A novel process for the direct utilization of copper slag and phosphate rock by compound modification and coreduction.

The traditional direct reduction-separation approach used to economically and effectively treat copper slag (CS) or phosphate rock (PR) encounters challenges, such as low metal recovery, high cost, and high additive requirements. In this paper, an ecofriendly process for synchronously utilizing CS and PR by compound modification and coreduction, accompanied by magnetic separation, is proposed to resolve these limitations. In this approach, use graphite as a reductant toreduce Fe and the CaO in the PR catalyzed the reduction of fayalite in the CS, thereby enhancing Fe formation. Owing to its low melting point, CS generated a liquid phase and improved the growth of particles, which was beneficial for producing ferrophosporus (Fe-P) alloys. The Fe-P and slag were separated and recovered, owing to their melting point and density differences, thereby highlighting the efficiency of the proposed method. After comprehensive consideration, a crude Fe-P alloy containing 82.31% Fe and 13.65% P was prepared under optimal conditions and suitable for the production of battery grade iron phosphate. [ABSTRACT FROM AUTHOR]