Reprocessing of copper by flotation via mineralogical characteristics from a copper slag case study

Copper slag (CS), a prominent industrial by-product derived from copper sulphide concentrate smelting, contains valuable copper minerals. Mineralogical analysis revealed 0.56% arsenical copper/chalcopyrite, 1.29% chalcocite, 0.25% cuprite, and 0.24% bornite as the primary copper-bearing phases. Given the rapid depletion of readily exploitable copper resources, CS has emerged as a significant source for copper production. A systematic investigation was conducted to establish optimal operational parameters for classification, grinding, and flotation. This study encompassed diverse scenarios and laboratory tests, with a particular focus on reagent application, including types and consumption rates. The findings demonstrated that Na₂S is used to activate copper oxide minerals that are difficult to recover after a period of grinding, increasing the recovery rate of CS from 53.92% to 87.58%, and the two-stage grinding process is beneficial for precise control of the particle size, considering both energy efficiency and mineral recovery rate. Upon conducting a comprehensive investigation into the closed-circuit flotation process for copper recovery from CS under optimal conditions, it was determined that the copper concentrate achieved a grade of 21.24% and a recovery rate of 36.31%. Additionally, the grade of copper in the flotation tailings was diminished to 0.20%. The synchronous enrichment of copper significantly curtails total emissions in pyrometallurgical processing, mitigating pollution from CS flotation tailings. This study offers a scientific foundation for sustainable CS tailing management, promoting resource recovery and reduced environmental impact.