A novel method for the stabilization of soluble contaminants in electrolytic manganese residue: Using low-cost phosphogypsum leachate and magnesia/calcium oxide

Stabilizing behaviors of Pseudomonas putida and Pseudomonas alcaligenes bacteria on heavy metal ions in electrolytic manganese residue

Electrolytic manganese residue (EMR) contains a significant amount of Mn ions as well as Zn, Cu and Cd ions, which have negative environmental impacts due to their toxicity. This study aims to investigate the effects of Pseudomonas putida (P. putida) and Pseudomonas alcaligenes (P. alcaligenes) on the stabilization of heavy metal ions in both simulated solutions and the EMR. The results demonstrated that the synergy of P. putida and P. alcaligenes was more effective than either P. putida or P. alcaligenes alone in stabilizing Mn ions. However, the presence of higher concentration of Zn, Cu and Cd ions in the simulated solution weakened the stabilization effect of Mn ions. Fortunately, when P. putida and P. alcaligenes were synergized together, they exhibited a stronger performance in stabilizing heavy metal ions present in the EMR compared to the bacteria employed alone. After 12 days of fermentation in the EMR slurry, almost all Mn ions were eliminated through the formation of deposits, while the concentrations of Zn, Cu and Cd ions decreased to 0.28 mg/L, 0.2 mg/L and 0.1 mg/L respectively after 10 days fermentation. Under the synergy of P. putida and P. alcaligenes, soluble components such as MnSO4·H2O, (NH4)2Mn(SO4)2·6 H2O and Zn, Cu and Cd compounds from the EMR were transformed into insoluble compounds including (MnCO3, Mn3(PO4)2·3 H2O, Mn2Zn(PO4)2·4 H2O, MnFe2(PO4)2(OH)2·8 H2O), Cu5Zn(PO4)2(OH)6·H2O and Cd(OH)2) for the stabilization of heavy metals ions in the EMR. This study proposes an eco-friendly and low-cost method for rendering EMR harmless through pretreatment.

The treatment of phosphogypsum leachate is more urgent than phosphogypsum

Phosphogypsum(PG) is one of the typical bulk industrial solid wastes generated in the phosphate chemical industry. Due to its huge production volume and immature resource treatment technology, a large amount of PG can only be stored and disposed in slag yards, and its impact on the ecological environment is becoming increasingly significant during long-term storage. Up to now, many researchers have focused their research on PG, with less attention paid to the PG leachate(PG-L). On the basis of the resource utilization of PG, this article analyzed the migration and transformation of pollutants and their impact on the ecological environment during long-term storage of PG. The content of pollutants in PG-L and PG was compared, and it was found that the content of toxic and harmful substances in PG-L was significantly higher than that in PG itself, and the pollution diffusion ability was greater than that of PG, the pollution of PG to the ecological environment is mainly caused by PG-L, indicating that the harmless treatment of PG-L is more urgent than PG. On the basis of traditional leachate treatment methods, a new technology of valuable element recovery and electrochemical synergistic treatment is proposed to achieve high value-added treatment of PG-L.

Life cycle assessment of electrolytic manganese metal production

Manganese is an indispensable metal widely used in various fields. China ranks as the fourth-largest producer of manganese ore and the largest producer of electrolytic manganese metal (EMM). However, EMM production is linked to high energy consumption and pollution. This study conducts a life cycle assessment (LCA) of EMM production in the Manganese Triangle region of China to comprehensively evaluate its environmental impact. Results show that Human carcinogenic toxicity, mainly from electricity generation (65.3 %) and mining activities (24.4 %), is the most significant environmental impact. Chromium (VI) is identified as the predominant hazardous substance, contributing up to 91 % to Human carcinogenic toxicity. Endpoint results estimate that the production of 1 t of EMM results in 1.01E-02 DALY of harm to human health, 1.97E-05 species.yr of harm to the ecosystem, and $227.15 worth of resource depletion. Simulation scenarios demonstrate that replacing thermal power with hydropower can reduce environmental pollution by over 90 %. Finally, based on the findings, technical measures for promoting clean production of EMM were proposed.

A review of metallurgical slags as catalysts in advanced oxidation processes for removal of refractory organic pollutants in wastewater

With the rapid growth of the metallurgical industry, there is a significant increase in the production of metallurgical slags. The waste slags pose significant challenges for their disposal because of complex compositions, low utilization rates, and environmental toxicity. One promising approach is to utilize metallurgical slags as catalysts for treatment of refractory organic pollutants in wastewater through advanced oxidation processes (AOPs), achieving the objective of "treating waste with waste". This work provides a literature review of the source, production, and chemical composition of metallurgical slags, including steel slag, copper slag, electrolytic manganese residue, and red mud. It emphasizes the modification methods of metallurgical slags as catalysts and the application in AOPs for degradation of refractory organic pollutants. The reaction conditions, catalytic performance, and degradation mechanisms of organic pollutants using metallurgical slags are summarized. Studies have proved the feasibility of using metallurgical slags as catalysts for removing various pollutants by AOPs. The catalytic performance was significantly influenced by slags-derived catalysts, catalyst modification, and process factors. Future research should focus on addressing the safety and stability of catalysts, developing green and efficient modification methods, enhancing degradation efficiency, and implementing large-scale treatment of real wastewater. This work offers insights into the resource utilization of metallurgical slags and pollutant degradation in wastewater.

Progress in comprehensive utilization of electrolytic manganese residue: a review

Electrolytic manganese residue (EMR) is a solid waste produced in the process of electrolytic manganese metal (EMM) production. In recent years, the accumulation of EMR has caused increasingly serious environmental problems. To better understand the state of EMR recycling in recent years, this paper used a comprehensive literature database to conduct a statistical analysis of EMR-related publications from 2010 to 2022 from two perspectives: harmless green treatment and resource utilization. The results showed that the research on the comprehensive utilization of EMR mainly focused on the fields of chemical hazard-free treatment and manufacturing building materials. The related studies of EMR in the fields of biological harmlessness, applied electric field harmlessness, manganese series materials, adsorbents, geopolymers, glass-ceramics, catalysts, and agriculture were also reported. Finally, we put forward some suggestions to solve the EMR problem, hoping that this work could provide a reference for the clean disposal and efficient utilization of EMR.

Utilization path of bulk industrial solid waste: A review on the multi-directional resource utilization path of phosphogypsum

Phosphogypsum is one of the hottest issues in the field of environmental solid waste treatment, with complex and changeable composition. Meanwhile, phosphogypsum contains a large number of impurities, thus leading to the low resource utilization rate, and it can only be stockpiled in large quantities. Phosphogypsum occupies a lot of land and poses a serious pollution threat to the ecological environment. This paper mainly summarizes the existing pretreatment and resource utilization technology of phosphogypsum. The pretreatment mainly includes dry method and wet method. The resource utilization technology mainly includes building materials, chemical raw materials, agriculture, environmental functional materials, filling materials, carbon sequestration and rare and precious extraction. Although there are many aspects of resource utilization of phosphogypsum, the existing technology is far from being able to consume a large amount of accumulated and generated phosphogypsum. Through the analysis, the comparison and mechanism analysis of the existing multifaceted and multi-level resource treatment technologies of phosphogypsum, the four promising resource utilization directions of phosphogypsum are put forward, mainly including prefabricated building materials, eco-friendly materials and soil materials, and new green functional materials and chemical fillers. Moreover, this paper summarizes the research basis of multi field and all-round treatment and disposal of phosphogypsum, which reduces repeated researches and development, as well as the treatment cost of phosphogypsum. This paper could provide a feasible research direction for the resource treatment technology of phosphogypsum in the future, so as to improve the consumption of phosphogypsum and reduce environmental risks.

Electrolytic manganese residue disposal based on basic burning raw material: Heavy metals solidification/stabilization and long-term stability

Solidification/stabilization (S/S) is an option for the treatment of electrolytic manganese residue (EMR). Basic burning raw material (BRM) could successfully solidify/stabilize EMR, though heavy metals S/S mechanism and long-term stability remain unclear. Herein, Mn²⁺ and NH₄⁺ S/S behavior, hydrated BRM and S/S EMR characterization, Mn²⁺ long-term leaching behavior, phase and morphology changes for long-term leaching were discussed in detail to clarify these mechanisms. Mn²⁺ and NH₄⁺ leaching concentrations as well as pH value in S/S EMR were respectively 0.02 mg/L, 0.68 mg/L and 8.75, meeting the regulations of Chinese standard GB 8978-1996. Long-term stability of EMR was significantly enhanced after S/S. Mn²⁺ leaching concentration, Mn²⁺ migration, Mn²⁺ cumulative release, Mn²⁺ apparent diffusion coefficient and conductivity of EMR reduced to 0.05 mg/L, 5.5 × 10^-6 mg/(m²·s), ~ 9 mg/m², 6.30 × 10^-15 m²/s and 435 μs/cm. Mechanism studies showed that the hydration of BRM forms OH^-, calcium silicate hydrate gels (C-S-H) and ettringite. Therefore, during S/S process, NH₄⁺ was escaped as NH₃, Mn²⁺ was solidified/stabilized as tephroite (Mn₂SiO₄), johannsenite (CaMnSi₂O₆) and davreuxite (MnAl₆Si₄O₁₇(OH)₂), and Pb²⁺, Cu²⁺, Ni²⁺, Zn²⁺ were solidified/stabilized by C-S-H and ettringite via substitution and encapsulation. This study provides a good choice for EMR long-term stable storage.

Exploring the microbial community inhabiting the phosphogypsum stacks of Huelva (SW SPAIN) by a high throughput 16S/18S rDNA sequencing approach

Around 100 Mt of phosphogypsum (PG) have been deposited in large stacks on the salt marshes of the Tinto River estuary in Huelva (SW Spain), covering about 1000 ha. These stacks contain extremely acidic water (pH < 2) with high concentrations of pollutants which can cause emissions into their surroundings, generating important environmental concerns. Despite many chemical, geological or hydrological studies have been conducted to characterize the PG stacks of Huelva, the microbial community inhabiting this extreme environment remains unexplored. Using a 16S/18S-rRNA-high throughput sequencing approach, we have uncovered the main taxonomic groups able to live in the acidic metal-contaminated water, which is in direct contact with the PG, demonstrating for the first time the existence of a huge diversity of microbial species in these extreme conditions. In addition, the physicochemical characteristics of the water sampled have been analyzed. These studies have revealed that the most abundant bacteria found in two different leachate samples of the PG stacks belong to the genera Acidiphilium, Pseudomonas, Leptosprillum, Acidithrix, or Acidithiobacillus, typically found in acid mine drainage (AMD) environments, which in total represent around 50% of the total bacterial community. Biodiversity of eukaryotes in PG water is lower than that of prokaryotes, especially in the water collected from the perimeter channel that surrounds the PG stacks, where the pH reaches a value of 1.5 and the activity concentrations exceed 300 Bq L^-1 for ²³⁸U or 20 Bq L^-1 for ²¹⁰Po, values which are from four to five orders of magnitude higher than those usually found in unperturbed surface waters. Even so, an unexpected diversity of algae, fungi, and ciliates have been found in the PG stacks of Huelva, where chlorophyte microalgae and basidiomycetes fungi are the most abundant eukaryotes. Additional bioinformatics tools have been used to perform a functional analysis and predict the most common metabolic pathways in the PG microbiota. The obtained data indicate that the extreme conditions of these PG stacks hide an unexpected microbial diversity, which can play an important role in the dynamics of the contaminating compounds of the PG and provide new strains with unique biotechnological applications.

Synergistic solidification/stabilization of electrolytic manganese residue and carbide slag

Electrolytic manganese residue (EMR) contains high concentrations of NH₄⁺ and heavy metals, such as Mn²⁺, Zn²⁺, Cu²⁺, Pb²⁺, Ni²⁺ and Co²⁺, while carbide slag (CS) contains high amount of OH^- and CO₃^2-, both posing a serious threat to the ecosystem. In this study, EMR and CS synergistic stabilization/solidification (S/S) was discussed science CS could stabilize or solidify EMR and simultaneously reduce its corrosive. The results showed that after the synergistic S/S for 24 h when liquid-solid ratio was 17.5% and CS dosage was 7%, Mn²⁺ and NH₄⁺ leaching concentrations of the S/S EMR were below the detection limits (0.02 mg/L and 0.10 mg/L) with a pH value of 8.8, meeting the requirements of the Chinese integrated wastewater discharge standard (GB 8978-1996). Mn²⁺ was stabilized as MnFe₂O₄, Mn₂SiO₄, CaMnSi₂O₆, and NH₄⁺ escaped as NH₃. Zn²⁺, Cu²⁺, Pb²⁺, Ni²⁺ and Co²⁺ in EMR can also be stabilized/solidified because of the react with OH^- and CO₃^2- in CS. Chemical cost was only $ 0.54 for per ton of EMR synergistic harmless treatment with CS. This study provided a new idea for EMR cost-effective and environment-friendly harmless treatment.

A critical review on approaches for electrolytic manganese residue treatment and disposal technology: Reduction, pretreatment, and reuse

Electrolytic manganese residue (EMR) has become a barrier to the sustainable development of the electrolytic metallic manganese (EMM) industry. EMR has a great potential to harm local ecosystems and human health, due to it contains high concentrations of soluble pollutant, especially NH₄⁺ and Mn²⁺, and also the possible dam break risk because of its huge storage. There seems to be not a mature and stable industrial solution for EMR, though a lot of researches have been done in this area. Hence, by fully considering the EMM ecosystem, we analyzed the characteristics and eco-environmental impact of EMR, highlighted state-of-the-art technologies for EMR reduction, pretreatment, and reuse; indicated the factors that block EMR treatment and disposal; and proposed plausible and feasible suggestions to solve this problem. We hope that the results of this review could help solve the problem of EMR and thus promote the sustainable development of EMM industry.

Selective recovery of manganese from electrolytic manganese residue by using water as extractant under mechanochemical ball grinding: Mechanism and kinetics

This research aimed to address the issue of residual manganese in electrolytic manganese residue (EMR), which is difficult to recycle and can easily become an environmental hazard and resource waste. This research developed a method for the efficient and selective recovery of manganese from EMR and the removal of ammonia nitrogen (ammonium sulfate) under the combined action of ball milling and oxalic acid. The optimum process parameters of this method were obtained through single-factor experiment and response-surface model. Results showed that the recovery rate of manganese can exceed 98%, the leaching rate of iron was much lower than 2%, and the leaching rates of manganese and ammonia nitrogen after EMR ball grinding were 1.01 and 13.65 mg/L, respectively. Kinetics and mechanism studies revealed that ammonium salts were primarily removed in the form of ammonia, and that insoluble manganese (MnO₂) was recovered by the reduction of FeS and FeS₂ in EMR under the action of oxalic acid. Iron was solidified in the form of Fe₂O₃ and Fe₂(SiO₃)₃. The technology proposed in this research has great industrial application value for the recycling and harmless treatment of EMR.

Electrolytic manganese residue-based cement for manganese ore pit backfilling: Performance and mechanism

Slag backfilling with electrolytic manganese residue (EMR) is an economical and environmentally-friendly method. However, high ammonium-nitrogen and manganese ions in EMRs limit this practice. In this study, a method of highly efficient simultaneous stabilization/solidification of ultrafine EMR by making EMR-based cementitious material (named EMR-P) was proposed and tested via single-factor and response surface optimization experiments. Results show that the stabilization efficiency of NH₄⁺ and Mn²⁺ were above 95%, and the unconfined compressive strength of the EMR-P was 18.85 MPa (megapascal = N/mm²). The mechanistic study concluded that the soluble manganese sulfate and ammonium sulfate in EMR were converted into the insoluble precipitates of manganite (MnOOH), gypsum (CaSO₄), MnNH₄PO₄·H₂O, and struvite (MgNH₄PO₄∙6 H₂O), leading to the stabilization of NH₄⁺ and Mn²⁺ in the EMR-P. Leaching tests of EMR-P indicated that NH₄⁺, Mn²⁺, and others heavy metals in the leachate were within the permitted level of the GB/T8978-1996. The novelty of this study includes the addition of phosphate and magnesium ions to precipitate ammonium-nitrogen and the combination between calcium ions (from CaHPO₄∙2 H₂O) and sulfate (from the EMR) to form calcium sulfate to improve the stability and unconfined compressive strength of cementitious materials (EMR-P).

Bio-leaching of manganese from electrolytic manganese slag by Microbacterium trichothecenolyticum Y1: Mechanism and characteristics of microbial metabolites

The related microbial metabolomics on biological recovery of manganese (Mn) from Electrolytic Manganese Slag (EMS) has not been studied. This study aimed at open the door to the metabolic characteristics of microorganisms in leaching Mn from EMS by using waste molasses (WM) as carbon source. Results show Microbacterium trichothecenolyticum Y1 (Y1) could effectively leach Mn from EMS in combination with using waste molasses as carbon and energy sources. For the first time, Y1 was identified to be capable of generating and then metabolizing several organic acids or other organic matter (e.g., fumaric acid, succinic acid, malic acid, glyoxylic acid, 3-hydroxybutyric acid, glutaric acid, L(+)-tartaric acid, citric acid, tetrahydrofolic acid, and L-methionine). The production of organic acids by Y1 bacteria was promoted by EMS with the carbon source. This study demonstrated for the first time that metabolic characteristics and carbon source metabolic pathways of Y1 in bioleaching of Mn from EMS.

A low cost of phosphate-based binder for Mn2+ and NH4+-N simultaneous stabilization in electrolytic manganese residue

Electrolytic manganese residue (EMR) is a solid waste remained in filters after using sulfuric acid to leaching manganese carbonate ore. EMR contains high concentration of soluble manganese (Mn²⁺) and ammonia nitrogen (NH₄⁺-N), which seriously pollutes the environment. In this study, a low cost of phosphate based binder for Mn²⁺ and NH₄⁺-N stabilization in EMR by low grade-MgO (LG-MgO) and superphosphate was studied. The effects of different types of stabilizing agent on the concentrations of NH₄⁺-N and Mn²⁺, the pH of the EMR leaching solution, stabilizing mechanisms of NH₄⁺-N and Mn²⁺, leaching test and economic analysis were investigated. The results shown that the pH of the EMR leaching solution was 8.07, and the concentration of Mn²⁺ was 1.58 mg/L, both of which met the integrated wastewater discharge standard (GB8978-1996), as well as the concentration of NH₄⁺-N decreased from 523.46 mg/L to 32 mg/L, when 4.5 wt.% LG-MgO and 8 wt.% superphosphate dosage were simultaneously used for the stabilization of EMR for 50 d Mn²⁺ and NH₄⁺-N were mainly stabilized by Mn₃(PO₄)₂·2H₂O, MnOOH, Mn₃O₄, Mn(H₂PO₄)₂·2H₂O and NH₄MgPO₄·6H₂O. Economic evaluation revealed that the treatment cost of EMR was $ 11.89/t. This study provides a low-cost materials for NH₄⁺-N and Mn²⁺ stabilization in EMR.