Eco-friendly treatment of copper smelting flue dust for recovering multiple heavy metals with economic and environmental benefits

Handling flue dust in an environmentally friendly manner has become an urgent task for pollution prevention in the copper industry. Here, driven by the low-carbon notion, we report a process that enables the selective retrieval of multiple metals (As, Cu, Pb, Zn, and Bi) from copper smelting flue dust (CSFD). This process employed low-temperature roasting to separate arsenic from heavy metals, thereby eliminating the tedious separation steps required by existing processes. Subsequently, Zn and Cu were dissolved in water, while Pb and Bi were left as a solid residue. We achieved 98.23% extraction of Cu via Zn cementation at a micro-voltage of 0.50 V. Utilizing the difference in solubility, Bi was selectively dissolved from the residue using a NaCl-HCl medium, which enabled the subsequent production of metallic Bi through electrowinning. Finally, more than 99% of Pb in the solid was reduced to elemental Pb by mechanochemical reduction. Through optimized process conditions, high-purity As2O3 (99.04%), lead ingot (99.95%), metallic copper (94.16%), and bismuth (99.20%) were obtained. Our economic assessment revealed significant advantages, demonstrating the industrial feasibility of this process. Consequently, this study presents an effective and cost-efficient system for CSFD disposal while minimizing the environmental impact and fostering a circular economy.