Controlled Jarosite Formation as a Multifunctional Hydrometallurgical Circuit-Integration Tool: Fundamentals, Applications, Benefits, and Limitations—A Critical Review
Keywords:
Jarosite precipitation, iron removal, circuit integration, impurity partitioning, solid–liquid separation, residue valorizationAbstract
Jarosite precipitation is typically treated as an iron-removal operation that produces a bulky residue. This critical narrative review evaluates controlled jarosite formation as a multifunctional tool for integrating hydrometallurgical circuits and asks when it also meets stricter process-intensification criteria. The evidence base combines recent literature from 2020–August 2026 with seminal studies on phase stability, precipitation kinetics, impurity incorporation, continuous operation, and seed recycling. Direct evidence is strongest for ferric-iron removal and zinc-liquor purification; benefits for ion exchange, membranes, high-purity crystallization, and some battery circuits remain largely inferential. Ideal alkali jarosites generate approximately 2.86–2.99 kg of solid, fix about 1.15 kg of sulfate, and produce about 1.76 kg of H2SO4 equivalent per kilogram of Fe precipitated. These stoichiometric penalties make residue mass and acid balance intrinsic design variables. Controlled precipitation can remove Fe(III), transfer sulfate to a separable solid, capture selected hazardous elements, and potentially reduce downstream impurity loads. Conversely, excessive supersaturation, uncontrolled neutralization, poor seed management, or deposition on mineral and equipment surfaces can cause ultrafines, scaling, passivation, losses of valuable metals, and unstable residues. Route selection must therefore consider residual Fe, target-metal retention, particle and cake properties, water and reagent balances, evidence maturity, annualized whole-circuit economics, and residue destination. The review proposes an evidence-qualified decision framework and identifies continuous campaigns, full impurity and wash balances, quantitative filtration data, activity-based thermodynamics, technoeconomic assessment, and life-cycle verification as research priorities
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