Recycling Technologies for Secondary Zn-Pb Resources

Description

This book is a reflection of all aspects of secondary Zn and Pb processing, including the global business trends of the metals, plant operations, fundamental developments, emerging technologies, and environmental considerations. It stands as a ready reference for the processing, engineering, and research communities concerned with the latest developments in the hydrometallurgical and pyrometallurgical processing of secondary Zn-Pb resources. Preface Introduction Memoriam Contents About the Editor Chapter 1: Global Lead and Zinc Resources, Production and Secondary Industry 1 Global Pb Reserves and Production 2 The Secondary Pb Industry 3 Global Zn Reserves and Production 4 Direct Zn Leaching Technology 5 The Secondary Zn Industry 5.1 Electric Arc Furnace Dust (EAF) 5.2 Galvanizing Process Wastes 5.3 Pyrometallurgical Processing of Secondary Zn Resources 5.4 Electrolytic Roasting-Leaching-Electrolysis (RLE) Process for ZnS Ores 5.5 Melting Cathodes 6 Economics of Secondary Feeds Versus Concentrates References Chapter 2: Assessment of Secondary Zinc and Lead Resources 1 Classification of Primary and Secondary Resources 2 Assessment of Secondary Zinc Reserves of Nations 3 Estimated Secondary Zinc Reserves and Their Comparison with Primary Zinc Reserves 4 About Life Cycle Assessment 4.1 IZA Role in LCA 4.2 Material Stewardship 4.3 About Cycles, Recycling, and Circular Economy 4.4 The Zn Cycle—Zinc Stocks and Flows Analysis 5 Steel Industry By-Products 6 Recent Trends for Secondary Processing 7 Assessment of Lead Resources 7.1 Lead Life Cycle Assessment 7.2 Material Stewardship 7.3 Lead Recycling 8 Hazardous Waste Assessment and Classification 9 Conclusions References Chapter 3: Zinc Extraction; In Brief Review from Past to Present 1 Introduction 1.1 Brief History 2 Zinc Production Methods 2.1 Pyrometallurgical Production of Zinc Metal 2.2 Hydrometallurgical Production of Zinc Metal 3 Current Situation 3.1 Direct Atmospheric Leach 3.2 Zn Calcine Leach 3.3 Zn Silicate Leaching 3.4 Solution Purification 3.5 Zn Solvent Extraction 3.6 Electrowinning with Jumbo Cathodes 3.7 Zn Melting and Casting References Chapter 4: Galvanizing Residue and Electrical Arc Furnace (EAF) Dust 1 Introduction 2 Zinc Recycling Background 2.1 Galvanizing Residues Recycling 2.2 EAF Dust 3 Recycling Practice and Technology 3.1 Electric Arc Furnace Process 4 Pyrometallurgical Processes for Recycling of EAF Dust 4.1 The Waelz Kiln Technology in EAF Dust Recycling 4.2 Why Pelletize EAF Dust? 4.3 Briquetting EAF Dust 4.4 Considerations in Recycling EAF Dust 5 EAF Dust Pyrometallurgical Treatment Process 5.1 Rotary Hearth Furnace (RHF) Process 5.2 Electric Smelting Reduction Furnace (ESRF) Process 5.3 Plasma Shaft Furnace 5.4 The Submerged Arc Technology 5.5 PRIMUS Process 5.6 OXYCUP Process 5.7 Coke-Packed Bed Process 5.8 Ausmelt Process 5.9 Plasma Dust Process 5.10 Submerged Plasma Process (SPP) 5.11 PIZO Process 5.12 Thermal Plasma Reduction Process 5.13 Solar Thermal Reduction Process 5.14 Iron Bath Smelting Process (IBSP) 5.15 Calcification Process 5.16 Halogenation Process 5.17 Other Thermic Processes 6 Slag Use and Application Areas 7 Improving Zinc Recovery from EAF Dust by Switching from Conventional Heating to Microwave Heating 8 Sulphating Roasting 9 INDUTEC/EZINEX Integrate Process on Secondary Zinc-Bearing Materials 10 Evaluation of Pyrometallurgical EAF Dust Processes 11 Some Important Zinc Operations in the World 11.1 AZR (American Zinc Recycling), USA 11.2 Steel Dust Recycling (SDR), Millport, Alabama, USA 11.3 Zinc Nacional, Mexico 11.4 Recytech, Pas-de-Calais, France 11.5 Befesa 11.6 Isfahan Zinc Smelting, Isfahan, Iran 12 Scrap Zn/Pb Recycling Statistics—Industry Associations 13 Conclusions References Chapter 5: H₂SO₄ Leaching of Zn Secondaries 1 Sulfuric Acid (H₂SO₄) and Its Effect on Leaching 2 Effect of Leaching Temperature 3 Effect of Reagent Concentration 4 Effect of Particle Size 5 Effect of Solid/Liquid (S/L) Ratio 6 Effect of Oxidants in H₂SO₄ Leaching 7 Effect of H₂SO₄ Concentration, Leaching Temperature, and Leaching Time on Metal Dissolution for Turkish Oxidized Pb–Zn Flotation Tailing 8 Previous Primary and Secondary Zn Leaching Studies 9 Sulfating Roasting of Zn-Ferrite 10 EAF Dust Processing Flowsheet 11 Conclusions References Chapter 6: Hydrometallurgical Recovery of Zinc from By-Products and Waste Materials of Hot-Dip Galvanizing Process 1 Introduction 2 Zinc Ash 2.1 Chemical and Phase Composition 2.2 Leaching 2.3 Purification of Leaching Liquor 2.4 Strategies of Chlorine Removal 2.5 Zinc Recovery 2.6 General Schemes 3 Bottom Dross 4 Flux Skimming 5 Spent Pickling Solutions 5.1 Ion-Exchange Resins 5.2 Solvent Extraction 5.3 Membrane Processes 6 Summary References Chapter 7: Waste Lead-Acid Battery Recycling Technologies 1 Introduction 2 Lead-Acid Batteries (LABs) 3 Pyrometallurgical Recycling Methods 3.1 Reverberatory Furnace Smelting 3.2 Rotary Furnace Smelting 3.3 Whole Ebonite Battery Smelting 3.4 Top-Submerged Lancing 3.5 Carbothermic Reduction Process 3.6 Outotec Ausmelt TSL Process 3.7 CSC Technology for Secondary Pb Smelting 4 Hydrometallurgical Recycling Routes 5 Industrial Applications from the World 5.1 Engitec Technologies Process 5.2 Aqua Metals, California, USA 5.3 Doe Run, USA 5.4 Kudret Metal Smelting Ind., Eskisehir, Turkey 6 Lead Refining 7 Recent Product/Process Developments 7.1 LABs 7.2 Supersoft Ultra Pb 7.3 Polypropylene Recovery 7.4 Effect of Li-Ion Batteries on Pb Recycling 7.5 Stabilization of Slag from Secondary Pb Smelter 7.6 Wet Electrostatic Precipitator (WESP) and Regenerative Thermal Oxidizer (RTO) 8 China Pb Market Prices 9 Secondary Lead Smelting: National Emission Standards for Hazardous Air Pollutants (NESHAP) 10 Conclusions References Chapter 8: Leaching of H₂SO₄, Citric Acid, and Malic Acid Leached Pb and Ag Residues (Electrohydrometallurgical Process) 1 PbSO₄ Leach from Lead Acid Batteries (LABs) 2 Brine Leaching of Lead Compounds 2.1 Water and Brine Chlorination Leach of Optimum H₂SO₄ Leach Residue 3 NaOH Leach of H₂SO₄ Leach Residues 4 Comparison of Acidic and Alkaline Media Processes with RLE Waelz Process 5 Case Study: Leaching of Turkish Oxidized Pb–Zn Flotation Tailing Using Water, NaCl, and CaCl₂ 5.1 Water Leaching of the Turkish PbSO₄ Residue 5.2 NaCl Leach of the Turkish PbSO₄ Residue 5.3 NaCl Leach of Other PbSO₄ Residues 5.4 CaCl₂ Leach of Turkish H₂SO₄ Leach Residue 5.5 CaCl₂ Leach of Other PbSO₄ Residues 5.6 NaOH Leach of the Turkish H₂SO₄ Leach Residue 5.7 NaOH and Glycerol Leach of the Turkish PbSO₄ Residue 5.8 NaOH, Glycerol, and Ascorbic Acid Leach of the Turkish PbSO₄ Residue 5.9 NaOH and Potassium-Sodium Tartrate Leach of the Turkish PbSO₄ Residue 5.10 Malic Acid Leach of the Turkish H₂SO₄ Leach Residue 5.11 Acetic Acid Leach of the Turkish H₂SO₄ Leach Residue 5.12 Sodium Citrate (Na₃C₆H₅O₇) (SC) Leach of H₂SO₄ Leach Residue 5.13 NaOH Leach of the Turkish Citric Acid Leach Residue 5.14 NaCl Leach of the Turkish Citric Acid Leach Residue 5.15 Acetic/Ethanionic Acid (CH₃COOH) Leach of Turkish Citric Acid Leach Residue 5.16 Urea (CH₄N₂O) Leach of the Turkish Citric Acid Leach Residue 5.17 Oxalic Acid Leach of the Turkish Citric Acid Leach Residue 5.18 NaOH and Potassium-Sodium Tartrate (PST) Leach of Citric Acid Leach Residue 5.19 Oxalic Acid Leach of the Turkish Malic Acid Leach Residue 5.20 NaOH + Potassium Sodium Tartrate Leach of Malic Acid Leach Residue 5.21 Single Stage Combined/Integrated Leach of Turkish Flotation Tailings 6 Citric Acid + NaNO₃ Leach of Zinc 7 Acetic Acid (CH₃COOH) + Na Citrate (Na₃C₆H₅O₇.2H₂O) Leach of Pb Compounds 8 PbSO₄ Leaching in Citric Acid (CA)/Sodium Citrate (SC) Solutions 9 Precipitation of Fe and Co from Zn Leach Solution with Ammonium Peroxodisulfate 10 Na₂S Precipitation of PbSO₄ Residue 11 Na₂S Precipitation of Pb Brine Leach Solution 12 Case Study: Brine Leach of PbSO₄ Residue 13 Conclusions References Chapter 9: Lead Blast Furnace Dust Recycling 1 Introduction 2 Characterization of Lead Smelting Dust 2.1 Chemical Composition 2.2 Phase Distribution 2.3 Morphology 3 Utilization of Lead Smelting Flue Dust 4 Conclusions References Chapter 10: Impurity Purification Before Electrowinning 1 Impurity Precipitation Before Electrowinning of Zn 2 Fe Chemical Precipitation/Removal from ZnSO₄ Solution with NaOH/CaO at Different pH Values 3 Pb and Cd Cementation After Fe Precipitation 4 Cu Precipitation (