The study proposes a zero-waste pyrometallurgical technology for the comprehensive recycling of copper smelting slag dumps to extract valuable components and obtain marketable products. Thermodynamic modelling in the temperature range of 600–1750°C confirmed the feasibility of producing three target products: zinc oxide, iron-carbon alloy, and silicate slag. Experiments demonstrated that using thermal coal instead of scarce coke as a reducing agent achieves a high degree of iron recovery, forming metallic nodules of 20–50 μm. Subsequent melting of reduced briquettes yields cast iron or ferrosilicon suitable for foundry applications. The resulting metal contains copper and sulfur, limiting its use in high-grade metallurgy but making it suitable for producing grinding cast iron balls with hardness up to 59 HRC, corresponding to class IV per GOST. The slag phase is processed into proppants and construction aggregates. A technological scheme of a microplant is proposed, ensuring integrated slag processing with minimal capital and operational costs. The development is supported by the Ural Scientific and Educational Center and aligns with the priorities of resource conservation, environmental safety, and import substitution in the metallurgical industry.

ADILOV G.A.

Candidate of technical sciences, researcher at the research institute «Hydrogen technologies in metallurgy», South Ural state university (NIU), Chelyabinsk, Russian Federation

Е-mail: adilovg@susu.ru, https://orcid.org/0000-0002-1012-8097

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copper smelting slags, pyrometallurgical processing, zinc oxide capture, iron recovery, cast iron products, ceramic products, micro-factories, waste-free technologies