High-value terminal treatment: Utilizing copper slag heat in the manufacture of copper-containing weathering steel

Abstract

Copper slag, a bulk non-ferrous solid waste, is critical in establishing a closed-loop cycle in the copper metallurgy industry. Currently, the processing techniques for copper slag are characterized by prolonged procedures, secondary waste discharge, limited value utilization, and high energy consumption. A novel approach was proposed to harness the thermal energy inherent in molten copper slag for producing copper-bearing weathering steel and cement while simultaneously synergistically recovering lead and zinc. The results indicate that under the conditions of smelting temperature of 1500 °C, alkalinity of 1.06, smelting time of 60 minutes, and mechanical stirring, the recovery rates of copper, iron, lead, and zinc in copper slag reached 98.83%, 99.59%, 97.45%, and 98.51%, respectively. Furthermore, the feasibility of this approach was validated by laboratory-scale preparation of Q355GNH-grade copper-bearing weathering steel and S95-grade cement clinker. Computational analysis for the direct carbothermal reduction of molten copper slag in its thermal state reveals that, compared to the traditional flotation process, this approach saved 1177 MJ of thermal energy per metric ton of copper slag, equivalent to a reduction of 147 kg of carbon dioxide emissions. This study facilitates the zero-waste, high-value, and sustainable development of the copper smelting industry.