Valorization of zinc electrolysis residues as a secondary raw material for industrial and metallurgical applications

Zarife Bajraktari Gashi; Bastri Zeka

doi:10.3989/revmetalm.e293.1757

Authors

Zarife Bajraktari Gashi Faculty of Geoscience, Department Materials and Metallurgy, University “Isa Boletini” https://orcid.org/0000-0003-4770-0664
Bastri Zeka Faculty of Geoscience, Department Materials and Metallurgy, University “Isa Boletini” https://orcid.org/0000-0001-9522-3263

DOI:

https://doi.org/10.3989/revmetalm.e293.1757

Keywords:

Clinker, Recycling, Thermodynamic modeling, Zinc electrolysis residues

Abstract

This study investigates the valorization of zinc electrolysis residues generated at the Trepça industrial facilities for their potential application in cement clinker production at the Sharrcem plant. These residues have been stockpiled for nearly 30 years in open environments, posing significant environmental and health risks. Chemical characterization was performed using a VITRIOX ELECTRIC furnace applying the fused-bead method, revealing a high iron oxide content (Fe₂O₃, 80.20 wt%) along with SiO₂, Al₂O₃, CaO, MgO, K₂O, Na₂O, and SO₃. The elevated Fe₂O₃ content plays a critical role in clinker mineralogy by promoting the formation of calcium ferrites (C₄AF), which influence burnability and phase stability. Phase equilibria and thermodynamic simulations conducted using the CALPHAD approach identified dominant phases such as BCC_A2, FCC_A1, DIAMOND_FCC_ A4, and IONIC_LIQ, with phase stability strongly dependent on temperature and silicon content. The results demonstrate that zinc electrolysis residues can be effectively integrated into clinker production, improving material efficiency while reducing the consumption of virgin raw materials. This approach offers a sustainable solution for industrial waste management and contributes to environmental protection and circular economy practices.

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