Toward Sustainable Hydrometallurgy: A Closed-Loop Acetic Acid Recycling Process for Transforming Mining Waste Rock into High-Grade Phosphate Ore and Brushite Mineral

Given the rising demand for phosphate, a critical mineral for many countries due to its essential role in fertilizer production and global food security, reprocessing waste generated during phosphate mining has become increasingly important to mitigate demand pressures and reduce the environmental impact of the mining industry. This study aims to develop a sustainable hydrometallurgical process to recover residual phosphate from a lithology present in mining waste rock. To this end, a thermodynamic analysis was first performed to assess reaction feasibility during leaching and precipitation. A two-step process was then proposed: the first step involves leaching carbonates (mainly calcite) using acetic acid, optimized through response surface methodology based on a Box–Behnken design; the second step consists of precipitating calcium with phosphoric acid to produce a value-added by-product (brushite) while simultaneously regenerating the acetic acid. A preliminary economic assessment was conducted to evaluate process feasibility. The results show that acetic acid is highly selective for carbonates, yielding a phosphate concentrate containing 30% P2O5 with complete phosphate recovery under the following conditions: 3.4 molL−1 acid concentration, 28 °C reaction temperature, a liquid-to-solid ratio of 6 mLg−1 (14.2% solids), and a reaction time of 49 min. In the precipitation step, a calcium recovery of 97% was achieved under optimal conditions (20 °C, 15 min, 500 rpm stirring, and a P:Ca ratio of 1). Furthermore, the preliminary economic assessment indicates that the developed process, based on the use of an organic acid and its recycling, generates a net profit, confirming its economic viability and its contribution to environmentally sustainable phosphate processing.