-OES). The characterization and sorption behavior of the CA beads were analyzed in detail via using scanning electron microscopy (SEM), fourier transform infrared spectroscopy (FTIR) and X-ray photoelectron spectroscopy (XPS). The adsorption experiments demonstrated that the CA beads exhibited a high removal efficiency for the selective adsorption of Cu(II) from the tetra metallic mixture solution and an excellent adsorption capacity of the heavy metals separately. According to the isotherm studies, the maximum uptake of Cu(II) could reach 107.53 mg/g, which was significantly higher than the other three heavy metal ions in the tetra metallic mixture solution. Additionally, after five cycles of adsorption and desorption, the uptake rate of Cu(II) on CA beads was maintained at 92%. According to the properties mentioned above, this material was assumed to be applied to reduce heavy metal pollution or recover valuable metals from waste water.

Structure and performance properties of environmentally-friendly biocomposites based on poly(ɛ-caprolactone) modified with copper slag and shale drill cuttings wastes

The potential application of two types of industrial wastes, drill cuttings (DC) and copper slag (CS), as silica-rich modifiers of poly(ɛ-caprolactone) (PCL) was investigated. Chemical structure and physical properties of DC and CS fillers were characterized using X-ray diffractometer, X-ray fluorescence spectroscopy, particle size and density measurements. PCL/DC and PCL/CS composites with a variable content of filler (5 to 50 parts by weight) were prepared by melt compounding in an internal mixer. It was observed that lower particle size of DC filler enhanced processing of biocomposites comparing to CS filler. Smaller particles of DC filler and thus the higher specific surface area, enabled better encapsulation of filler by polymer chains, hence lower porosity and consequently higher tensile properties comparing to PCL/CS biocomposites. It was noticed, that the impact of waste filler characteristics on tensile properties became negligible at higher loadings. This indicates weak interactions between waste filler and PCL matrix, due to aggregation of filler particles and formulation of voids in phase boundary. This phenomenon was confirmed by scanning electron microscopy, headspace analysis and thermogravimetric analysis. Microbial tests revealed that prepared biocomposites show no toxic effect towards analyzed bacterial strains, therefore could be considered as environmentally-friendly.

The mechanisms of heavy metal immobilization by cementitious material treatments and thermal treatments: A review

Safe disposal of solid wastes containing heavy metals is a significant task for environment protection. Immobilization treatment is an effective technology to achieve this task. Cementitious material treatments and thermal treatments are two types of attractive immobilization treatments due to that the heavy metals could be encapsulated in their dense and durable wasteforms. This paper discusses the heavy metal immobilization mechanisms of these methods in detail. Physical encapsulation and chemical stabilization are two fundamental mechanisms that occur simultaneously during the immobilization processes. After immobilization treatments, the wasteforms build up a low permeable barrier for the contaminations. This reduces the exposed surface of wastes. Chemical stabilization occurs when the heavy metals transform into more stable and less soluble metal bearing phases. The heavy metal bearing phases in the wasteforms are also reviewed in this paper. If the heavy metals are incorporated into more stable and less soluble metal bearing phases, the potential hazards of heavy metals will be lower. Thus, converting heavy metals into more stable phases during immobilization processes should be a common way to enhance the immobilization effect of these immobilization methods.

Recycling of inorganic waste in monolithic and cellular glass-based materials for structural and functional applications

The stabilization of inorganic waste of various nature and origin, in glasses, has been a key strategy for environmental protection for the last decades. When properly formulated, glasses may retain many inorganic contaminants permanently, but it must be acknowledged that some criticism remains, mainly concerning costs and energy use. As a consequence, the sustainability of vitrification largely relies on the conversion of waste glasses into new, usable and marketable glass-based materials, in the form of monolithic and cellular glass-ceramics. The effective conversion in turn depends on the simultaneous control of both starting materials and manufacturing processes. While silica-rich waste favours the obtainment of glass, iron-rich wastes affect the functionalities, influencing the porosity in cellular glass-based materials as well as catalytic, magnetic, optical and electrical properties. Engineered formulations may lead to important reductions of processing times and temperatures, in the transformation of waste-derived glasses into glass-ceramics, or even bring interesting shortcuts. Direct sintering of wastes, combined with recycled glasses, as an example, has been proven as a valid low-cost alternative for glass-ceramic manufacturing, for wastes with limited hazardousness. The present paper is aimed at providing an up-to-date overview of the correlation between formulations, manufacturing technologies and properties of most recent waste-derived, glass-based materials. © 2016 The Authors. Journal of Chemical Technology & Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry.

Pre-treatment and conditioning of chabazites followed by functionalization for making suitable additives used in antimicrobial ultra-fine powder coated surfaces

Durability of functionalized chabazite containing ultrafine powder coated surface.

Magnetic Glass Ceramics by Sintering of Borosilicate Glass and Inorganic Waste

Ceramics and glass ceramics based on industrial waste have been widely recognized as competitive products for building applications; however, there is a great potential for such materials with novel functionalities. In this paper, we discuss the development of magnetic sintered glass ceramics based on two iron-rich slags, coming from non-ferrous metallurgy and recycled borosilicate glass. The substantial viscous flow of the glass led to dense products for rapid treatments at relatively low temperatures (900–1000 °C), whereas glass/slag interactions resulted in the formation of magnetite crystals, providing ferrimagnetism. Such behavior could be exploited for applying the obtained glass ceramics as induction heating plates, according to preliminary tests (showing the rapid heating of selected samples, even above 200 °C). The chemical durability and safety of the obtained glass ceramics were assessed by both leaching tests and cytotoxicity tests.

Leaching behaviour and mechanical properties of copper flotation waste in stabilized/solidified products

This research describes the investigation of a cement-based solidification/stabilization process for the safe disposal of copper flotation waste and the effect on cement properties of the addition of copper flotation waste (CW) and clinoptilolite (C). In addition to the reference mixture, 17 different mixtures were prepared using different proportions of CW and C. Physical properties such as setting time, specific surface area and compressive strength were determined and compared to a reference mixture and Turkish standards (TS). Different mixtures with the copper flotation waste portion ranging from 2.5 to 12.5% by weight of the mixture were tested for copper leachability. The results show that as cement replacement materials especially clinoptilolite had clear effects on the mechanical properties. Substitution of 5% copper flotation waste for Portland cement gave a similar strength performance to the reference mixture. Higher copper flotation waste addition such as 12.5% replacement yielded lower strength values. As a result, copper flotation waste and clinoptilolite can be used as cementitious materials, and copper flotation waste also can be safely stabilized/solidified in a cement-based solidification/stabilization system.

Utilization of flotation wastes of copper slag as raw material in cement production

Copper slag wastes, even if treated via processes such as flotation for metal recovery, still contain heavy metals with hazardous properties posing environmental risks for disposal. This study reports the potential use of flotation waste of a copper slag (FWCS) as iron source in the production of Portland cement clinker. The FWCS appears a suitable raw material as iron source containing >59% Fe(2)O(3) mainly in the form of fayalite (Fe(2)SiO(4)) and magnetite (Fe(3)O(4)). The clinker products obtained using the FWCS from the industrial scale trial operations over a 4-month period were characterised for the conformity of its chemical composition and the physico-mechanical performance of the resultant cement products was evaluated. The data collected for the clinker products produced using an iron ore, which is currently used as the cement raw material were also included for comparison. The results have shown that the chemical compositions of all the clinker products including those of FWCS are typical of a Portland cement clinker. The mechanical performance of the standard mortars prepared from the FWCS clinkers were found to be similar to those from the iron ore clinkers with the desired specifications for the industrial cements e.g. CEM I type cements. Furthermore, the leachability tests (TCLP and SPLP) have revealed that the mortar samples obtained from the FWCS clinkers present no environmental problems while the FWCS could act as the potential source of heavy metal contamination. These findings suggest that flotation wastes of copper slag (FWCS) can be readily utilised as cement raw material due to its availability in large quantities at low cost with the further significant benefits for waste management/environmental practices of the FWCS and the reduced production and processing costs for cement raw materials.

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.

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.