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Waste Treatment and Utilization
in Heavy Metal Metallurgy
Jiang Kaixi
BGRIMM
Apr. 12-13, 2012, Santiago, Chile 1
M2R2
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19.17 million
tons
34.24 million
tons
46 million
tons
2006 2011 2015
Introduction
Production of top ten non-ferrous metals in China
Ranking the position 1 for 9 years in the world;
34.24 million tons in 2011;
Forecasting: 46 million tons in 2015.
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Introduction
800 mil t waste water discharged
into environment in 2011;
220 kt dust in off-gas emission
annually.
310 mil t solid waste annually.
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About BGRIMM
Founded in 1956, ca. 3800 employees, but only 1000 professionals;
A state-owned enterprise administrated by SASAC – the State
Asset Supervision and Administration Commission.
A main Chinese technology supplier of innovative technologies,
technical and engineering service in mining and metallurgy for
nonferrous metals.
Research & Development
Consulting & Engineering
Manufacturing
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R&D
Mining Engineering
Explosives & Blasting
Engineering
Mineral Engineering
Metallurgy Engineering & Recycling
Materials
Machinery
Environmental
Engineering
Resources Evaluation
& Mineralogy
Online Instruments
& Automation
Chemical Analysis
BGRIMM’S
R&D
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Metallurgy Department
Pyro- and hydrometallurgy
Copper bath smelting (a side-blown) technology;
Lead flash smelting;
Fluidized-bed roasting for zinc, cobalt pyrite and arsenic containing gold concentrates, etc.
Direct reduction iron;
Process R&D for nickel laterite; Leaching (pressure, heap, tank leaching); SX and ion exchange; EW and electrolysis; Slurry electrolysis;
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Valuable metals comprehensive recovery like rare metal
extraction of metallurgical flow-sheets; Waste treatment and utilization; Oceanic mineral resource metallurgy; Secondary metal resource recycling; Recycling of PGMs in BGRIMM-Xuzhou Institute of Metal
Recycling.
Metallurgy Department
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Solid wastes’ utilization
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Copper metallurgy
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Copper Metallurgy
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Slag treatment:
Dressing is the trend
-- Flotation: also for smelting slags
from Flash furnace and local
smelting processes
-- High copper recovery;
-- Low energy consumption;
-- Cost: about 2-2.5kg Cu per 1t
slag;
-- Magnetite from converting slags
(50-55% Fe in iron conc. ).
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Copper industry
11 Copper concentrates Tailing
Slag
Size: 80% -0.074mm
Size: 80% -0.038mm
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Copper industry
Practice in Guixi Smelter of Jiang Copper:
Copper slag: Cu 1.82%, Fe 40.98%, Pb 0.85%, Zn 2.64%;
Copper grade in concentrate: 29.93%;
Copper recovery: 87.48%;
Copper in tailings: 0.24%;
Operation cost: 100 RMB/t slag, total cost ca. 2kg copper.
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Copper industry
Arsenic waste treatment:
More than 10kt arsenic goes into copper smelter every year in
China;
About 60% arsenic goes into SO2 gas;
Arsenic wastes: (1) Arsenic sulphide residue, 15-25% As
(2) Flue dust, 0.1-4% As
(3) Black copper slime, 20-25%As
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BGRIMM developed
Pressure Leaching Technology
2As2S3+ 6H2O+5O2= 6S+4H3AsO4
2CuS+2H2SO4+O2= 2S + 2CuSO4 + 2H2O
Low operation cost;
High metal recovery;
Cleaning process/Environmental
friendly;
Cu\As\Bi\Re\Ag\Au\S recovery.
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Copper industry
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Copper industry
Pressure leaching plant for arsenic sulfide cake
This technology was adopted in Guixi Smelter to replace copper
sulfate cementation process (Sumitomo process). It was
commissioned in 2008.
• Capacity: 2000t-As2O3/a
• Recovery:
As >95% into
product,
Cu >95%,
Re >90%
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Copper industry
BGRIMM also
developed the process
to treat arsenic
sulphide cake and
black copper mud for
Tongling Copper
Smelter.
It is becoming a
standard process for
copper smelters.
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Copper industry
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Recovery of rare and precious metals from
flue dusts and anode slimes
-- Mo, Re, Ge, In from dusts;
-- Se and Te from anode slimes;
-- Au, Ag and PGMs from anode slimes;
-- Sb, Bi from both.
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Copper industry
Pressure leaching
In XiangGuang Copper, the
anode slime treatment
capacity is 2400t/a.
Guixi and Tong Ling Kaldo
process was put into
production in 2009, with
anode slime treatment
capacity 4000t/a.
The recovery of Au and Ag is
over 99%.
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Copper industry
Crude selenium
To produce Se or SeO2
Copper telluride
Process: alkaline leaching --
neutralization -- electrolysis
Products: refined Te
Recovery: Te >92%
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Zinc metallurgy
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Zinc industry
Problems of the Jarosite process
Large quantity residues;
High zinc lost;
Instability and potential pollution.
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30 million tons piled
Contain 1.5 million tons
zinc (5%)
Rare metals>3000t
1 million tons
per year
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Zinc industry
First stage hot acid leaching solution
O2 Zinc concentrate
Pressure leaching
L/S
Residue Leaching solution
Go to lead smelter Recirculated to neutral leaching stage
BGRIMM developed
new process to avoid
producing jarosite
residue in zinc
metallurgy
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Zinc industry
Jarosite process Pressure leaching process
Output 100kt 130kt
Zinc recovery 90-92% 95%
Operation cost 4300RMB/tZn 4150RMB/tZn
Iron residue 70-80kt/a 30-35kt/a
Zinc in residue 6% 2-3%
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Zinc industry
Recovery of rare and precious metals:
Rotary kiln volatilization process in Zhuzhou and Laibin, etc.
Ge, In, Zn goes to dust;
Ga remains in slag;
Ge recovery less than 55%;
Ga recovery less than 10%;
Ag recovery less than 20%.
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Zinc industry
Indium recovery
BGRIMM developed
a indium recovery
process with iron
removal as hematite
Laibin Zinc Plant.
Recovery: Zn 96%,
In 87%.
Pilot test finished
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Zinc industry
SO2 reductive pressure leaching for recovery of Ga and Ge:
BGRIMM developed SO2 reductive leaching process to
recover Ga and Ge from zinc leaching residues:
Leaching conducted in autoclave at 105C;
Zn, Fe, Ga and Ge into leaching solution;
Pb and Ag remain in residue, Ag is enriched more than
2000g/t;
Fe3+ is less than 0.2g/L.
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Zinc industry
SO2 reductive leaching for recovery of Ga and Ge:
Ga and Ge precipitated by limestone;
SX for separation of Ga and Ge;
G315 was used as extractant produced by BGRIMM.
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Zinc industry
SO2 reductive leaching for recovery of Ga and Ge:
Recovery: Zn 90%, Ga 85%, Ge 78%, Pb 98%, Ag 99%;
Pb-Ag residue can be enriched more than 10 times;
Lab and pilot tests were finished by BGRIMM and Fankou
Lead and Zinc Mine.
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Zinc industry
Two stages pressure leaching for Ga and Ge recovery:
Low temperature and pressure leaching with weak oxiation at
First stage to reduce Fe3+ in solution
High teperature and pressure leaching to ensure zinc recovery
at second leaching stage
Precipitation Ga and Ge from first stage leaching solution
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Lead metallurgy
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Lead industry
Lead processes:
Sintering - blast furnace
ISP
Kivcet process
QSL process
SKS process
Ausmelt/ISA
Kaldo furnace
Hua Bao flash smelting (BGRIMM)
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Lead industry
Hua Bao flash smelting technology:
Developed by BGRIMM
Low capital and operation cost
Low energy consumption
Wide flexibility of raw materials
High metal recovery for Pb, Zn, Ag, etc.
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Lead industry
Pb and Zn combined smelter is a trend for metal recovery
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Zinc plant Lead smelter
Pb-Ag residue
Zinc leaching residue
Zinc dust
Pb/Zn/Ag/Au/Slag Zn/Pb/Cu/In
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Conclusions
Solid wastes treatment will become a focus after the problems
of gas, dusts and waste water are solved;
Joint technology by mineral process and metallurgy is the
trend for metal recovery from wastes;
Copper, lead and zinc complex smelter may be the trend for
interchange materials or wastes to recovery metals and reduce
slag and residues quantity;
Hazardous waste (arsenic, cadium residues, etc) should be
treated by advanced and clean process like pressure leaching;
Jarosite process should be replaced by pressure leaching;
Spent lead battery should be treated combined with lead
concentrate by advanced flash smelting process.