Hazard-free treatment of electrolytic manganese residue and recovery of manganese using low temperature roasting-water washing process

Synergistic solidification and mechanism research of electrolytic manganese residue and coal fly ash based on C-A-S-H gel material

Electrolytic manganese residue (EMR) is known for high concentrations of Mn2+, NH4+, and heavy metals. Failure to undergo benign treatment and landfill disposal would undeniably lead to negative impacts on the quality of the surrounding ecological environment. This study sought to mitigate the latent environmental risks associated with EMR using a cooperative solidification/stabilization (S/S) method involving coal fly ash (CFA). Leveraging leaching toxicity tests, the leaching behavior of pollutants in electrolytic manganese residue-based geopolymer materials (EMRGM) was determined. At the same time, mechanistic insights into S/S processes were explored utilizing characterization techniques such as XRF, XRD, FT-IR, SEM-EDS, and XPS. Those results confirmed significant reductions in the leaching toxicities of Mn2+ and NH4+ to 4.64 μg/L and 0.99 mg/L, respectively, with all other heavy metal ions falling within the permissible limits set by relevant standards. Further analysis shows that most of NH4+ volatilizes into the air as NH3, and a small part is fixed in the EMRGM in the form of struvite; in addition to being oxidized to MnOOH and MnO2, Mn2+ will also be adsorbed and wrapped by silicon-aluminum gel together with other heavy metal elements in the form of ions or precipitation. This research undeniably provides a solid theoretical foundation for the benign treatment and resourceful utilization of EMR and CFA, two prominent industrial solid wastes.

Enhanced green remediation and refinement disposal of electrolytic manganese residue using air-jet milling and horizontal-shaking leaching

The reclamation and reuse of electrolytic manganese residue (EMR) as a bulk hazard solid waste are limited by its residual ammonia nitrogen (NH4+-N) and manganese (Mn2+). This work adopts a co-processing strategy comprising air-jet milling (AJM) and horizontal-shaking leaching (HSL) for refining and leaching disposal of NH4+-N and Mn2+ in EMR. Results indicate that the co-use of AJM and HSL could significantly enhance the leaching of NH4+-N and Mn2+ in EMR. Under optimal milling conditions (50 Hz frequency, 10 min milling time, 12 h oscillation time, 400 rpm rate, 30 ℃ temperature, and solid-to-liquid ratio of 1:30), NH4+-N and Mn2+ leaching efficiencies were optimized to 96.73% and 97.35%, respectively, while the fineness of EMR was refined to 1.78 µm. The leaching efficiencies of NH4+-N and Mn2+ were 58.83% and 46.96% higher than those attained without AJM processing. The AJM used strong airflow to give necessary kinetic energy to EMR particles, which then collided and sifted to become refined particles. The AJM disposal converted kinetic energy into heat energy upon particle collisions, causing EMR phase transformation, and particularly hydrated sulfate dehydration. The work provides a fire-new and high-efficiency method for significantly and simply leaching NH4+-N and Mn2+ from EMR.

Ammonia removal and simultaneous immobilization of manganese and magnesium from electrolytic manganese residue by a low-temperature CaO roasting process

A large amount of open-dumped electrolytic manganese residue (EMR) has posed a severe threat to the ecosystem and public health due to the leaching of ammonia (NH4+) and manganese (Mn). In this study, CaO addition coupled with low-temperature roasting was applied for the treatment of EMR. The effects of roasting temperature, roasting time, CaO-EMR mass ratio and solid-liquid ratio were investigated. The most cost-effective and practically viable condition was explored through response surface methodology. At a CaO: EMR ratio of 1:16.7, after roasting at 187 °C for 60 min, the leaching concentrations of NH4+ and Mn dropped to 10.18 mg/L and 1.05 mg/L, respectively, below their discharge standards. In addition, the magnesium hazard (MH) of EMR, which was often neglected, was studied. After treatment, the MH of the EMR leachate was reduced from 60 to 37. Mechanism analysis reveals that roasting can promote NH4+ to escape as NH3 and convert dihydrate gypsum to hemihydrate gypsum. Mn2+ and Mg2+ were mainly solidified as MnO2 and Mg(OH)2, respectively. This study proposes an efficient and low-cost approach for the treatment of EMR and provides valuable information for its practical application.

Innovative co-treatment technology for effective disposal of electrolytic manganese residue

Electrolytic manganese residue (EMR) stockpiles contain significant amounts of Mn2+ and NH4+-N which pose a risk of environmental pollution. For EMR safe disposal, an innovative approach is proposed that involves direct sodium silicate-sodium hydroxide (Na2SiO3-NaOH) collaborative technology. This approach utilises Na2SiO3 and NaOH as the solidifying agent and activator, respectively, to treat EMR without hazardous effects. The study also provides insights into the kinetics of Mn2+ leaching under the effect of Na2SiO3-NaOH. Leaching efficiency was determined by varying parameters such as stirring rate, reaction temperature, pH of the initial solution, Na2SiO3 concentration, and reaction time to investigate the efficacy of this method. The study indicates that the co-treatment technology of Na2SiO3-NaOH can achieve maximum solidification efficiencies of 99.7% and 98.2% for Mn2+ and NH4+-N, respectively. The process can successfully solidify Mn2+ by synthesising Mn(OH)2 and MnSiO3 in an alkaline environment under optimal conditions including stirring rate of 450 rpm, initial solution pH of 8, test temperature of 40 °C, test time of 420 min, and Na2SiO3 content of 5%. The findings of this study have confirmed that surface chemistry plays a vital role in regulating the test rate and the proposed equation accurately describes Mn2+ leaching kinetics. Overall, the co-treatment technology involving Na2SiO3-NaOH is a viable solution for EMR resource utilisation without compromising environmental safety. This method has the potential to be implemented for other waste streams with comparable compositions, ultimately promoting the sustainable management of waste.

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.

Characteristic pollutants risk assessment of modified manganese residue utilization in sintered product

The resource disposal of electrolytic manganese residue can effectively solve the problem of environmental pollution caused by it, among which the problem of heavy metal pollution is the most prominent. In this study, a new type of eco-friendly brick mixed with electrolytic manganese residue was designed. The influence of the content of electrolytic manganese residue on its macroscopic properties, microscopic properties, and leaching characteristics was analyzed by test methods such as compressive strength test, radioactivity test, XRF, XRD, FTIR, and ICP test of bricks. The results showed that the manganese content in the EMR leachate was 8120 mg/L, which exceeded the Chinese standard. The leaching experiment of ordinary aqueous solution of sintered bricks mixed with 20% EMR showed that the content of heavy metals was far lower than the Chinese national standard. There was no non-carcinogenic risk of heavy metals in the strong acid leaching solution of sintered bricks mixed with 20% EMR. Only the carcinogenic risk values of Cr for adults and children were 4.21 × 10^-4 and 9.82 × 10^-4 respectively, both exceeding the USEPA limit, but the application scene of sintered bricks was difficult to achieve strong acidity, so it was judged that it had no carcinogenic risk to the human body. Characteristic heavy metals such as Mn, Cr, and As existed stably in sintered bricks through substitution and encapsulation. In addition, the compressive strength and radioactivity of EMR sintered bricks met the requirements of the Chinese national standard "Fired Ordinary Bricks." This product can be used as national standard MU20 grade brick. This study provided an efficient method for the safe and environmentally friendly disposal of EMR in a sustainable control system.

Co-stabilization/solidification of heavy metals in municipal solid waste incineration fly ash and electrolytic manganese residue based on self-bonding characteristics

Municipal solid waste incineration (MSWI) fly ash and electrolytic manganese residue (EMR) were classified as hazardous waste, must be harmlessly processed prior to subsequent treatment or disposal. The competition between massive free manganese ions of raw EMR and other heavy metals was found, thus raw EMR was pretreated by calcining to eliminate competition of manganese with other heavy metals for stabilizer complexation. MSWI fly ash was successfully solidified with 6% NaH₂PO₄, 6% H₂NCSNH₂ and 20% sintered EMR (800 °C). The addition of sintered EMR enhanced solidification/stabilization of heavy metals in fly ash and the resulting product had a higher compressive strength for further reutilization like trench backfilling, structural fill and void filling. The stabilization/solidification mechanism of heavy metals was attributed to the combined interaction of heavy metal precipitation in stabilizers and ion exchange or physical encapsulation in silicate compounds like calcium silicate, which is a feasible and valuable approach to co-disposal of MSWI fly ash and EMR.

The Mechanical and Tribological Properties of Epoxy-Based Composites Filled with Manganese-Containing Waste

Waste from large-scale production processes is a growing environmental problem that can potentially be solved by using this waste as fillers in polymeric composites to improve the mechanical and tribological properties of polymeric matrixes. This paper presents research concerning how the introduction of fillers in the form of manganese residue and manganese(II) oxide changes the mechanical and tribological properties of epoxy composites produced by gravity casting. The research was carried out for composites with 2.5 wt.%, 5 wt.%, and 10 wt.% of fillers. Properties such as the density, hardness, resilience, flexural strength, deflection, flexural modulus, tensile strength, elongation at break, and Young's modulus were determined. Moreover, based on the ball-on-plate test, the wear volume and friction coefficients of the tested materials were determined. Microscopic images of the abrasion profiles were also obtained. The geometry of the wear paths was measured with a profilometer, and the results showed that introducing fillers reduced the abrasive wear of the composites; however, in all cases, the fillers decreased the strength of the tested materials.

Screening of silicon-activating bacteria and the activation mechanism of silicon in electrolytic manganese residue

Electrolytic manganese residue (EMR) is a kind of solid waste with a high silicon content. Most of the silicon in EMR, however, exist in the state of SiO₂, which cannot be directly absorbed by plants. Currently, it is very challenge to recover the silicon from EMR. In this study, a preliminary screening of strains with silicon-activating ability was conducted, and four strains were screened out and isolated from the soil around the tailings pond of EMR. Then, single factor experiments were conducted to obtain the optimal growth conditions of the four strains, and the results indicated that the Ochrobactrum sp. T-07 had the best silicon-activating ability from EMR after nitrosoguanidine mutagenesis (Ochrobactrum sp. T-07-B). The available silicon (in terms of SiO₂) in the leaching solution was up to 123.88 mg L^-1, which was significantly higher than that produced by Bacillus circulans and Paenibacillus mucilaginosus, the two commercial available pure culture strains. Results of direct/indirect contact experiments between Ochrobactrum sp. T-07-B and EMR revealed that bioleaching was promoted under the synergistic effect of bacteria growth on the surface of and metabolism within EMR. The newly isolated strains with silicon-activating effect are different from the existing-known silicate bacteria and may be used for more efficient silicon activation in silicate minerals.

Analysis of Basic Physical and Chemical Characteristics of Manganese Slag before and after Solidification and Its Feasibility as Highway Slope

Manganese slag is a kind of industrial waste produced by electrolytic production of manganese metal. The traditional method of stacking manganese slag not only causes waste of resources, but also produces environmental pollution. Finding harmless, effective, and economical disposal technology of manganese slag has gradually become a research hotspot and difficulty in the field of electrolytic manganese industry and environmental protection. To verify the feasibility of using manganese slag as roadbed material, the basic physical and chemical properties of manganese slag were analyzed based on X-ray diffraction, X-ray fluorescence spectrum, SEM scanning electron microscope, and particle analysis, the basic engineering characteristics of raw materials of manganese slag and solidified manganese slag mixed with quicklime were analyzed through a compaction test and a CBR test. Finally, based on the Monte Carlo method, the stability of a highway slope in the Guizhou Province of China is simulated by the finite element method, considering the spatial variability of manganese slag material strength parameters. The results show that the solidified manganese slag material can be used as highway subgrade material. This study has important reference significance for manganese slag highway construction projects.