Thermodynamic and CFD analysis of recycling Cu-As-containing filter cake waste and black copper sludge by feeding them back into FSF

[Display omitted] •An industrial waste treatment method that feeding wastes back into FSF was proposed and the feasibility of this waste treatment method was verified.•The mineralogy, morphologies and compositions of the industrial wastes filter cake and black copper sludge were determined by XRD, SEM-EDS coupled with ICP-OES analysis.•Reaction mechanism of those wastes in FSF under the current conditions was thermodynamically determined.•A new CFD model was established and the influence of operational parameters on the production status was discussed. The Cu-As-containing filter cake waste and black copper sludge are the main by-products, besides sulphuric acid and slag, in the copper production. To achieve sustainability in copper making and satisfy more strict environmental requirements, this study discusses the possibility of feeding them back into the smelting step. By collecting samples of filter cake waste and black copper sludge from copper industry, followed by Inductively Coupled Plasma-Atomic Emission Spectroscopy, X-ray Diffractometry and Scanning Electron Microscopy-Energy Dispersive X-ray Spectrometry, the mineralogy, morphologies and compositions of filter cake and black copper sludge were determined. Furthermore, the reaction mechanism of the by-products in FSF was discussed from thermodynamic aspects. Finally, a CFD simulation was conducted on an industrial furnace scale using different copper concentrate/by-product ratios, and the pyrometallurgical recycling of the filter cake waste and black copper sludge were discussed and evaluated.