Pyrometallurgical Process to Recover Lead and Silver from Zinc Leaching Residue

During the roasting, leaching, and electrodeposition of zinc ores, lead–silver residues are produced. These residues contain valuable metals (Pb, Zn, and Ag) and toxic metals (Cd and As). In this study, a pyrometallurgical process is proposed for treating Pb-Ag residues, consisting of drying, roasting, and reduction steps to recover valuable metals, such as silver in a metallic Pb phase, while converting the waste into an environmentally friendly slag. First, the Pb-Ag residue is dried at 100 °C, then roasted at 700 °C, and finally reduced at a high temperature, with Na₂CO₃ as a flux and CaSi as a reducing agent, rather than carbon-based reducing agents (carbon or carbon monoxide), to minimize greenhouse gas production. The effects of the reduction temperature and the mass of the reducing agent were investigated on a laboratory scale. The metallic phase and slag obtained in the reduction step were characterized by their chemical composition and mineralogy via chemical analysis, X-ray diffraction, and SEM-EDS. The results showed that silver and lead formed a metallic phase, and that silver content decreased from 1700 ppm in the Pb-Ag residue to 32 ppm in the final slag at 1300 °C. The Pb-Ag residue and final slag were leached with an aqueous acetic acid solution to evaluate their chemical stability.