3.1 Physico-chemical property of copper slag tailing
Knowledge of chemical, mineralogical and textural characteristics of slag tailing, which determined potential biological toxicity and environmental stability of environmental sensitive elements (As, Pb, Zn, etc.), is particularly significant for the disposal of slag and utilization properly (Piatak et al., 2004; Shu et al., 2021). Variation in smelted ores, fluxes, additives and pyrometallurgical conditions (furnace, atmosphere, temperature, cooling time) causes that the bulk chemical, mineralogical and textural characterizations vary among different smelting plant, and finally affecting the environmental stability of slag tailing (Saez et al., 2003). The bulk chemical compositions of the selected slag tailing are presented in Table 2. The selected slag tailing is mainly composed of Fe2O3 (54.8%) and SiO2 (28.1%), with minor quantity of Al, Ca Na and K oxides, which is different from the previous studies in Australia (Lottermoser, 2005), USA (Piatak et al., 2004), Spain (Saez et al., 2003), Portugal (Mateus et al., 2011), and Poland (Kierczak et al., 2013) (Table 1). The elevated Fe content in slag tailing is originated from the bornite (FeCu5S4), chalcopyrite (CuFeS2) in the Cu concentrate (Mikula et al., 2021). Silica in the slag tailing is derived from both primitive ore and the silica flux which added during smelting processes (Mikula et al., 2021). Alkali oxides in the slag tailing refers to the concentrations of these compounds in gangue minerals of Cu concentrate (Schmukat et al., 2013). Meanwhile, Ca-based oxides are added to reduce the viscosity of silica and enhance Cu separation efficiency during smelting processes (Potysz et al., 2015).
Table 2
The chemical compositions of the selected copper slag.
Major elements (wt. %) | SiO2 | Al2O3 | Fe2O3 | CaO | Na2O | K2O |
This study | 28.1±0.54 | 3.80±0.22 | 54.8±2.54 | 3.58±0.68 | 0.70±0.49 | 1.35±0.10 |
Australia (Lottermoser, 2005) | 28.7-35.8 | 3.12-5.41 | 31.5-43.5 | 9.12-15.5 | 0.04-0.26 | 0.05-1.16 |
USA (Piatak et al., 2004) | 14.5-20.3 | 1-4.9 | 21-37 | 0.83-4.1 | 0.1-1.9 | 0.23-1.2 |
Spain (Saez et al., 2003) | 13.8-68.7 | 0.01-15 | 6.72-50.6 | 0.2-7.85 | 0.11-1.25 | 0.01-3.05 |
Portugal (Mateus et al., 2011) | 28.5-34.4 | 1.51-1.97 | 58.2-58.5 | 4.95-6.28 | 0.02-0.15 | 0.22-0.26 |
Poland (Kierczak et al., 2013) | 31.9-70.7 | 3.84-11.9 | 5.58-51.1 | 0.59-1.68 | 0.15-2.05 | 1.25-4.37 |
Miner elements (mg/kg) | Zn | As | Cu | Pb | Cr | Ni |
This study | 2034±65 | 901±124 | 563±187 | 341±25 | 72.7±21.8 | 35.8±17.7 |
Australia (Lottermoser, 2005) | 12266-58560 | 24-635 | 1410-8586 | 90-51620 | | 0-25 |
USA (Piatak et al., 2004) | 2300-19700 | 0.5-2 | 1900-13500 | 8.1-47 | 40-276 | 2.8-27 |
Spain (Saez et al., 2003) | 58-1423 | 58-8623 | 1400-280600 | 16-4562 | 118-653 | 53-217 |
Portugal (Mateus et al., 2011) | >10000 | 180 | 3280 | >5000 | | |
Poland (Kierczak et al., 2013) | 1294-9360 | 3-315 | 3030-13400 | 11-738 | | |
The concentrations of environmental sensitively toxic elements (Zn, As, Cu, Pb, Cr and Ni) are shown in Table 1 and decreasing in the order of Zn> As> Cu> Pb> Cr> Ni. The elevated concentrations of these elements in slag tailing may lead to potential environmental impacts during disposal and utilization. In comparison with other copper slags (Kierczak et al., 2013; Lottermoser, 2005; Piatak et al., 2004; Saez et al., 2003), the selected slag tailing contains elevated As content and should be received greatly concern. Nevertheless, the lowest concentration of Cu in the selected slag tailing suggested that the excellent efficiency of Cu metallurgical processes in the selected furnace.
The selected slag tailing was screened by using sieves of 150 (106 µm), 200 (75 µm) and 325 (45 µm) mesh to investigate the distribution characteristics of particle sizes. The particle sizes fractions of the selected slag tailing in < 45 µm, 45-75 µm, 75-106 µm, and >106 µm are 25.4%, 52.4%, 14.3%, and 7.9%, respectively. The selected slag tailing is mainly existed in fine particles (<75 µm) with proportions up to77.8% and primary presented in 45-75 µm (52.4%). The morphology characterizations of the selected slag tailing are presented in Fig. 2. Slag tailing is displayed as angular grains in different size fractions, which is attributed to the milling procedure. The fine amorphous materials are increased with the decreasing of particle sizes.
Metallic elements (Cu, Pb, As, Zn) are mainly associated with copper sulfides in Cu concentrate (Schmukat et al., 2012; Schmukat et al., 2016), which are released and redistributed with the transformation of their host minerals during high temperature smelting processes. The mineral phases of Cu concentrate undergo various complex physico-chemical transformations, i.e. volatilization, decompositions, oxidation, reduction and crystallization, and result in the formation of Cu matte and new phases in the smelting slag (Siddique et al., 2020; Vitkova et al., 2011). Generally, the mineral phases in the slag are regarded as synthetic analogues of naturally minerals, which are formed by anthropogenic activities and determined by smelting conditions (smelting temperature, cooling speed) as well as the chemical compositions of the slag (Pareuil et al., 2011). It is a consensus that the phase variety is more abundant in slower cooled slags than that of cooled at the faster rates (Piatak et al., 2015; Potysz et al., 2016). It is attributed to the closer equilibrium of crystallization of phases in slow cooling. Meanwhile, the phase compositions of slag are greatly influenced by the smelting temperature (Gorai et al., 2003). Spinel, melilite, olivine, pyroxene and glass are formed at different temperature and time. Generally, the mineral phases of slag tailing including silicates (olivine, pyroxene), oxides (magnetite and hematite), sulfides (chalcocite, chalcopyrite, galena, sphalerite and bornite), pure metals, intermetallic compounds and glass matrixes (Li et al., 2021b). The mineralogical characteristics of slag tailing in the different size fractions are depicted in Fig. 3. The mineral phases in slag tailing are fayalite, hematite, magnetite, galena, sphalerite, arsenopyrite and chalcopyrite. Fayalite, hematite and magnetite are the most identified Fe-based minerals, while fayalite and silicate glasses are the mainly silicate phases. Meanwhile, sulfides (galena, sphalerite, arsenopyrite and chalcopyrite) are commonly found in the selected slag tailing with small quantities, which are consistent with previous studies from other furnaces (Kierczak et al., 2013; Mateus et al., 2011). Despite sulfides are volumetrically minor phases in slag tailing, these minerals should be taken fully consideration for the potential environmental risks (Khorasanipour & Esmaeilzadeh, 2016). In comparison with the mineralogical distribution among different size fractions, the peaks of fayalite and hematite are increasing with the decreasing of size fractions, suggesting that these secondly phases are preferred to existed in fine particles.
3.2 Association and chemical speciation of arsenic in copper slag tailing
In smelting furnace, arsenic as an impurity is removed by volatilization and slagging (Safarzadeh & Howard, 2018). Arsenic sulfide and elemental arsenic are oxidized to arsenic trioxide during high temperature smelting processes (Montenegro et al., 2013). Arsenic trioxide is volatilized and condensed on the surface of fine particulates in the smoke dust collection processes. Subsequently, arsenic trioxide could react with oxygen to form non-volatilized arsenic pentoxide under oxidizing environment (Ganne et al., 2006). It has been reported that the volatilization ratio is approximately 76-85% with 7%-17% existed in slag during flash smelting processes (Potysz et al., 2015). For the high Cu content (up to 40%) in the collected dust, the collected arsenic-containing dust is recycled to the smelting furnace and resulted in the deterioration of Cu matte. Therefore, smelting slag is the only discharge outlet of various pyrometallurgical impurities (As, Zn, Pb, and Ni) to ensure the pyrometallurgical quality. The release and environmental mobility of elements from slags are controlled by various factors, i.e. geochemical/ mineralogical compositions of slags, association and speciation of elements, and disposal processes (Long et al., 2012; Rozendaal & Horn, 2013). Among them, the association and chemical speciation can provide greatly significant information about the toxicity and bioavailability of As. Therefore, SEM-EDS, XPS and sequential chemical extraction procedures are applied to illustrate the association and chemical speciation of As.
The two-dimensional distribution images of elements in the slag tailing and in different size fractions are present in Fig. 4 and Fig. S1. According to Fig. S1, arsenic is mainly existed in the fine particles (<75 µm). The overlap area of silicate, iron, arsenic and oxygen in the EDS images suggested that As may be associated with silicate minerals as Si-Fe-As-O phases (Zhou et al., 2021a). According to the distributions of elements in different size fractions (Fig. S1), the Si-Fe-As-O phases are mostly found in the fine particulates (<75 µm). Many studies reported that As-O phases disseminated in the silicate minerals are the primary Si-Fe-As-O phases in slag tailing (Montenegro et al., 2013; Zhang et al., 2021a). Meanwhile, the overlap areas of arsenic and sulfur are also found in the selected slag tailing, suggested that the arsenic sulfides are existed in the slag tailing. Therefore, arsenic is mainly existed in silicate minerals, sulfide minerals and oxides in the slag tailing.
The associations of As determined by sequential chemical extraction are presented in Fig. 5. As is mainly existed in residual (82.1%), Fe-Mn oxides bound (9.6%), and organic matter bound (6.2%). The elevated fractions of As in residue and Fe-Mn oxides bound suggested that As are mainly associated with silicate minerals. The organic matter bound of As may be explained by the adsorption of unburned organic matter.
The chemical speciation of As provides extremely information for the toxicity and bioavailability of As in slag tailing. According to the valence states of As, As compounds could be clustered into arsine (As−3), elemental As (0), arsenite (As+3), arsenate (As+5) (Zhou et al., 2021a). Among them, arsenite (As(III)) and arsenate (As(V)) are the mainly valence states of As in slag tailing (Zhang et al., 2021b). The As3d peaks obtained by XPS spectral are conducted to illustrate the chemical speciation of As and shown in Fig. 6. As3d3 and As3d5 are known as the two peaks of As3d peaks. Two separated peaks are found at 49.98 eV and 44.53 eV, which are regarded as the As3d of metallic arsenic. It is obviously found that As in slag tailing could be existed in both As(III) and As(V) with the proportions of 59.4% and 40.6%, respectively. For the high toxicity of As(III), the environmental risks of slag tailing caused by As deserve further concern.
3.3 Potential environmental risks of copper slag tailing
Under natural weathering condition, the environmental risks of environmental sensitively elements in slag tailing are related to both total concentration and chemical speciation (Ganne et al., 2006). Determination of the total concentrations of elements in slag tailing provide important information about pollution levels. Nevertheless, the environmental stability and toxicity of elements are greatly determined by the leaching potential and duration.
The results of CN-SWEP and TCLP leaching tests are listed in Table 3. It could be found that the leaching of elements (As, Cu, Zn, Pb, Ni and Cr) in the selected slag tailing is far below the legislation limits and could be considered as non-hazardous inert wastes. Meanwhile, the results of sequential chemical extraction procedure may be applied as an indication to evaluate the potential environmental risk. The risk assessment code (RAC) determined that element could be considered safe (no risk) to the ecosystem when the exchangeable and carbonate bound fractions are less than 1% of the total value. On the contrary, the element can have a strong environmental impact (very high risk) when the aforementioned fractions of any of these elements are more than 50% of the total value. Meanwhile, 1-10%, 11-30% and 31-50% of RAC values are regarded as low risk, medium risk and high risk, respectively. The fractionation characteristics of elements in slag tailing are presented in Fig. 5. The selected environmental sensitively elements are primary existed in residual. The RAC values of Zn, Pb, Cr and Ni reveal that the environmental impacts of these elements could be regarded as negligible. However, speciation patterns of As and Cu show a low risk and medium risk, respectively. Therefore, the environmental impacts induced by these elements in slag tailing should be taken into consideration during disposal and utilization.
Table 3
Leaching of toxic elements from the selected copper slag as obtained by CN-SNEP and TCLP (mg/L).
Methods | As | Cu | Zn | Pb | Ni | Cr |
CN-SNEP | 2.512 | 24.150 | 2.478 | 0.274 | 0.112 | 0.034 |
TCLP | 2.529 | 8.056 | 0.521 | 0.013 | 0.020 | ND |
China limitation | 5 | 100 | 100 | 5 | 5 | 1 |
USA limitation | 5 | 20 | 250 | 5 | 5 | 1 |
The results of leaching tests are difference to that of RAC model, which may be explained by the interaction between exchangeable element and Fe. High content of Fe in form of Fe2+ is existed in slag tailing, Fe2+ is quickly oxidized to Fe3+ in the water phase, and other elements are co-precipitated with Fe during the formation of iron (hydr)oxide colloids. Finally, the dissolved elements (Cu and As) could be reduced effectively during leaching tests.