Recovery of lead and silver from zinc acid-leaching residue via a sulfation roasting and oxygen-rich chlorination leaching method

A large amount of acid-leaching residue is produced during the conventional Zn hydrometallurgy process, and this residue has a large concentration of a variety of valuable metals. The purpose of this study was to evaluate the ability of a procedure that entails the use of sulfation roasting, water leaching, and chlorination leaching (blowing oxygen technique) to recover Pb and Ag, followed by cooling crystallization and the replacement of Ag with lead sheet, to realize the full recovery of all valuable metals from zinc acid-leaching residue; consequently, good results were achieved. The best results were obtained under the following conditions: a sulfuric acid at 70% of the raw material quality, roasting temperature of 300 °C and roasting time of 2 h, followed by the process of leaching the roasted residue for 1 h by applying a water-to-solid ratio of 5:1 at room temperature. The recovery rates of Zn and Fe were 98.69% and 92.36%, respectively. The main parameters of the chlorine salt leaching system were as follows: Cl concentration of 300 g/L, Fe concentration of 25 g/L, acid concentration of 2 mol/L, liquid-to-solid ratio of 9 mL:1 g, temperature of 90 °C, and leaching time of 0.5 h; this leaching process was followed by filtration separation. These conditions resulted in high extents of leaching for Pb and Ag (i.e., 98.87% and 96.74%, respectively). Finally, the kinetics of the process of Ag leaching using Cl ions in an oxygen-rich medium was investigated. It was found that the leaching process was controlled by the diffusion of the product layers, and the activation energy was 19.82 kJ/mol.