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An Overview of Recovery of Metals From Slags
An Overview of Recovery of Metals From Slags
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Abstract
Various slags are produced as by-products in metallurgical processes or as residues in incineration processes. According to the
origins and the characteristics, the main slags can be classied into three categories, namely ferrous slag, non-ferrous slag and
incineration slag. This paper analysed and summarised the generation, characteristics and application of various slags, and discussed the potential eects of the slags on the environment. On this basis, a review of a number of methods for recovery of metals
from the slags was made. It can be seen that a large amount of slags is produced each year. They usually contain a quantity of valuable
metals except for blast furnace slag and they are actually a secondary resource of metals. By applying mineral processing technologies,
such as crushing, grinding, magnetic separation, eddy current separation, otation and so on, leaching or roasting, it is possible to
recover metals such as Fe, Cr, Cu, Al, Pb, Zn, Co, Ni, Nb, Ta, Au, and Ag etc. from the slags. Recovery of metals from the slags and
utilisation of the slags are important not only for saving metal resources, but also for protecting the environment.
# 2003 Elsevier Science Ltd. All rights reserved.
1. Introduction
Various slags are produced as by-products in metallurgical processes or as residues in incineration processes. According to the origins and the characteristics,
the main slags can be classied into three categories,
namely ferrous slag, non-ferrous slag and incineration
slag. Slags usually contain a quantity of valuable metals.
They are actually a secondary resource of metals, rather
than an end-waste and have been applied as a resource
material in many areas. In addition, for some applications, slags have comparable or even better properties
than their competitive materials. The third feature is
that some slags contain a notable amount of harmful or
heavy metals. The release of these metals may cause
environmental problems.
The conventional method for disposal of slags is
dumping. The increasing dump of slags not only occupies plenty of land, but also wastes resources and can
potentially have an impact on the environment due to
water pollution. Therefore, it is desirable to recover
metals from slags and to utilise the slags.
0956-053X/03/$ - see front matter # 2003 Elsevier Science Ltd. All rights reserved.
doi:10.1016/S0956-053X(02)00164-2
934
2. Ferrous slag
Table 1
Production of steel slag in the dierent countries
Country
Reference
Europe
USA
China
Japan
12
8
14.07
12.6
935
CaO
MnO
MgO
SiO2
P2O5
Al2O3
1420
1520
1828
2029
4555
4250
3040
2535
<5
<5
<6
<6
<3
58
48
815
1218
1215
1217
1015
<2
<2
<1.5
<1.5
<3
<3
47
47
NR
NR
NR
NR
17.5
15.2
44.3
38.0
5.3
6.0
6.4
6.0
13.8
19.0
NR
NR
1.5
7.0
0.07
0.38
China
BOF slag
1727
3448
1.56
2.510
915
0.9
0.92.8
0.2
USA
BOF slag
1530
4050
510
510
1015
13
NR
Country
Slag
Europe
BOF slag
BOF slag
EAF slag
EAF slag
Japan
NR=no report.
Table 3
Comparison of toxicity characteristic leaching procedure (TCLP) slag leachate concentrations to TCLP criteria
Metal (element)
Arsenic
Barium
Cadmium
Chromium (VI)
Chromium (total)
Lead
Mercury
Selenium
Silver
Exceed criterion?
BF
BOF
EAF
BF
BOF
EAF
0.0048
1.2
0.0054
0.026
0.22
ND
ND
ND
ND
0.0054
0.88
0.01
ND
0.04
0.015
0.0005
ND
0.029
0.011
1.67
0.037
0.018
1.0
0.063
0.00089
0.0073
0.027
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
ND=not detected.
a
From Method 1311 Toxicity Characteristic Leaching Procedure.
936
Table 4
Technical properties of steel slags, in comparison with natural aggregates
Property
Unit
BOF slag
EAF slag
Basalt
Granite
Bulk density
Resistance to impact determined on crushed aggregates (812 mm)
Absorption of water
Freeze/thaw resistance (particle size < 5 mm)
Los Angeles test (test aggregates: 812 mm)
Polished stone value (PSV)
Compressive strength
g/cm3
wt.%
wt.%
wt.%
wt.%
3.13.7
1026
0.21.0
< 1.0
918
5457
> 100
3.23.8
1026
0.21.0
<1.0
815
5863
>100
2.83.1
920
<0.5
<1.0
4555
>250
2.62.8
1227
0.31.2
0.82.0
1520
4555
>120
N/mm2
937
Ratio of utilization
Production
(103 t/year) (%)
Utilization
Unit
814
692
7.99
6.80
3316
32.57
124
1.22
1080
3960
10.61
38.89
10,181 9965
100
102.2
938
Table 6
Chemical composition of stainless steel slags
Table 8
Chemical analysis of leachates, ppm and EC50 values (mg/l)
Component
Element
CrTotal Pb
Cd
Fe
Mn Ni
Cu
EC50
pH
AOD
1.0
1.0
1.0
<5
<0.1
<0.1
<0.1
<1
<0.5
<0.5
<0.5
0.5
0.5
0.5
< 0.5
< 0.5
< 0.5
>3000
>3000
>3000
<3000
11.0
9.5
10.0
AOD slag
CaO
SiO2
Al2O3
MgO
MnO
FeTotal
Na2O
K2O
CrTotal
Cu
Ti
Zn
Pb
Ni
Cd
Free CaO
Loss on ignition
Basicity (CaO/SiO2)
47.60
31.24
1.66
3.65
1.60
1.75
0.08
0.05
3.47
0.05
0.13
0.02
0.05
0.25
<0.01
3.21
1.52
45.50
26.32
9.69
7.30
2.06
3.50
0.07
0.05
4.28
0.05
0.68
0.02
0.05
0.22
<0.01
0.51
1.75
45.50
27.61
1.65
7.30
1.41
7.40
0.03
0.05
2.48
0.12
0.20
0.03
0.04
0.45
<0.01
0.91
7.14
1.65
4
5
6
Standard
< 0.5
< 0.5
< 0.5
<5
<0.5
<0.5
<0.5
Table 7
Mineralogical composition of AOD slags
AOD slag
Element
Ca
Si
Al
Mg
Mn
Fe
Cr and Ni
Melilite
Merwinite
C2S
C2S.SiO2
Fluorite
Melilite
Merwinite
Ti-CaOxide
Melilite
Merwinite
C2S
C2S.SiO2
Calcite
Fluorite
Silicate
Melilite
Silicate
periclase
Chromites
Chromites
Chromites
Silicate
Melilite
Silicate
periclase
Chromites
Chromites
Chromites
Silicate
Melilite
Silicate
periclase
MgO.Cr2O3
Chromites
Chromites
a Fe
Chromites
939
Component (%)
Reference
FeTotal
SiO2
CaO
MgO
Al2O3
Cr
FeO: 4.0
27.8
7.0
29.2
23.8
812
37
2632
4548
37
29
34
940
stipulated by the World Health Organization for discharge into lakes and rivers (Coetzer et al., 1997). In
view of this fact, charge chrome slag may be also a
hazardous slag and care must be taken for the treatment
of this slag. Further disposal of the plant water from
wet treatment is necessary and dust control must be
strict in the dry processes.
3. Non-ferrous slag
There are a variety of non-ferrous slags produced
from non-ferrous smelters. Extensive studies on metal
recovery from non-ferrous slags have been carried out
for the past decades. Most of the studies were on metal
recovery from copper slag. Recently, attention was also
paid to the treatment of salt slag due to its rapid
increase and its serious eect on the environment. There
were also additional reports on recovery of Nb and Ta
from tin slag, Au and Ag from tin slag or other slags
and so on. Unlike iron and steel slags, the application of
non-ferrous slags may cause environmental concerns
since they usually contain a notable amount of heavy
metals or even toxic elements with a relatively high
solubility (Manz and Castro, 1997; Atzeni et al., 1996).
The reports on the application of non-ferrous slags are
relatively few.
3.1. Copper slag
3.1.1. Chemical and mineralogical composition of copper
slag
The chemical composition of copper slags from different origins is shown in Table 10. In general, the main
Table 10
Chemical composition of copper slags
Elements (%)
Slag 1
Slag 2
Slag 3
Slag 4
Slag 5
Slag 6
Slag 7
Cu
Co
Ni
Ag (ppm)
Pb
Zn
Fe
SiO2
Al2O3
CaO
MgO
Mn
Ti
S
As
2.60
0.36
0.045
NR
NR
0.425
52.0
NR
NR
NR
NR
NR
NR
4.90
NR
0.58
0.21
0.57
NR
NR
NR
38.6
Si: 17.40
Al: 2.51
Ca: 1.11
Mg: 1.65
0.03
0.15
0.93
NR
3.70
0.25
NR
2
0.18
0.44
49.99
22.45
1.14
NR
NR
NR
NR
1.56
0.05
1.22
NR
NR
NR
NR
NR
32.24
NR
NR
NR
NR
NR
NR
NR
NR
2.753.30
0.50.7
0.91.2
NR
NR
NR
4548
2426
NR
NR
NR
NR
NR
NR
NR
20.7
NR
NR
NR
1.33
11.35
NR
NR
NR
NR
NR
NR
NR
NR
NR
0.63.2
NR
NR
NR
NR
NR
32.737.3
32.537.3
2.44.0
1.87.5
1.64.0
NR
NR
0.51.0
NR
Slag 1: Converter slag from Ergani Mining Co., Turkey (Altundogan and Tumen, 1997). Slag 2: Slowcooled slag from INCOs ash smelting
furnace in Sudbury, Ontario, Canada (Gbor et al., 2000). Slag 3: Converter slag from Mount Isa copper smelter, Australia (Barnes et al., 1993). Slag
4: Reverberatory slag from Remet Division, Chile (Herreros et al., 1998). Slag 5: Converter slag (CS(iii)) from Ghatsila copper plant, India (Rao
and Nayak, 1992). Slag 6: Brass smelting slag from EIMaady Co. for Engineering Industries, Cairo, Egypt (Basir et al., 1999). Slag 7: Copper slag,
Czechoslovakia (Vircikova and Molnar, 1992). NR: no report.
941
Cu2 O H2 S *
) Cu2 S H2 O
2Cu H2 S 1=2O2 *
) Cu2 S H2 O
Co3 X4 4 H2 S *
) 3 CoS S 4 H2 X
942
M 1=2 O2 *
) MO
MS 3=2 O2 *
) MO SO2
MO SO3 *
) MSO4
2MO SO3 *
) MOMSO4
MO Fe2 O3 *
) MOFe2 O3
10
Na
Si
Mg
Ca
Fe
24.08 21.89 7.47 3.69 2.83 1.07 0.71 0.60 0.50 0.13
Table 12
Mineralogical composition of salt slag
Mineral
wt.%
Al metal
AlN
Al4C3
Al2S3
MgO.Al2O3
Al2O3
bCaO.SiO2
SiO2
Na2O.SiO2
K2O.SiO2
NaCl
KCl
FeSi
7.25
2.10
2.40
0.20
16.59
7.68
2.68
1.85
4.30
0.48
41.92
4.66
0.75
11
12
13
14
15
943
944
Table 13
Variation in contents of Al component with calcinations temperature
Temperature ( C)
Component (wt.%)
Al metal
gAl2O3
aAl2O3
Al2O3.MgO
Al2O3Totala
Al4C3
Al2S3
AlN
a
500
700
1000
1200
1300
1500
3.70
20.37
20.92
25.74
67.30
1.40
0.19
0.36
2.70
24.66
27.69
25.74
70.40
0.60
0.20
0.30
1.50
9.25
46.50
30.42
76.20
0.40
0.06
0.10
0.95
5.45
47.48
31.59
77.30
0.18
0
0.07
0.90
0.38
55.79
30.42
77.30
0.16
0
0.05
0.90
0.38
53.60
31.59
76.60
0.064
0
0.04
Al2O3Total=gAl2O3+aAl2O3+alumina in Al2O3.MgO.
Table 14
Chemical composition of the tin slag and leaching concentrates (wt.%)
Sample
Nb2O5
Ta2O5
SiO2
CaO
FeO
Al2O3
SnO2
MnO
K2O
TiO2
H2O
Slag
LGCa
HGCb
5.2
6.3
28.0
7.5
13.7
31.1
41.9
43.3
10.0
11.6
9.8
0.6
3.3
2.5
0.2
11.2
5.2
0.6
0.7
0.9
0.2
3.7
2.3
0.0
1.4
0.8
0.4
1.3
1.2
1.4
20
a
b
Lowgrade concentrate.
Highgrade concentrate.
945
Nb and Ta
recovery (%)
Purity of Nb and
Ta product
Conditions
Nb and Ta
recovery (%)
Purity of Nb and
Ta product
Conditions
LGC
1000 C, 24 h
Nb: 84 Ta: 65
1000 C, 24 h
1000 C, 24 h
HGC
4. Incineration slag
With an increase in municipal solid waste (MSW) and
landll cost, more and more MSW is treated by incineration. For example, in Switzerland, Japan, Germany,
France, Sweden and Denmark, 50% or more of the
unrecycled waste is being or will be incinerated (Hjelmar, 1996). Incineration reduces the volume of the
waste by approximately 90% and allows for recovery of
much of energy bound in the waste. But when incinerating 1 ton of MSW, 300350 kg incinerator bottom
residue, 035 kg lter dust and 540 kg residue from
ue-gas purication system are produced (Schmelzer,
1995). The increasing incineration of MSW will produce
a considerable amount of MSW incineration (MSWI)
residues which must subsequently be utilised or landlled. For instance, in Japan and Germany, 6 and 3
million tons of MSWI residues are produced respectively each year (Sakai and Hiraoka, 2000; Pretz and
Meier-Kortwig, 2000). Over recent years, several studies
have been reported on the treatment, utilisation and
metal recovery from MSWI slag, mostly in Germany
and Japan.
4.1. Characteristics of MSWI residue
Depending on the MSW incinerated, the composition
of MSWI residues varies with the origins. Hjelmar
(1996) summarised the ranges of composition of some
MSWI bottom ash (excluding the scrap metal portion
and the size fraction larger than 45 mm) and y ash, as
shown in Table 16. From the results, it can be seen that
in the incineration process Fe and Cu mainly remain in
4500 C 24 h
Table 16
Composition of MSWI residues
Component
Unit
Bottom ash
Fly ash
Si
Al
Fe
Ca
Mg
K
Na
Ti
S
Cl
P
Mn
Ag
As
Ba
Be
Cd
Co
Cr
Cu
Hg
Mo
Ni
Pb
Se
Sn
Sr
V
W
Zn
PAH
CB
PCB
CP
PCDD
PCDF
TCDD
TOC
LOI
g/kg
g/kg
g/kg
g/kg
g/kg
g/kg
g/kg
g/kg
g/kg
g/kg
g/kg
g/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
mg/kg
g/kg
g/kg
210290
4772
27150
6597
7.719
9.222
2241
3.27.2
1.38
1.23.2
2.913
<0.71.7
4.114
1980
9002700
Nd
1.440
<1040
230600
9004800
<0.013
2.540
60190
13005400
0.68
<1001300
170350
3690
<2050
18006200
0.232200
6.745
<40
1634
0.210
0.444.5
0.020.22
4.813
5.950
95190
4978
1835
74130
1119
2347
2257
7.512
1132
45101
4.89.6
0.81.7
3195
49320
9201800
Nd
250450
2969
140530
8601400
0.87
1549
92240
740019000
6.131
14001900
<80250
32150
Nd
1900041000
30110
50890
<40
1201800
115140
4869
1.52.5
4.917
1145
946
needs special treatments, such as vitrication by remelting and extraction using acid or other solvents. For
bottom ash, two disposal strategies were reported. In
the rst, it is processed mechanically and then used, for
example, in the construction of streets, roads, and dams.
In the second, more secure treatment, it is pre-processed
mechanically and then treated with vitrication in which
the organic contaminants are destroyed and inorganic
contaminants are stabilised, namely by binding into
mineral matrix and by evaporation and collection in a
highly concentrated form as vitrication y ash. The
re-melted slag is used as a resource. In both treatments,
metal recovery from bottom ash is performed in the
mechanical processing stage. Metal recovery from vitrication y ash has also been reported.
Schmelzer (1995) reported a process for metal recovery from incineration bottom ash, as shown in Fig. 7.
The pilot operation results show that 62.6 wt.% processed ash, 35.5 wt.% magnetic material and 1.9 wt.%
non-ferrous material can be obtained from the bottom
ash. The magnetic material contains 2030% Fe. After
further processing with impact crushing, screening and
wet magnetic separation, ne scrap with 9095% Fe
and iron concentrate with 5055% Fe were produced.
The non-ferrous material mainly comprises Al, Cu, Zn
and other metals. By further wet gravity separation,
light product containing 95% Al and heavy product
with Cu 52.161.2%, Zn 25.236.5%, Pb 1.23.5%,
Sn 0.671.46% and Ag 02.0% were obtained
(Schmelzer et al., 1996).
A wet treatment reported for recovery of Pb and Zn
from vitrication y ash is shown in Fig. 8 (Sakai and
Hiraoka, 2000). The y ash is mixed with acid solution.
Zn and Cu are dissolved into the solution and separated from non-soluble Pb by ltration. Then, Zn and
Cu are changed into hydroxide through neutralization
and sulphured. After that Zn cake is obtained by ltration again. By this treatment, lead and zinc cakes
grading about 35% Pb and 31% Zn, respectively, are
produced from a vitrication y ash containing 3.14%
Pb and 6.86% Zn.
947
5. Conclusions
(1) A large amount of various slags are produced as byproducts in metallurgical processes or as residues in
incineration processes. According to the origins and the
characteristics, the main slags can be classied into three
categories, namely ferrous slag, non-ferrous slag and
incineration slag. They usually contain a quantity of
valuable metals except for BF slag. Recovery of metals
from the slags and uitilization of the slags not only can
save metal resource, but also can protect the environment.
(2) Ferrous slags mainly include iron slag, steel slag,
alloy steel slag and ferroalloy slag. Iron and steel slags
have comparable or even better properties than their
competitive materials for a range of applications. The
metals in iron and steel slags are tightly bound to the
slag matrix and not readily leached, and there are few
environmental concerns regarding their application.
They have been applied in many areas. BF slag contains
little metal and recovery of metal from it is not important. Steel slag is usually subjected to metal recovery
prior to its application outside the iron and steel making
process. By applying mineral processing technologies
such as crushing, grinding, classication and magnetic
separation, it is possible to produce steel scrap (Fe:
90%) and iron concentrate (Fe > 55%) from steel slag.
The amount of stainless steel slag is the largest among
the alloy steel slags and it contains high Cr and a certain
amount of Ni. Since stainless steel slag can release a
noticeable amount of Cr as high as 1 ppm and its leachate EC50 value exceeds the standard level of 3000 mg/
l, it may cause environmental concerns. It is desirable to
treat stainless steel slag prior to its application or even
landlling. Recovery of Cr and Ni from stainless steel
slag is not only cost-eective, but also very important
for the environment. Magnetic separation and gravity
separation methods were reported for recovery of Cr
and Ni from this slag, but few detailed papers were
948
Acknowledgements
The authors are grateful to the Minerals and Metals
Recycling Research Center, Lulea University of Technology, Sweden, for nancial support and approval of
this paper for publication.
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