Recovery of Zinc from Metallurgical Slag and Dust by Ammonium Acetate Using Response Surface Methodology

Metallurgical slag and dust (MSD) are abundant Zn-containing secondary resources that can partially alleviate the shortage of zinc minerals, with hazardous characteristics and a high recycling value. In this work, the process conditions of recycling Zn from MSD materials leaching by ammonium acetate (NH₃-CH₃COONH₄-H₂O) were optimised using response surface methodology (RSM). The influences of liquid/solid ratio, stirring speed, leaching time, total ammonia concentration, and the interactions between these variables on the Zn effective extraction rate during the ammonium acetate leaching process were investigated. Additionally, the predicted regression equation between the Zn effective extraction rate and the four affecting factors was established, and the optimal process parameters were determined with a stirring speed of 345 r/min, leaching temperature of 25 °C, [NH₃]/[NH₄]⁺ of 1:1, total ammonia concentration of 4.8 mol/L, liquid/solid ratio of 4.3:1, and leaching time of 46 min. The Zn effective extraction rates predicted by the proposed model and the measured values were 85.25% and 84.67%, respectively, with a relative error of 0.58% between the two values, indicating the accuracy and reliability of the proposed model. XRD and SEM-EDS analysis results showed that Zn₂SiO₄, ZnS, and ZnFe₂O₄ were among the main factors affecting the low extraction rate of zinc from metallurgical slag dust. This work established a new technology prototype for the effective and clean extraction of zinc resources, which can provide new routes to effectively utilise Zn-containing MSD materials and lay a foundation for developing other novel techniques for recycling Zn from Zn-containing secondary resources.