An efficient approach to utilize copper smelting slag: Separating nonferrous metals and reducing iron oxide at high temperature

[Display omitted] •A novel scheme of joint processing copper slag and steelmaking slag proposed.•It achieves separation percentages of 90.3% copper, 81.9% zinc and 82.7% lead.•Optimization conditions for nonferrous metal separation were determined.•Cu slag is used for nonferrous metal and iron recycling, rock wool preparation. Over 50 million tons of copper slag are produced worldwide annually. Stacking is currently the primary method used to treat copper slag, resulting in resource wastage and environmental issues. Using slag as a raw material in the steel industry is areasonablesolution. However, the presence of nonferrous metals degrades steel performance and corrodes smelting equipment, and the remaining slag poses environmental and sustainable challenges. Thus, this study focused on removal of nonferrous metals from copper slag and subsequent reduction of iron oxide. The experimental results showed that increasing the percentage of the chlorinating agent (calcium chloride), temperature, and duration, the removal percentage of copper initially increased linearly, then plateaued. The acidity coefficient had a marginal effect on copper removal percentage. The optimum chlorination roasting conditions were 13 % calcium chloride, 1373 K, and 0.5 h, resulting in removal percentages of 90.3 %, 81.9 %, and 82.7 % for copper, zinc, and lead, respectively. The appropriate oxygen partial pressure for chlorination roasting was 10-5–0.7 atm. The reduction percentage of iron oxide was approximately 82 % under roasting conditions of 1.5 h at 1373 K. Based on these results, a novel scheme for copper slag utilization is proposed that involves chlorination roasting for nonferrous metal removal, reduction roasting for iron oxide reduction, and melting to obtain molten iron and separate molten slag. The iron and slag are used for steel manufacturing and rock wool preparation, respectively. This scheme provides apromisingway to efficiently use copper slag, which will reduce primary resource consumption and pollution.