<p>The present study explores a one-step hydrometallurgical process for recycling an iron-rich waste generated from blasting brass objects with steel shots. The process involves controlled leaching using H<sub>2</sub>SO<sub>4</sub>–H<sub>2</sub>O<sub>2</sub> solutions to recover copper metal through a consecutive dissolution-cementation mechanism. Experimental parameters included H<sub>2</sub>SO<sub>4</sub> concentration, H<sub>2</sub>O<sub>2</sub> concentration, leaching temperature, and time. Analysis of Fe, Zn, and Cu dissolution versus time plots confirmed that dissolved copper tends to reduce back to metallic copper via cementation by the undissolved zinc and iron. Higher H<sub>2</sub>SO<sub>4</sub> concentrations increased iron and zinc dissolution but decreased copper dissolution. Increasing H<sub>2</sub>O<sub>2</sub> accelerated the dissolution of all three metals, particularly copper and zinc, emphasizing the need to carefully control the oxidant amount to optimize copper recovery in its metallic form. Elevated temperatures enhanced iron dissolution and copper recovery via cementation. Optimal conditions—7.5 vol.% H<sub>2</sub>SO<sub>4</sub>, 1.5 vol.% H<sub>2</sub>O<sub>2</sub>, 60&#xa0;°C, and 360&#xa0;min—maximized Fe dissolution and Cu recovery. Under these conditions, 97.4% of iron and 84.6% of zinc were ultimately extracted into the solution, while the dissolution of copper was limited to below 0.01%. The final leach residue consisted mainly of Cu, Cu<sub>5</sub>Zn<sub>8</sub>, and a minor amount of Cu<sub>2</sub>O, making it a suitable charge material for brass casting.</p> Graphical Abstract <p></p>

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A One-Step Hydrometallurgical Method for Separation and Recovery of Copper Metal From an Iron-Containing Brass Residue: Introducing the Cementation-in-Leach Process

  • Mohammad Reza Farmani,
  • Alireza Zakeri,
  • Mohammad Asadrokht

摘要

The present study explores a one-step hydrometallurgical process for recycling an iron-rich waste generated from blasting brass objects with steel shots. The process involves controlled leaching using H2SO4–H2O2 solutions to recover copper metal through a consecutive dissolution-cementation mechanism. Experimental parameters included H2SO4 concentration, H2O2 concentration, leaching temperature, and time. Analysis of Fe, Zn, and Cu dissolution versus time plots confirmed that dissolved copper tends to reduce back to metallic copper via cementation by the undissolved zinc and iron. Higher H2SO4 concentrations increased iron and zinc dissolution but decreased copper dissolution. Increasing H2O2 accelerated the dissolution of all three metals, particularly copper and zinc, emphasizing the need to carefully control the oxidant amount to optimize copper recovery in its metallic form. Elevated temperatures enhanced iron dissolution and copper recovery via cementation. Optimal conditions—7.5 vol.% H2SO4, 1.5 vol.% H2O2, 60 °C, and 360 min—maximized Fe dissolution and Cu recovery. Under these conditions, 97.4% of iron and 84.6% of zinc were ultimately extracted into the solution, while the dissolution of copper was limited to below 0.01%. The final leach residue consisted mainly of Cu, Cu5Zn8, and a minor amount of Cu2O, making it a suitable charge material for brass casting.

Graphical Abstract