1. Introduction
Selenium is found in most rocks and soils in the earth’s crust. It is an essential material with a wide range of applications in medicine and the production of food, semiconductors, sensors, and photochemical devices. Selenium is rarely found in its native state, 90% being obtained from copper anode slimes, which are a byproduct of the copper electrorefining process [
1,
2,
3,
4,
5,
6].
During electrolysis, copper dissolved from the anode is deposited on the cathode. However, other elements in copper anodes, such as gold, silver, arsenic, antimony, selenium, tellurium, bismuth, lead, iron, and nickel are released from the anode. Some of these are soluble and accumulate in the solution, while the insoluble elements sink to the bottom of the cell and form raw anode slime [
7], which is collected periodically from the bottom of the electrolytic cell for subsequent treatment [
8,
9].
Table 1 shows the ranges of the chemical elements in typical anodic slimes from refineries such as the Canadian Copper Refinery; Outokumpu (Finland); Saganoseki (Japan); Balkhash Mining-Metallurgical Combine (Kazakhstan); Kovoguty Krompakhi (Slovakia, closed); La Caridad Copper Refinery (Mexico); Jinchuan (China); Baiyin (China); and Ronnskar (Sweden) [
10,
11,
12,
13,
14]. The elemental contents vary widely, depending on the origin of the anode slime.
Selenium is currently recovered from anode slimes by hydrometallurgical and pyrometallurgical processes [
5,
15,
16]. Although the traditional pyrometallurgical method recovers selenium effectively, there are difficulties relating to high energy costs and increasingly strict environmental regulations [
1,
3,
6,
17,
18]. Therefore, new alternatives have been proposed, such as hydrometallurgical processes in oxidizing media such as nitric acid, alkaline leaching with sodium nitrate, wet chlorination, pressure leaching, sodium hydroxide, and acid leaching with MnO
2 or hydrogen peroxide, among others [
1,
2,
4,
6,
9,
17,
18,
19,
20]. The hydrometallurgical process allows a better stabilization of selenium with respect to the pyrometallurgical process.
Selenium is commonly present in copper anodes as copper selenide (Cu
2Se), but in anode slimes, it occurs in various phases of Ag-Cu selenides [
2,
4,
12,
14,
15,
16,
21]. Selenide is usually one of the main carriers of silver in anode slimes, this is because the silver in the solid copper matrix and the dissolved silver during electrorefining react with Cu
2Se to form Ag-Cu selenide compounds.
Ag-Cu selenides in anode slimes maintain the morphology of copper selenide (Cu
2Se) in the anode [
12,
14]. Small quantities of Te, S, and Au were detected in selenide particles and, according to the literature, almost all the Te, S, and Au initially present in the Cu
2Se of the copper anode remain in the selenides in anode slimes [
9,
14].
Sodium hypochlorite (ClO
−/OH
−) was used in several investigations as a highly oxidizing reagent that can be applied to leach chalcopyrite, enargite, and precious metals [
22,
23,
24,
25,
26,
27]. The authors [
25,
28] performed leaching experiments on enargite (Cu
3AsS
4) in ClO
−/OH
− media and found that arsenic dissolves and can be directly precipitated as a stable phase such as scorodite or as an amorphous ferric arsenate. According to [
24], copper selenides (krutaite, CuSe
2) and gold telluride (calaverite, AuTe
2) are attacked by a ClO
−/OH
− system, dissolving selenium and tellurium, while copper and gold remain in the solid as tenorite (CuO) and elemental gold, respectively. Sodium hypochlorite was also widely used as an oxidant in various fields, for example, in flotation processes with ilmenite [
29], the extraction of molybdenum from a Ni-Mo mineral by oxidant leaching [
30,
31], and the extraction of molybdenum from a copper concentrate [
25].
The objective of this study is to evaluate the effect of the variables that influence the dissolution of selenium from decopperized anode slimes by alkaline oxidative leaching (ClO−/OH−). Considering the oxidative characteristics of sodium hypochlorite, in addition, this reagent has not been directly explored for the dissolution of selenium from anode slimes. Decopperized anode slime was obtained by the pretreatment of raw anode slime by agitated acid leaching with air injection. This paper does not analyze the decopperization process. The variables analyzed in this study are ClO−/OH− concentration, temperature, and pH.
2. Materials and Methods
2.1. Materials
The sample of decopperized anode slime used in this work was obtained from a large Chilean electrolytic refinery. The sample was washed three times with distilled water to remove impregnated soluble copper and acid, and the solid sample was dried at 343 K (70 °C) for subsequent chemical analysis by atomic absorption spectrometry (AAS) (Perkin Elmer, model PinAAcle 500, Singapore) and X-ray diffraction (XRD) (Siemens model D5600, Bruker, Billerica, MA, USA) with an analysis time of one hour. The ICDD (International Centre for Diffraction Data, Version PDF-2, Bruker, Billerica, MA, USA) database was used to identify the phases present, and the TOPAS (total pattern analysis software, Version 2.1, Bruker, Billerica, MA, USA) program was used for quantification. The XRD equipment uses an internal corundum standard. Scanning electron microscopy (SEM) (JEOL USA Inc., Peabody, MA, USA) with dispersive X-ray energy spectroscopy (EDX) (Zeiss Ultra Plus, Zeiss, Jena, Germany) was used to determine particle size.
The copper anode slimes were characterized in an earlier work [
8], which indicated that the average particle size was 11 µm, and contained the following main elements: Se (10.9%), Cu (0.97%), As (0.92%), Pb (1.1%), Sb (1.1%), Au (0.23%), and Ag (0.49%). The main phases in the decopperized anode slime were selenium, such as CuAgSe, and phases of Ag-Se, Ag
(2–x)Se, Sb-As-O, and antimony arsenate, AsSbO
4, as well as phases of BaSO
4 and AgCl.
2.2. Leaching Experiments
The leaching experiments were conducted in a 500 mL, four-necked glass reactor at atmospheric pressure, with 10 g of the sample treated in a 250 mL solution. The central reactor opening had a mechanical stirrer with a digital display screen (IKA, model RW20, Staufen im Breisgau, Germany). Temperature, pH, and Eh were measured using a pH-ORP meter (Hanna Instrument, HI 3221, Padova, Italy), which was inserted in a lateral neck of the reactor. The system was placed in a thermostatic bath (Julabo, model MP-19A, St. Louis, MO, USA) to maintain the required temperature. A 25 mL microburette was used to add sodium hydroxide (NaOH, 3 M) and sulfuric acid (H
2SO
4, 1 M) through the lateral neck to control the pH level. The aqueous solution was sampled at 5, 15, 30, 60, and 120 min of leaching to measure selenium and hypochlorite concentrations. Selenium was measured by AAS and Flow Injection System (FIAS) for hydride generation and hypochlorite by iodometric titration. The parameters of the study varied from 0.27, 0.4, and 0.54 M of ClO
−; 25, 35, and 45 °C; and pH 11.5, 12.0, and 12.5. All experiments were run at a stirring speed of 300 min
−1. At the end of the leaching, the product solution and residue were filtered. The leaching residue was washed three times with distilled water and then dried in a drying oven at 70 °C for 24 h. Experiments were performed in duplicate, and the results presented here are the averages of the obtained data (±2.0% in selenium dissolution). In addition, the elements of the experimental setup can be identified in
Figure 1 (e.g. reactor, stirrer, pH-ORP meter, thermostatic bath, etc.).
The residue leaching sample was briquetted with epoxy resin, polished, and coated with carbon. The briquette obtained was analyzed using scanning electron microscopy (SEM) (JEOL, model JSM 840) with dispersive X-ray energy spectroscopy (EDX), which provides information on elemental analysis and the morphology of the different phases.
2.3. Taguchi Experimental Design
The Taguchi optimization method was used to determine the optimal combination of variables. Three factors and three levels were evaluated in the experiments, as shown in
Table 2:
The application of the orthogonal Taguchi matrix yielded the L
27 experimental model to evaluate the reaction progress (see
Table 3) and the L
9 model to identify the optimal combination of variables. This orthogonal array was selected because of its potential to pattern the interactions among the factors.
Table 4 shows the experimental design developed in this research (L
9).
4. Conclusions
The Levels of pH of 11.5 and 12 have a positive effect on selenium dissolution, yielding 90 and 80% dissolution, respectively. The dissolution decreases at pH 12.5, reaching a maximum of 60% since the hypochlorite decomposition increases significantly at pH levels above 12.5. A ClO−/OH− concentration of 0.54 M significantly affects the selenium dissolution, reaching values of over 60%, with a maximum of 90%, for all the evaluated parameters of pH and temperature. However, no significant effect on selenium dissolution was observed over time for concentrations 0.27 and 0.4 M, and at pH 11.5 and a temperature of 45 °C. The temperature was noted to affect selenium dissolution in the assessed range of 25 °C to 45 °C. The best results of 74 and 90% dissolution were obtained at 35 and 45 °C, respectively. The temperature has a significant effect on the dissolution of selenium. However, temperatures above 50 °C accelerated the decomposition of ClO−/OH−. The best conditions for dissolving selenium are pH 11.5; 45 °C and 0.54 M of ClO−, which yields a dissolution of 90%, according to the Taguchi design The selenium was not completely dissolved because a layer of AgCl is generated around the selenium particles (Ag(2–x)Se) during leaching that obstructs the progress of the reaction. Ag, Pb, Sb, and Cl compounds were detected as major phases in the leaching residue from the test at pH 11.5, 45 °C, and 0.54 M of ClO−. Silver was found mainly as AgCl. Lead sulfate became lead oxide. The arsenic phase present in the decopperized anode as SbAsO4 decreases after leaching with ClO−/OH−. This occurs because arsenic dissolves in alkaline oxidizing media.
Our results at the laboratory level indicate that hypochlorite is an interesting reactant for dissolving selenium from anode slime, and the pyrometallurgic stage can be replaced by hydrometallurgical process under moderate conditions.