Iron recovery from copper-slag with lignite-based direct reduction followed by magnetic separation

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Μένθη Βουρδουμπάς
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1 Vol.21 No.5 The Chinese Journal of Nonferrous Metals May (2011) ( ) 39.96%( ) CaO 100:30: min 85% 43µm 92.05% 81.01% 30 µm TF09 X758 A Iron recovery from copper-slag with lignite-based direct reduction followed by magnetic separation YANG Hui-fen, JING Li-li, DANG Chun-ge (Civil and Environmental Engineering School University of Science and Technology Beijing, Beijing , China) Abstract: In order to recycle iron from copper slag with total iron content (TFe) of 39.96%(mass fraction), a technique with lignite-based direct reduction followed by magnetic separation was presented. After analysis of chemical composition and crystalline phase, according to experimental mechanism, the tests for studying the effects of different parameters on the recovery of iron were carried out. The results show that the optimum parameters are proposed as follows: the mass ratio of copper slag/lignite/cao is 100:30:10, the reduction temperature is 1 250, the time is 50 min, and the particle size of 85% roasted product is smaller than 43 µm, under which the direct reduction iron powders with TFe of 92.05% and iron recovery rate of 81.01% are obtained. After reduction, the fayalite (Fe 2 SiO 4 ) and magnetite (Fe 3 O 4 ) in copper slag are reduced to metallic iron. The metallic iron particles whose sizes are mainly larger than 30 µm, are loosely supported on the surface of slag particles. So the monomer dissociation of metallic iron particles is easily achieved by grinding, then the dissociated metallic iron particles are recovered via magnetic separation method. Key words: copper slag; direct reduction; grinding; magnetic separation; metallic iron 800 t Fe Cu Zn Pb Co Ni Au Ag Fe (TFe>27%) [1] [2] [3 5] [6] Cu Zn Pb Co [7 13] Fe Fe Fe (Fe 2 SiO 4 ) [14 17] Fe 3 O 4 Fe 2 O 3 [15, 18] Fe Fe Fe 2 SiO 4 Fe yanghf@ustb.edu.cn

2 Fe 3 O [16 17] 4 [16] [17] Fe 2 SiO 4 Fe 3 O 4 Fe 2 SiO 4 Fe Fe ~3 mm ARL-ADVANT XP X TFe Cu Zn Pb S P 0.12 m(cao+mgo)/m(al 2 O 3 +SiO 2 )= Table 1 Main chemical composition of received copper slag (mass fraction, %) TFe SiO 2 Al 2 O 3 CaO MgO Cu Pb Zn S P XRD Fig.1 XRD pattern of received copper slag Fe 2 SiO 4 Fe 3 O 4 [19] Fe 3O4 + 2C = 3Fe + 2CO2 (1) Fe2 SiO4 + 2C = 2Fe + SiO2 + 2CO (2) Fe2 SiO4 + CaO + 2C = CaSiO3 + 2Fe + 2CO (3) 2 (1) (2) (3) G Θ 1 XRD 1 Fe (Fe 2 SiO 4 ) (Fe 3 O 4 ) ( ) 37.09% 43.52% 13.18% 6.21% 0.19% CaO 2 (1)~(3) G Θ Fig.2 Relationship between standard free energy ( G Θ ) and temperature for reactions (1) (3) 1.2 Fe 2 SiO 4 Fe 3 O K Fe 3 O 4 Fe 3 O 4 FeO Fe Fe 2 SiO 4 298~1 600 K FeO 2 G Θ Fe 3 O 4 Fe 2 SiO K CaO Fe 2 SiO 4

3 Fe 2 SiO 4 Fe 2 SiO 4 Fe 3 O 4 Fe 2 SiO 4 CaO Fe 3 O 4 Fe 2 SiO g CaO 111 ka/m (4) Fe Fe R Fe =w(fe r )m r /[w(fe s )m s ] (4) R Fe Fe w(fe r ) Fe m r w(fe s ) Fe 39.96% m s 100 g XRD CuK α 40 kv 100 ma 8( )/min 10º~100º 3 Fe Fig.3 Effects of lignite ratio on iron recovery rate Fe 2.2 CaO Fe 30% min (50% ) 43 µm CaO Fe ( ) CaO (CaO ) 2.1 Fe CaO 15% min (50% ) 43 µm Fe 3 3 Fe Fe 30% 4 CaO Fe Fig.4 Effects of CaO ratio on iron recovery rate 4 CaO Fe CaO Fe CaO CaO 10% CaO

4 Fe CaO 50 min CaO CaO Fe 2 SiO Fe 30% CaO 10% 40 min (50% ) 43 µm Fe 5 6 Fe Fig.6 Effects of reduction time on iron recovery rate 5 Fe Fig.5 Effects of reduction temperature on iron recovery rate 5 Fe Fe Fe 2 (1) (2) (3) G Θ Fe 3 O 4 Fe 2 SiO Fe 30% CaO 10% min Fe 7 7 Fe Fe Fe Fe Fe 85% 43 µm Fe 92.05% Fe 81.02% 2.4 Fe 30% CaO 10% (50% ) 43 µm Fe 6 6 Fe 7 Fe Fig.7 Effects of grinding rate( 43 µm) of boasting product on iron recovery rate

5 % CaO 10% min XRD 8 XRD 8 9 Fig.9 Microstructure of roasted product under optimized reduction conditions 8 XRD Fig.8 XRD pattern of roasted product under optimized reduction conditions µm 5 µm 10 XRD Fig.10 XRD pattern of obtained direct reduction iron powders 2 Table 2 Main chemical composition of obtained direct reduction iron powders(mass fraction, %) TFe SiO 2 Al 2 O 3 CaO MgO Cu Pb Zn S P XRD 10 2 Fe 4 1) Fe

6 % CaO 10% min (85% ) 43 µm Fe 92.05% Fe 81.02% 2) 30 µm REFERENCES [1],,,,,,. [J]., 2009(2): CAO Hong-yang, FU Nian-xin, WANG Ci-gong, ZHANG Li, XIA Feng-shen, SUI Zhi-tong, FENG Nai-xiang. Selective precipitation and separation of Fe components from copper smelting slags[j]. Multipurpose Utilization of Mineral Resources, 2009(2): [2] ALTER H. The composition and environmental hazard of copper slag in the context of the Basel convention[j]. Resources, Conservation and Recycling, 2005, 43(4): [3] SHI C J, MEYER C, BEHNOOD A. Utilization of copper slag in cement and concrete[j]. Resources, Conservation and Recycling, 2008, 52(10): [4] KHANZADI M, BEHNOOD A. Mechanical properties of high-strength concrete incorporating copper slag as coarse aggregate[j]. Construction and Building Materials, 2009, 23(6): [5] JABRI K S A, HISADA M, ORAIMI S K A, SAIDY A H A. Copper slag as sand replacement for high performance concrete[j]. Cement & Concrete Composites, 2009, 31(7): [6] KAMBHAM K, SANGAMESWARAN S, DATER S R, KURA B. Copper slag: optimization of productivity and consumption for cleaner production in dry abrasive blasting[j]. Journal of Cleaner Production, 2007, 15(5): [7] BANZA A N, GOCK E, KONGOLO K. Base metals recovery from copper smelter slag by oxidizing leaching and solvent extraction[j]. Hydrometallurgy, 2002, 67(1/3): [8] ARSLANA C, ARSLANA F. Recovery of copper, cobalt, and zinc from copper smelter and converter slag[j]. Hydrometallurgy, 2002, 67(1/3): 1 7. [9] RUDNIK E, BURZŃSKA L, GUMOWSKA W. Hydrometallurgical recovery of copper and cobalt from reduction-roasted copper converter slag[j]. Minerals Engineering, 2009, 22(1): [10] MAWEJA K, MUKONGO T, MUTOMBO I. Cleaning of a copper matte smelting slag from a water-jacket furnace by direct reduction of heavy metals[j]. Journal of Hazardous Materials, 2009, 164(2/3): [11] SARRAFI A, RAHMATI B, HASSANI H R, SHIRAZI H H A. Recovery of copper from reverberatory furnace slag by flotation[j]. Minerals Engineering, 2004, 17(3): [12] CARRANZA F, ROMERO R, MAZUELOS A, IGLESIAS N, FORCAT O. Biorecovery of copper from converter slag: Slag characterization and exploratory ferric leaching tests[j]. Hydrometallurgy, 2009, 97(1/2): [13],,. [J]., 2001, 11(2): DENG Tong, WEN Zheng, LIU Dong. Leaching of copper residue with oxygen in sulfuric acid with participation of chloride[j]. The Chinese Journal of Non ferrous Metals, 2001, 11(2): [14],. [J]., 2001, 11(5): DENG Tong, LING Yun-han. Process mineralogy of cobalt-bearing copper converter slag[j]. The Chinese Journal of Non ferrous Metals, 2001, 11(5): [15],. [J]., 2009, 18(2): HAN Wei, QIN Qing-wei. Recovery of copper and iron from copper slag[j]. Mining & Metallurgy, 2009, 18(2): [16],,,,. [J]., 2009(1): LIU Gang ZHU Rong WANG Chang-an WANG Zhen-zhou GAO Feng. Experiment of molten oxidation iron extraction in copper slag[j]. China Non ferrous Metals, 2009(1): [17],,,,,. [J]., 2009, 9(2): CAO Hong-yang, FU Nian-xin, ZHANG Li, XIA Feng-shen, SUI Zhi-tong, FENG Nai-xiang. Migration and precipitation behavior of Fe components in copper smelting slag[j]. The Chinese Journal of Process Engineering, 2009, 9(2): [18]. [J]., 2003, 13(2): WANG Heng. Recovery of copper and iron In the converter slag from a copper smelter[j]. Journal of Guangdong Non-ferrous Metals, 2003, 13(2): [19]. [M].. :, GUO Han-jie. Course of metallurgical physical chemistry [M]. 2nd ed. Beijing: Metallurgical Industry Press, ( )

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