Leaching and selective copper recovery from acidic leachates of Três Marias zinc plant (MG, Brazil) metallurgical purification residues.

Zinc plant purification residue (ZPR), a typical Zn-hydrometallurgical waste, was collected from the Três Marias Zn plant (MG, Brazil). ZPR was characterized for its metal content and fractionation, mineralogy, toxicity and leachability. Toxicity characteristics leaching procedure (TCLP) and European Community Bureau of Reference (BCR) sequential extraction results revealed that this ZPR displays high percentages of metals (Cd, Cu, Zn and Pb) in the highly mobilizable fractions, increasing its hazardous potential. Bulk chemical analysis, pH dependent leaching and acid (H2SO4) leaching studies confirm that the ZPR is polymetallic, rich in Cd, Cu and Zn. The sulfuric acid concentration (1 M), agitation speed (450 rpm), temperature (40 °C) and pulp density (20 g L(-1)) were optimized to leach the maximum amount of heavy metals (Cd, Cu and Zn). Under optimum conditions, more than 50%, 70% and 60% of the total Cd, Cu and Zn present in the ZPR can be leached, respectively. The metals in the acid leachates were investigated for metal sulfide precipitation with an emphasis on selective Cu recovery. Metal sulfide precipitation process parameters such as initial pH and Cu to sulfide ratio were optimized as pH 1.5 and 1:0.5 (Cu:sulfide) mass ratio, respectively. Under optimum conditions, more than 95% of Cu can be selectively recovered from the polymetallic ZPR leachates. The Cu precipitates characterization studies reveal that they are approximately 0.1 µm in diameter and mainly consist of Cu and S. XRD analysis showed covellite (CuS), chalcanthite (CuSO4·5H2O) and natrochalcite (NaCu2(SO4)2(OH)·H2O) as the mineral phases. ZPRs can thus be considered as an alternative resource for copper production.

Fractionation and leachability of heavy metals from aged and recent Zn metallurgical leach residues from the Três Marias zinc plant (Minas Gerais, Brazil).

Various mineral processing operations to produce pure metals from mineral ores generate sludges, residues, and other unwanted by-products/wastes. As a general practice, these wastes are either stored in a reservoir or disposed in the surrounding of mining/smelting areas, which might cause adverse environmental impacts. Therefore, it is important to understand the various characteristics like heavy metal leaching features and potential toxicity of these metallurgical wastes. In this study, zinc plant leach residues (ZLRs) were collected from a currently operating Zn metallurgical industry located in Minas Gerais (Brazil) and investigated for their potential toxicity, fractionation, and leachability. Three different ZLR samples (ZLR1, ZLR2, and ZLR3) were collected, based on their age of production and deposition. They mainly consisted of Fe (6-11.5 %), Zn (2.5 to 5.0 %), and Pb (1.5 to 2.5 %) and minor concentrations of Al, Cd, Cu, and Mn, depending on the sample age. Toxicity Characteristic Leaching Procedure (TCLP) results revealed that these wastes are hazardous for the environment. Accelerated Community Bureau of Reference (BCR) sequential extraction clearly showed that potentially toxic heavy metals such as Cd, Cu, Pb, and Zn can be released into the environment in high quantities under mild acidic conditions. The results of the liquid-solid partitioning as a function of pH showed that pH plays an important role in the leachability of metals from these residues. At low pH (pH 2.5), high concentrations of metals can be leached: 67, 25, and 7 % of Zn can be leached from leach residues ZLR1, ZLR2, and ZLR3, respectively. The release of metals decreased with increasing pH. Geochemical modeling of the pH-dependent leaching was also performed to determine which geochemical process controls the leachability/solubility of the heavy metals. This study showed that the studied ZLRs contain significant concentrations of non-residual extractable fractions of Zn and can be seen as a potential secondary resource for Zn.