Removal of copper in leachate from mining residues using electrochemical technology

• An electrochemical process was used to recover Cu in leachate from mining residues.
• FD and CCD methodologies have been successively applied to optimize the process.
• Current intensity and time influence the electrochemical deposition of Cu.
• Their contribution on Cu removal is 65.8% and 33.9%, respectively.
• Under optimal conditions, 86% of Cu can be recovered from MRL.

This research is related to a laboratory study on the performance of a successive mining residues leaching and electrochemical copper recovery process. To clearly define the experimental region for response surface methodology (RSM), a preliminary study was performed by applying a current intensity varying from 0.5 A to 4.0 A for 60 min. By decreasing the current intensity from 4.0 A to 0.5 A, a good adhesion and a very smooth and continuous interface of copper was formed and deposited on the cathode electrode. However, the removal rate of Cu decreased from 83.7% to 37.9% when the current intensity passed from 4.0 A to 0.5 A, respectively. Subsequently, the factorial design and central composite design methodologies were successively employed to define the optimal operating conditions for copper removal in the mining residues leachate. Using a 23 factorial matrix, the best performance for copper removal (97.7%) was obtained at a current intensity of 2.0 A during 100 min. The current intensity and electrolysis time were found to be the most influent parameters. The contribution of current intensity and electrolysis time was around 65.8% and 33.9%, respectively. The treatment using copper electrode and current intensity of 1.3 A during 80 min was found to be the optimal conditions in terms of cost/effectiveness. Under these conditions, 86% of copper can be recovered for a total cost of 0.56 $ per cubic meter of treated mining residues leachate.