Synergistic preparation and application in PCU of α-calcium sulfate hemihydrate whiskers from phosphogypsum and electrolytic manganese residue

The α-calcium sulfate hemihydrate whiskers (α-CSHWs) were first prepared using phosphogypsum (PG) and electrolytic manganese residue (EMR) as raw materials for coating urea, demonstrating excellent controlled-release properties. The effects of different reaction conditions on α-CSHWs, achieved by optimizing the reaction time, the concentrations of NH4+, Mn2+, and other factors, were discussed. Results showed that when the EMR content was 25 wt%, the reaction temperature was 100 °C, and the reaction time was 3 h, α-CSHWs with a length-to-diameter ratio of 39 were obtained. Through experiments and density functional theory (DFT), the mechanism of α-CSHWs preparation was elucidated. The results show that the addition of EMR reduces the content of impurity ions PO43- and F- in PG while introducing NH4+ and Mn2+. Interestingly, both NH4+ and Mn2+ can reduce the nucleation time of α-CSHWs, while PO43-, Mn2+, and F- are more likely to adsorb on the (0 0 6) crystal plane of α-CSHWs, NH4+ readily adsorbs on the (4 0 0) crystal plane. The controlled-release performance of modified α-CSHWs incorporated into polyurethane-coated urea (PCU) was investigated, and it was found that the addition of Mα significantly prolonged the nutrient release period, with the period extending up to 116 days for coatings of 5wt% and above. This work not only enhances the efficiency of PG and EMR utilization but also serves as a reference for the straightforward synthesis and application of α-CSHWs.

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.

Effect of the inoculation of Phanerochaete chrysosporium on nitrogen migration and organic matter conversion during electrolytic manganese residue composting

Composting has made it practicable to dispose electrolytic manganese residues (EMR) in a less toxic way, nevertheless, the decomposition and the loss of nitrogen is a critical issue. This study aimed to investigate the role of Phanerochaete chrysosporium (PC) inoculation on nitrogen migration and promotion of decomposing organic matter (OM), as well as the effect on bacterial community structure during EMR composting. The results exhibited that nitrogen loss tallied with the first-order kinetic model. PC inoculation increased the relative microbial abundance of Firmicutes, which improved the efficiency of nitrogen nitrification and OM degradation, and increased the germination index and total nitrogen content by 13.8% and 2.95 g/kg, respectively. Moreover, aromatic benzenes replaced heteropolysaccharides, alcohols and ethers as the main components of OM in fertilizer, leading up to a more stable humus structure. This study provides a rationale and a novel perspective on the resource and nutrient conservation of EMR-contaminated soils.

Enabling efficient and economical degradation of PCDD/Fs in MSWIFA via catalysis and dechlorination effect of EMR in synergistic thermal treatment

Catalytic thermal treatment is an efficient and low-energy consumption method for degrading polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) in municipal solid waste incineration fly ash (MSWIFA). However, catalysts with high activity are expensive, difficult to separate and reuse from the treated MSWIFA, and they usually pose a risk of heavy metal pollution. Herein, a synergistic thermal treatment method of MSWIFA and electrolytic manganese residue (EMR) at relatively low temperatures was proposed after an in-depth analysis of their mineralogy composition to achieve detoxification of PCDD/Fs in MSWIFA. The mass and WHO-TEQ degradation efficiencies of PCDD/Fs significantly increased from -92.79% and -51.46%-98.57% and 96.10%, respectively, by the addition of electrolytic manganese residue (EMR) with an MSWIFA/EMR ratio of 3:7 in the thermal treatment of MSWIFA at 250 °C for 60 min. The WHO-TEQ concentration of PCDD/Fs in the treated sample decreased to 3.7 ng WHO-TEQ/kg, meeting the European end-of-waste criteria (20 ng WHO-TEQ/kg). The excellent degradation effect of EMR on PCDD/Fs in MSWIFA could be attributed to two aspects: 1) the manganese oxides in EMR has a catalytic effect on the degradation of PCDD/Fs; 2) the NH3 generated by the decomposition of (NH4)2SO4 in EMR is conducive to the degradation and resynthesis inhibition of PCDD/Fs. Besides, the thermodynamic calculations indicated that CaClOH in MSWIFA played a crucial role in the decomposition of (NH4)2SO4 in EMR. In addition, the degradation pathways and mechanisms of PCDD/Fs-homologues under the synergistic effect of manganese oxides, ammonia, and thermal field were investigated through comparative analysis of concentration and fingerprint of PCDD/Fs.

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.

Kinetic and thermodynamic analysis on preparation of belite-calcium sulphoaluminate cement using electrolytic manganese residue and barium slag by TGA

Electrolytic manganese residue (EMR) is a solid filter residue obtained from manganese carbonate ore during the production of metal manganese. A potential avenue towards large-scale utilisation of EMR is its use in cement preparation. However, the preparation of cement materials using EMR requires high-temperature calcination. In this study, the thermal properties and pyrolysis kinetics of belite-calcium sulfoaluminate cement raw meal were systematically studied using a multiple-heating-rate method based on thermogravimetric analysis and a kinetic model. The kinetic and thermodynamic parameters was studied using non-isothermal Flynn-Wall-Ozawa (FWO), Kissinger-Akahira-Sunose (KAS), Friedman and Kissinger methods. The results showed that from 30 to 1300°C, the pyrolysis reaction of cement raw meal was mainly divided into four steps: the crystalline water removal from calcium sulphate dihydrate and bauxite, the ammonia nitrogen removal from ammonium salts and the calcium sulphate crystal transformation; the decomposition of calcium carbonate and carbon-containing organic matter; the sulphate and carbonate substance decomposition and the clinker mineral phase formation. The average activation energies calculated when using the non-isothermal FWO, KAS, Friedman and Kissinger methods were 244.49, 240.7, 239.24 and 380.60 kJ/mol and the average pre-exponential factors were 1.75 × 1020, 3.65 × 1020, 7.11 × 1021 and 1.55 × 1013 s-1, respectively. Herein, the pyrolysis kinetics of the cement raw meal was divided into two main stages: In stage 1 (α: 0.15-0.8, 524°C-754°C), the mechanism of P2/3 accelerated nucleation in the Mampel Power rule, and the reaction mechanism function was G(α)=α3/2. In stage 2 (α: 0.80-0.95, 754°C-1165°C), during the local conversion of α = 0.2-0.8, when α was <0.5, the chemical reaction mechanism of the R3 phase boundary was noted and the mechanism function was G(α) = 1 - (1-α)1/3; however, when α was >0.5, a random nucleation and subsequent growth mechanism of A6 was noted and the mechanism function was G(α) = [-ln(1 - α)]2/3.

Exploring the migration and transformation behaviors of heavy metals and ammonia nitrogen from electrolytic manganese residue to agricultural soils through column leaching test

Heavy metals (HMs) and ammonia nitrogen (AN) leaching from electrolytic manganese residue (EMR) result in the contamination of agricultural soils and water bodies. Batch and column leaching tests were conducted to simulate the release of HMs and AN in EMR during precipitation, as well as their migration and transformation in agricultural soils. The results show that Mn, AN, Cd, Ni, and Zn present in the EMR had high acid soluble fraction (un-fixed AN) content, and the leachability of Mn and AN was significantly higher than that of other hazardous elements. The cumulative release of hazardous elements in the EMR stockpile was well-fitted (R2 > 0.95) by the HILL model. Significant HMs and AN accumulated in the agricultural soils after contamination from the EMR leachate. The pollution degree of HMs in agricultural soils was ranked as Mn > Ni > Pb ≈ Zn ≈ Cr > Cd. The acid soluble fraction (un-fixed AN) content of Mn, Ni, Zn, and AN in agricultural soils increased significantly. The risk assessment code shows that the risk level of Mn in agricultural soils changed from medium to high; Ni and Zn in surface soils changed from low to medium. These results indicated that the leaching from EMR would significantly increase the ecological risk of HMs in surrounding agricultural soils, and the large release of AN would pose a great threat to aquatic systems if not properly addressed.

Deep insight into green remediation and hazard-free disposal of electrolytic manganese residue-based cementitious material

This work presents an innovative approach to developing a low-carbon and hazard-free cementitious material (EGC) by activating ground granulated blast-furnace slag (GGBS) with electrolytic manganese residue (EMR), which has an excellent heavy metal solidified capacity. Herein, the multi-step leaching was creatively conducted to investigate the solidified morphology of heavy metals in hazardous EMR. CO₂ emission per unit strength factor was calculated to quantitatively analyze the low-carbon degree. The results show that the added hazardous EMR rich in sulfate and the dilution effect caused by the decrease in GGBS lessen the final setting time and fluidity. Low-temperature calcination (200 °C) alters the dissolution rate of ettringite and AFm-like phases by changing the sulfate crystal. Excessive acidic EMR consumes more calcium hydroxide and lowers the pH of the EGC system, resulting in weakened GGBS activity. The formation of jouravskite, thaumasite, and henritermierite are AFm-like hydrated lamellated structures, which provides evidence for the immobilization of Mn²⁺ in EMR. Vast Mn²⁺ are embedded in the main interlayer of [Ca₂Al(OH)₆]⁺ by substituting Al to form AFm-like phase. The lowest 60d unit compressive strength carbon emission of the EGC system containing 20 % calcinated EMR is 0.78 kg∙MPa^-1∙m^-3, meaning the substitution barrier is better addressed by adding calcined EMR. This work provides an innovative solution for high value-added and hazard-free utilization for EMR and carbon reduction in the cement industry.

Study on mutual harmless treatment of electrolytic manganese residue and red mud

Electrolytic manganese residue (EMR) and red mud (RM) are solid waste by-products of the metal manganese and alumina industries, respectively. Under long-term open storage, ammonia nitrogen and soluble manganese ions in EMR and alkaline substances in RM severely pollute and harm the environment. In order to alleviate the pollution problem of EMR and RM. In this study, the alkaline substances in RM were used to treat ammonia nitrogen and soluble manganese ions in EMR. The results confirm the following suitable treatment conditions for the mutual treatment of EMR and RM: EMR-RM mass ratio = 1:1, liquid-solid ratio = 1.4:1, and stirring time = 320 min. Under these conditions, the elimination ratios of ammonia nitrogen (emitted in the form of ammonia gas) and soluble manganese ions (solidified in the form of Mn3.88O7(OH) and KMn8O16) are 85.87 and 86.63%, respectively. Moreover, the alkaline substances in RM are converted into neutral salts (Na2SO4 and Mg3O(CO3)2), achieving de-alkalinisation. The treatment method can also solidify the heavy metal ions-Cr3+, Cu2+, Ni2+, and Zn2+-present in the waste residue with leaching concentrations of 1.45 mg/L, 0.099 mg/L, 0.294 mg/L, and 0.449 mg/L, respectively. This satisfies the requirements of the Chinese standard GB5085.3-2007. In the mutual treatment of EMR and RM, the kinetics of ammonia nitrogen removal and manganese-ion solidification reactions are controlled via a combination of membrane diffusion and chemical reaction mechanisms.

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.

Release characteristics of heavy metals from electrolytic manganese residue under varying environmental factors

High levels of manganese (Mn) and other heavy metals from electrolytic manganese residue (EMR) stockpiled would be released into the environment under natural conditions. A batch-leaching test was carried out to investigate the release characteristics of heavy metals from EMR with different storage times under simulated environmental conditions such as acid rain with different pH (3.0, 4.5, 5.6, and 7.0) at contact times of 1, 2, 4, 6, and 12 h; liquid to solid ratio (L/S) (5:1, 10:1, 20:1, and 30:1); and temperature (15, 25, 35, and 45 °C). The results showed that low pH (3.0 and 4.5) and high temperature (35 and 45 °C) could significantly promote heavy metal leaching from EMRs and increasing the L/S ratio above 20:1 mL/g significantly decreased heavy metal leachate concentrations due to dilution effect. Cr, Mn, and Pb concentrations in leachate increased almost continuously throughout the leaching process, while Zn decreased slightly at the 12th hour. Meanwhile, heavy metal concentrations in EMR1 (fresh EMR) were higher than in EMR2 (out stockpiled for more than 3 months). The concentrations of Mn, Pb, and Zn in leachates from EMRs at pH 3.0 and 4.5 leaching far exceeded the allowable maximum discharge concentrations for pollutants of the integrated wastewater discharge standard in China (GB8978-1996) by 57.5-59.0, 1.3-4.3, and 1.1-1.8 and 53.5-56.0, 3.04-7.25, and 1.0-1.91 times, respectively. Additionally, the Mn concentrations from both EMR leachates at pH 7.0 were above the national safe emission threshold. The morphological structure of EMRs changed after leaching, and XRD analysis showed the disappearance of MnO₂, SiO₂, FeS₂, and CaSO₄. The XPS revealed that Cr, Mn, Pb, and Zn existed as Cr³⁺, MnO, PbSO₄, and ZnSiO₃, respectively, after leaching. The study concluded that Mn, Pb, and Zn from EMRS leached by acid rain might pose a high potential environmental risk. Therefore, developing appropriate disposal techniques for EMR is necessary to prevent heavy metal pollution.

Environmentally-friendly biorecovery of manganese from electrolytic manganese residue using a novel Penicillium oxalicum strain Z6-5-1: Kinetics and mechanism

Bioleaching is a promising route for electrolytic manganese (Mn) residue (EMR) reutilization due to being eco-friendly and cost-effective. However, microbes with high bioleaching efficiency are scarce. This work aimed to isolate, screen, and characterize a novel fungal strain with high Mn-bioleaching efficiency from EMR, and study the kinetics and mechanism. The novel Penicillium oxalicum strain Z6-5-1 was found to selectively bioleach Mn from EMR. A maximum Mn²⁺ recovery of 93.3 % was achieved after 7 days and was mainly dependent upon acidolysis of the bio-organic acids, specifically gluconic acid and oxalic acid, as well as mycelial biosorption. This efficiency was the highest reported in the literature for a fungus over such a short time. EMR strongly induced P. oxalicum to produce gluconic acid and oxalic acid. The novel transcription factor PoxCxrE of P. oxalicum controlled the production of bio-organic acids by regulating the expression of rate-limiting enzyme genes involved in the biosynthesis of bio-organic acids. Scanning electron microscopy, laser particle size analysis, X-ray diffraction, X-ray photoelectron spectroscopy, and Fourier transform infrared spectroscopy were employed to analyze EMR changes after bioleaching. This study provides an alternative fungal resource for Mn-bioleaching of EMR, and a novel target for metabiotic engineering to improve bio-organic acid production.

Highly efficient persulfate catalyst prepared from modified electrolytic manganese residues coupled with biochar for the roxarsone removal

The contamination of organoarsenic is becoming increasingly prominent while SR-AOPs were confirmed to be valid for their remediation. This study has found that the novel metal/carbon catalyst (Fe/C-Mn) prepared by solid waste with hierarchical pores could simultaneously degrade roxarsone (ROX) and remove As(V). A total of 95.6% of ROX (20 mg/L) could be removed at the concentration of 1.0 g/L of catalyst and 0.4 g/L of oxidant in the Fe/C-Mn/PMS system within 90 min. The scavenging experiment and electrochemical test revealed that both single-electron and two-electron pathways contributed to the ROX decomposition. Spectroscopic analysis suggested the ROX has been successfully mineralized while As(V) was fixed with the surface Fe and Mn. Density functional theory (DFT) calculation and chromatographic analysis indicated that the As7, N8, O9 and O10 sites of ROX molecule were vulnerable to being attacked by nucleophilic, electrophilic and radical, resulting in the formation of several intermediates such as phenolic compounds. Additionally, the low metal leaching concentration during recycling and high anti-interference ability in various water matrices manifested the practicability of Fe/C-Mn/PMS system.

Comprehensive effects of grain-size modification of electrolytic manganese residue on deep dehydration performance and microstructure of sludge

As the by-product accompanied by sewage treatment, sludge has complex composition and high moisture content, therefore, its reutilization and disposal are still a challenge. In this paper, five kinds of quartz sand conditioners with different particle sizes (denoted as QS1, QS2, QS3, QS4 and QS5, respectively) were used to explore the effect of particle size distribution of conditioners on sludge dewatering performance. The moisture content, capillary suction time (CST), time to filter (TTF), specific resistance of filtration (SRF), particle size distribution curve, pore distribution law, scanning electron microscopy, isothermal adsorption-desorption curve and extracellular polymeric substances distribution were employed to characterize the modified sludge and explore the improvement mechanism. The results show that the particle size distribution of the conditioner significantly affects the efficiency of sludge dewatering. The wt% of sludge regulated with QS1 (QS1-S) could be reduced to 52%, and its CST value, TTF value and SRF value is 57.93 s, 278 s and 1.84 × 10⁸ s² g^-1, respectively. The conjecture about the effect of difference of particle size distribution on sludge dewatering performance was verified with the original Electrolytic Manganese Residue (EMR) and the grain-size modified Electrolytic Manganese Residue (EMR6). Compared with those of the EMR-conditioned sludge, the CST, TTF and SRF of EMR6-conditioned sludge was decreased by 8.7%, 22.3% and 11.2%, respectively. According to analysis of surface microstructure, the surface of the sludge cake modified with QS1 is rough and sparse with rich pore structure. Compared with those of the undisturbed sludge (A0), the pore volume and specific surface area of the sludge modified with QS1 was increased by 61.65% and 38.62%, respectively. After grain-size modification, the dehydration effect of EMR6 (D10 4.25 μm, D50 19.65 μm, D90 73.26 μm) was significantly enhanced, and the D10, D50 and D90 value was close to that of QS1. It can be concluded that the particle size of QS1 (D10 3.27 μm, D50 15.66 μm, and D90 62.23 μm) can improve the dewatering performance of sludge by shearing the sludge particles to change the original sludge particle size distribution and improving the blockage of sludge dewatering channels.

A novel slag composite for the adsorption of heavy metals: Preparation, characterization and mechanisms

The utilization of solid waste for resource recovery and production of value-added products is the theme of green chemistry. Currently, how to using solid wastes to prepare environmentally-functional materials with high performance and strength is one of the hot topics. In this research, electrolytic manganese residue (EMR) was thermally activated with calcite to prepare a silicon-based functionalized adsorbent (C-EMR) for the removal of cadmium (Cd²⁺, 467.14 mg/g) and lead (Pb²⁺, 972 mg/g). The thermodynamic results indicated that the removal process of Cd²⁺ and Pb²⁺ by C-EMR were endothermic and spontaneous. HNO₃ can effectively strip the two adsorbed metals from C-EMR with the stripping efficiency of nearly 80% for Cd²⁺ and 99.92% for Pb²⁺, indicating that adsorption and ion exchange may be the main reason for the removal of the metals on C-EMR. Besides, surface precipitation was also responsible for removing some Pb²⁺ from the aquatic environment according to the X-ray photoelectron spectrometry (XPS) analysis. Results indicate that -SiO₃^- has stronger affinity with Pb²⁺ and Cd²⁺ than other groups ((-MnO₂), -OH) by theoretical calculation (VASP, GGA-PBE). This study shows that this novel adsorbent (C-EMR) can be adopted as an environmentally-friendly, inexpensive and efficient adsorbent for removal of Cd²⁺ and Pb²⁺ from aquatic solution. This technique not only provides potential adsorbent for the elimination of heavy metals but also proposes an alternative route for the treatment and utilization of waste solid.

Effects of different silicate minerals on silicon activation by Ochrobactium sp. T-07-B

As a kind of solid waste with a high silicon content, electrolytic manganese residue (EMR) can be utilized as silicon source by plants through bioleaching processes. EMR contains a variety of silicate minerals. In order to determine the source of available silicon in the bioleaching process of EMR, it is necessary to investigate the influence of silicate minerals in EMR on silicon-activating behavior of specific minerals. In this study, Ochrobactium sp. T-07-B was used to conduct bioleaching experiments on five kinds of silicate minerals with different structures (quartz, muscovite, biotite, olivine, and rhodonite); the growth of Ochrobactium sp. T-07-B, their acid- and polysaccharide-producing capacity, and evolution of surface morphology and structure of the silicate minerals in different systems were determined, so as to explore the silicon-activating capacity of Ochrobactium sp. T-07-B and the selectivity toward different minerals in the bioleaching process. Results showed that the effects of Ochrobactium sp. T-07-B for different silicate minerals were obviously different, and the sequence of silicon-activating efficiency from high to low was as follows: muscovite (65.84 mg·L^-1) > biotite (63.84 mg·L^-1) > olivine (55.76 mg·L^-1) > rhodonite (50.98 mg·L^-1) > quartz (23.63 mg·L^-1). Results of this study may be of guiding significance for the future research on the silicon-activating behavior of solid waste.

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.

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.

Multi-step purification of electrolytic manganese residue leachate using hydroxide sedimentation, struvite precipitation, chlorination and coagulation: Advanced removal of manganese, ammonium, and phosphate

Water pollution caused by the release of manganese (Mn²⁺) and ammonia nitrogen (NH₄⁺-N) from electrolytic manganese residue (EMR) generated from industrial activities poses a serious threat to ecosystems and human health. In this study, an integrated process consisting sequentially of hydroxide sedimentation, struvite precipitation, breakpoint chlorination, and ferric chloride coagulation was optimized to remove Mn²⁺ and NH₄⁺-N from EMR leachate, and to address the issue of residual orthophosphate caused by struvite precipitation. The precipitates were characterized using X-ray diffraction, scanning electron microscopy, and thermogravimetric analyses. Results show that Mn²⁺ ions and the resulting chemical oxygen demand (COD) were mainly removed using hydroxide precipitation at a sedimentation pH of 10.2, with poor-crystalline manganese hydroxide as the main precipitate. NH₄⁺-N was primarily removed and recovered using struvite precipitation with well crystalline struvite as the main product, and then further eliminated using breakpoint chlorination. The residual orthophosphate introduced by struvite precipitation is successfully removed with ferric coagulation, and the effluent pH (7.5) is also lowered to discharge limits by means of hydrolysis of ferric coagulant. The concentration of COD, Mn²⁺, NH₄⁺-N, and orthophosphate concentrations in the final effluent were 30.52 ± 9.38, 0.026 ± 0.013, 0.87 ± 0.01, and 0.06 ± 0.002 mg/L, respectively, meeting all local discharge standards. This combined process has robust pollutant removal efficiency, high resource recovery potential and few environmental constraints; thus, it is recommended as a potential solution for the treatment of Mn²⁺- and NH₄⁺-N-rich acid mine drainage.

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.

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.

Multi-walled carbon nanotubes facilitated Roxarsone elimination in SR-AOPs by accelerating electron transfer in modified electrolytic manganese residue and forming surface activated-complexes

A novel catalyst (MT/EMR) used for SR-AOPs with high removal efficiency toward roxarsone (ROX) (90.96% within 60 min) was prepared for the first time by ball milling multi-walled carbon nanotubes (MWCNTs) with electrolytic manganese residue (EMR). The incorporation of MWCNTs could improve the adsorption capacity and accelerate the transformation of metals in EMR with partial mass loss to facilitate the PDS activation. Additionally, pH test, quenching experiment and electrochemical test verified a two-electron pathway involving surface activated-complex contributed to the directly ROX oxidization. Benefit from the introduction of MWCNTs, the degradation rate (k_obs) of catalytic reaction was increased by 10.1 times compared with that of single-EMR. Additionally, the M-O-C (M=Fe or Mn) bonds in MT/EMR making the catalyst more stable than EMR. This work provided a novel and effective strategy to establish waste solid-based catalysts for green preparation and expanded the adsorption-oxidation technology to solve the problem of organoarsenic pollution.

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).

Efficient removal of diethyl dithiocarbamate with EDTA functionalized electrolytic manganese residue and mechanism exploration

The recycling of solid wastes is obligable as it can reduce the environmental pollution and prevent the diffusion of secondary pollution. In this study, a novel cheap adsorbent was prepared by modifying electrolytic manganese residue (EMR) with EDTA. The maximum adsorption capacity of adsorbents for diethyl dithiocarbamate (DDTC) was 133.46 mg/g under initial pH of 7.32 at room temperature. Adsorption kinetics study revealed the DDTC adsorption on EDTA-EMR is mainly controlled by chemisorption and isotherm studies implied the adsorption is a monolayer process. Mechanism exploration found that the DDTC molecules could enter into the holes of EDTA-EMR, and the transition metal-based sorption sites were crucial for the target molecule immobilization and chelation. High pH value (> 10) was found to have inhibited the adsorption capacity of adsorbent, which should be due to the fact that the decreasing of functional groups on adsorbents surface and the competition between DDTC and OH^-. The ionic strength has negligible effect on the adsorption and the as-synthesized adsorbents showed excellent performance after five cycles. The overall results reveal that EDTA-EMR is a promising adsorbent ascribed by its low cost, good recyclability and excellent adsorption capacity.

Co-sintering MSWI fly ash with electrolytic manganese residue and coal fly ash for lightweight ceramisite

The MSWI fly ash (FA) is classified as hazardous waste and electrolytic manganese residue (EMR) as the harmful industrial waste. FA, water-washed FA (WFA), EMR and coal fly ash (CFA) were co-recycled to form lightweight MFCE ceramisites. The effects of FA, WFA and mixed MSWI fly ash on ceramisites were discussed. The approach to mixing FA and WFA increased the recycling amount of MSWI fly ash. The optimal mixture of 34.5% EMR, 24.1% CFA, 20.7% FA and 20.7% WFA sintered at 1160 °C for 12 min with a procedural heating rate (10 °C/min) and belonged to Class 800 artificial lightweight aggregate (GB/T 17431.1-2010); the quantity of MSWI fly ash in ceramisite was as high as 41.4%. Volatilization rates of Cd, Pb, Cu, Zn, Mn and Cr for ceramisite were higher 75.0, 24.2, 62.7, 133, 343 and 764% than FA respectively, attributed to the co-existence of chlorides and sulfates. The remained Zn, Cu, Pb, Mn and Cr were exchanged with Mg²⁺/Ca²⁺/Al³⁺ of diopside and wollastonite to form residual fractions. Our findings provided a feasibility method of co-recycling MSWI fly ash and electrolytic manganese residue to produce green lightweight aggregates.

Species identification and mutation breeding of silicon-activating bacteria isolated from electrolytic manganese residue

A strain of silicon-activating bacteria was isolated from electrolytic manganese residue (EMR); identified as a species of Ochrobactrum by integrated microscopic morphological characteristics, biochemical index determination, and clone analysis (i.e., results of 16S rRNA sequence); and temporarily named as Ochrobactrum sp. T-07 (T-07). The optimal growth conditions of the strain T-07 were obtained as follows: temperature of 30 °C, initial pH of 7.0, shaking speed of 180 rev. min^-1, and loading volume of 100 mL. In order to enhance its activation activity of silicon, T-07 went through the ultraviolet (UV) mutagenesis and nitrosoguanidine (NTG) mutagenesis breeding, and the mutant strain T-07-B with higher activity was obtained. Under the optimal fermentation condition (leaching time of 20 days, temperature of 30 °C, initial pH of 7, pulp concentration of 5%, shaking speed of 180 rev. min^-1, and particle diameter of EMR ≤ 180 μm), the available silicon content in the supernatant reached 98.8 mg L^-1, which was 2.4 times of the original strain T-07. Therefore, T-07 can be used as a good backup in developing biological silicon fertilizer for plants.

Removal of cadmium and lead from aqueous solutions by thermal activated electrolytic manganese residues

Electrolytic manganese residues (EMR) is produced from the electrolysis manganese industry. In this study, the thermal activated EMRs (T-EMR) were used to adsorb cadmium and lead from aqueous solution. X-ray diffractometer (XRD), scanning electron microscope-Energy Dispersive Spectrometer (SEM-EDS), X-ray photoelectron spectroscopy (XPS) were adopted to characterize EMR before and after the modification, and the performance and adsorption mechanisms of T-EMR for cadmium and lead were determined. Results show that the pH has a strong influence on the adsorption of cadmium and lead and the maximum adsorption capacity can be achieved at pH 6. The adsorption of Cd(II) can be better fitted by the Lagergren pseudo-first-order dynamic model, while that of Pb(II) fits the pseudo-second-order kinetic model better. The Freundlich isotherm model fits the adsorption of two metals better than Langmuir model. The thermodynamic results demonstrate that the adsorption of Cd(II) or Pb(II) on T-EMR is endothermic and spontaneous. As the nitric acid with pH 0.5 was used, nearly all of the adsorbed Cd(II) and 75% Pb(II) can be desorbed from the loaded T-EMR. It is concluded that the adsorption of Cd(II) and Pb(II) on T-EMR is in virtue of electrostatic attraction, ion-exchange and surface precipitation. The heavy metals are mainly adsorbed on ferric and manganese oxides and silicate minerals in T-EMR by electrostatic attraction. In addition, cadmium and lead also can be adsorbed via the ion exchange reaction. Moreover, some Pb(II) are adsorbed by forming lead sulfate. Thus, T-EMR may be an environmentally-friendly, effective adsorbent for the removal of heavy metals from aqueous solution.

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.

Bioleaching of silicon in electrolytic manganese residue (EMR) by Paenibacillus mucilaginosus: Impact of silicate mineral structures

Electrolytic manganese residue (EMR) is characterized by high silicon content, and thus, is an important silicon source. While considerable research has been conducted on bioleaching EMR for silicon recovery, sufficient information is not available on the impact of specific silicate mineral structures in EMR on silicon bioleaching. In the present study, the mineral composition of EMR was determined firstly, and then the leaching effect of Paenibacillus mucilaginosus on these different silicate minerals were investigated by shake flask experiments. Results showed that the silicon in EMR was mainly composed of quartz, sericite, muscovite, biotite, olivine and rhodonite; Paenibacillus mucilaginosus had a significantly different weathering and decomposition effects on different silicate minerals. Among them, sericite, muscovite and biotite with layered structure had the most obvious silicon leaching effect, followed by rhodonite with island structure, while silicon leaching from olivine with chained structure and quartz with frame structure was much more difficult. One can roughly judge the adaptability of bioleaching of silicon in EMR using Paenibacillus mucilaginosus if the main form of silicate minerals in EMR is determined.

An innovative method for manganese (Mn2+) and ammonia nitrogen (NH4+-N) stabilization/solidification in electrolytic manganese residue by basic burning raw material

High concentrations of manganese (Mn²⁺) and ammonia nitrogen (NH₄⁺-N) in electrolytic manganese residue (EMR) have seriously hindered the sustainable development of electrolytic manganese industry. In this study, an innovative basic burning raw material (BRM) was used to stabilize/solidify Mn²⁺ and NH₄⁺-N in EMR. The characteristics of EMR and BRM, stabilize mechanism of NH₄⁺-N and Mn²⁺, and leaching test were investigated. The concentrations of NH₄⁺-N and Mn²⁺ were 12.8 mg/L and 0.1 mg/L, respectively, when the solid liquid ratio was 1.5:1, and the mass ratio of EMR and BRM was 100:10, at the temperature of 20 °C reacting for 12 h Mn²⁺ was mostly solidified as bustamite ((Mn,Ca)Si₂O₆), groutite (MnOOH) and ramsdellite (MnO₂). NH₄⁺-N was mostly recycled by (NH₄)₂SO₄ and (NH₄)₃H(SO₄)₂. Leaching test results indicated that the concentrations of heavy metals were within the permitted level for the integrated wastewater discharge standard (GB8978-1996). Economic evaluation revealed that the cost of EMR treatment was $ 10.15/t by BRM. This study provided a new research idea for EMR harmless disposal.

Using Electrolytic Manganese Residue to prepare novel nanocomposite catalysts for efficient degradation of Azo Dyes in Fenton-like processes

In this study, Electrolytic Manganese Residue (EMR) was treated by EDTA-2Na/NaOH, ultrasonic etching, and hydrothermal reaction to obtain a novel nanocomposite catalyst (called N-EMR), which then was used, together with H₂O₂, to treat synthetic textile wastewater containing Reactive Red X-3B, Methyl Orange, Methylene blue and Acid Orange 7. Results indicated that the N-EMR had a nano-sheet structure in sizes of 100-200 nm; new iron and manganese oxides with high activity were produced. The mixture of a small amount of N-EMR (40 mg/L) and H₂O₂ (0.4 × 10^-3 M) could removal about 99% of azo dyes (at 100 mg/L in 100 mL) within 6-15 min, much faster than many advanced oxidation processes (AOPs) reported in the literature. The elucidation of the associated mechanism for azo dyes degradation indicates that azo dyes were attacked by superoxide radicals, hydroxyl radicals, and electron holes generated within system. N-EMR was found to be reusable and showed limited inhibition by co-existing anions and cations. Moreover, high removal efficiency of azo dyes could happen in the system with a wide range of pH (1-8.5) and temperatures (25-45 °C), indicating that the process developed in this study may have broad application potential in treatment of azo dyes contaminated wastewater.

Preparation of road base material by utilizing electrolytic manganese residue based on Si-Al structure: Mechanical properties and Mn2+ stabilization/solidification characterization

Electrolytic manganese residue (EMR) is a potentially harmful industrial solid waste that should be addressed. In the study, the red mud, carbide slag and blast furnace slag were used as stabilization/solidification (S/S) agents to S/S Mn²⁺, and simultaneous reused it as raw material to prepare road base material. The S/S behavior of manganese, unconfined compressive strength (UCS) of road base material with different Al/Si ratios, leaching test and the S/S mechanisms were investigated. The results showed that the Mn²⁺ can be well solidified when the S/S agents reach up to 20 %. The 7-day UCS of the road base material was 6.1 MPa with the Al/Si ratio of 0.48, which meets the highway standards. When Al/Si = 0.48, the formation amount of CaAl₂Si₂O₈·4H₂O and ettringite increased, which promoted the adsorption and wrap of Mn²⁺. The content of active Al^Ⅳ and Al^Ⅵ increased after S/S. Mn₂SiO₄ and Ca₄Mn₄Si₈O₂₄ were produced by the charge balance effect, and the new chemical bond was formed. Meanwhile, the Mn²⁺ is oxidized to more stable MnO₂ to achieve the S/S of Mn²⁺. This research provides an effective way to solidify Mn²⁺ and solves the problem of large-scale utilization of EMR and other solid waste.

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

Electrolytic manganese residue (EMR) contains a large amount of NH₄⁺-N and Mn²⁺ and can negatively impact the environment. A stabilization treatment of soluble contaminants in the EMR is necessary for its reuse and safe stacking. This study presents experimental results for the stabilization of NH₄⁺-N and Mn²⁺ in the EMR using phosphogypsum leachate as a low-cost phosphate source and MgO/CaO (PLMC) process. The results demonstrated that the stabilization efficiency of NH₄⁺-N and Mn²⁺ was 93.65% and 99.99%, respectively, under the following conditions: a phosphogypsum leachate dose of 1.5 mL g^-1, an added MgO dose of 0.036 g g^-1, an added CaO dose of 0.1 g g^-1 and a reaction time of 2 h. The stabilization effect of the PLMC process was higher and more cost effective than that of using Na₃PO₄·12H₂O and MgO/CaO. The concentration of NH₄⁺-N and Mn²⁺ in the leaching liquor decreased to 80 mg L^-1 and 0.5 mg L^-1, respectively, after the stabilization under the optimum conditions. The stabilization characteristics indicated that NH₄⁺-N was stabilized to form NH₄MgPO₄·6H₂O (struvite) and that Mn²⁺ was stabilized to form Mn₅(PO₄)₂(OH)₄, Mn₃(PO₄)₂·3H₂O and Mn(OH)₂. PO₄^3--P, F^-, and heavy metal ions of the phosphogypsum leachate were removed from the leaching liquor and stabilized in the treated EMR.

Preparation of non-sintered permeable bricks using electrolytic manganese residue: Environmental and NH3-N recovery benefits

The present study aims to prepare non-sintered permeable bricks using significant amount of electrolytic manganese residue (EMR), discharged by electrolytic metal manganese industry. Mechanical and environmental properties were investigated. The microstructure was analyzed by means of XRD, FTIR, TG-DSC and SEM-EDS. It was observed that the splitting tensile strength and permeability coefficient of the optimum proportion were 3.53 MPa and 3.2 × 10^-2 cm/s respectively. The main hydration products were found to be ettringite, C-S-H, aluminosilicates and C-A-S-H. The leaching test showed that Mn, Pb, Cd, total Cr and NH₃-N in the non-sintered permeable bricks were solidified up to concentrations lower than groundwater standard. In addition to that, the NH₃-N produced during the process was transformed into ammonia water which was in turn recycled and reused in manganese electrolysis. Besides, non-sintered permeable bricks have been produced at large scale and applied successfully as pavement materials in Songtao, China. Therefore, the use of EMR to produce non-sintered permeable bricks possesses important environmental and economic significance because the process not only utilizes large quantities of EMR and saves EMR disposal cost, but also saves a lot of natural resources and improves the urban environment.

Enhanced geopolymeric co-disposal efficiency of heavy metals from MSWI fly ash and electrolytic manganese residue using complex alkaline and calcining pre-treatment

The predominant heavy metals in MSWI fly ash and electrolytic manganese residue (EMR) were determined to be Zn, Pb, Cd, and Mn, with lesser amounts of Cu and Cr. The curing efficiency of heavy metals in MSWI fly ash and EMR was improved using complex alkaline activators (NaOH and KOH), base addition (calcium hydroxide and complex Portland cement), and EMR calcining (at 800 °C for 3 h) based on a geopolymeric system. The best formulation of the geopolymeric system was composed of 75 wt% MSWI fly ash and 25 wt% EMR with a KOH/NaOH (1:1) complex solution (7.5 M OH^-)/solid of 0.5. Calcium ions were dissolved aluminosilicate under the strongly basic conditions to form complex products (ternesite) which further improved the strength. The primary curing mechanism of heavy metals (Pb, Zn, Cd, Mn, Cr, and Cu) mainly was primarily influenced by the acid-base buffering capacity of geopolymers, followed by the physical encapsulation of geopolymeric gels.

Bioleaching of silicon in electrolytic manganese residue using single and mixed silicate bacteria

Electrolytic manganese residue (EMR) is a type of industrial solid waste with a high silicon content. The silicon in EMR can be used as an essential nutrient for plant growth, but most of the silicon is found in silicate minerals with very low water solubility, that is, it is inactive silicon and cannot be absorbed and used by plants directly. Thus, developing a highly effective and environmentally friendly process for the activation of silicon in EMR is important both for reusing solid waste and environmental sustainability. The aim of this study was to investigate the desilication of EMR using cultures of Paenibacillus mucilaginosus (PM) and Bacillus circulans (BC). The results showed that the two types of silicate bacteria and a mixed strain of them were all able to extract silicon from EMR with a high efficiency, but the desilication performance of the mixed PM and BC was the best. Fourier transform infrared spectroscopy indicated that silicate bacteria can induce a suitable micro-environment near the EMR particles and release Si into the solution through their metabolism. X-ray diffraction analysis confirmed that layered crystal minerals, such as muscovite and diopside, were more likely to be destroyed by the bacterial action than quartz, which has a frame structure. Scanning electron microscopy-energy dispersive spectrometry proved that the silicate structures were destroyed and that Si in the residue was decreased, indicating the dissolution of silicon under the action of these microorganisms. This study suggests that bioleaching may be a promising method for the activation of silicon in EMR.

An innovative method for synergistic stabilization/solidification of Mn2+, NH4+-N, PO43- and F- in electrolytic manganese residue and phosphogypsum

Electrolytic manganese residue (EMR) contains large quantities of manganese (Mn²⁺) and ammonia nitrogen (NH₄⁺-N). Phosphogypsum (PG) contains plenty of phosphate (PO₄^3-), fluorine (F^-) and some heavy metals. Separate storage of EMR and PG could seriously damage the ecological environment. In this study, synergistic stabilization/solidification (S/S) of EMR and PG was studied. The effects of EMR:PG mass ratio, S/S pH, solid-liquid ratio and temperature on the concentrations of NH₄⁺-N, PO₄^3-, Mn²⁺ and F^- in the leaching solution, and the characteristics of EMR and PG were studied. Meanwhile, the synergistic S/S mechanisms of EMR and PG, and leaching test were investigated. The results showed that the concentrations of F^-, PO₄^3-, NH₄⁺-N and Mn²⁺ in the leaching solution were 4.5 mg/L, 13.6 mg/L, 55.5 mg/L and 0.8 mg/L, respectively, when the mass ratio of EMR to PG was 1:2 and the pH was 9.0 adjusted by MgO after 20 days S/S. Manganese was mainly solidified as Mn₃(PO₄)₂·7H₂O and Mn(OH)₂, and ammonia nitrogen was mainly stabilized as struvite; fluorine was mainly stabilized as (Mn, Ca, Mg)F₂, and phosphate was mainly solidified as (Mn, Ca, Mg)₃(PO₄)₂ and (Mn, Ca, Mg)HPO₄. The leaching test results showed that PO₄^3- and NH₄⁺-N were reduced to 13.6 mg/L and 55.5 mg/L, respectively, and the concentrations of all the measured heavy metals and F^- were within the permitted level for the GB8978-1996 after 20 days S/S.

Enhanced electrokinetic remediation of manganese and ammonia nitrogen from electrolytic manganese residue using pulsed electric field in different enhancement agents

Electrolytic manganese residue (EMR) is a solid waste generated in the process of producing electrolytic metal manganese and contains a lot of manganese and ammonia nitrogen. In this study, electrokinetic remediation (EK) of manganese and ammonia nitrogen from EMR were carried out by using pulse electric field (PE) in different agents, and sodium dodecyl benzene sulfonate (SDBS), citric acid (CA) and ethylene diamine tetraacetic acid (EDTA) were used as enhancement agents. The removal behavior of ammonia nitrogen and manganese under direct current field (DC) and PE, and the relationship between manganese fractionation and transport behavior, as well as the energy consumption were investigated. The results demonstrated that the removal efficiency of ammonia nitrogen and manganese using PE were higher than DC. SDBS, EDTA and CA could enhance electroosmosis and electromigration, and the sequence of enhancement agent effects were CA, SDBS, EDTA, distilled water. The highest removal efficiency of manganese and ammonia nitrogen were 94.74% and 88.20%, and the effective removal amount of manganese and ammonia nitrogen was 23.93 and 1.48 mg·wh^-1, when CA and SDBS+CA was used as the enhancement agents, respectively. Moreover, electromigration was the main removal mechanism of manganese and ammonia nitrogen in the EK process.

Co-disposal of MSWI fly ash and electrolytic manganese residue based on geopolymeric system

MSWI fly ash (MSWI FA) and electrolytic manganese residue (EMR) were successfully co-disposed by use of a geopolymeric system. Alkaline products of MSWI FA and NaOH were used to elicit chemical reactions to promote solidification. The best performing formulation of EMR-based geopolymer for immobilization of heavy metals was composed of 75 wt% MSWI FA and 25 wt% EMR with NaOH solution (7.5 M)/solid of 0.5. Solidification was most effective for the heavy metals: Pb > Cu > Cr > Zn > Mn, respectively. The EMR-based geopolymer had high structural stability likely due to the high ratio of SiO₂/Al₂O₃. The Solidification/Stabilization (S/S) mechanism for heavy metals of geopolymers is likely due to alkaline conditions and geopolymeric encapsulation, highlighting the utility and feasibility of this approach.

Simultaneous stabilization/solidification of Mn2+ and NH4+-N from electrolytic manganese residue using MgO and different phosphate resource

This study examined simultaneous stabilization and solidification (S/S) of Mn²⁺ and NH₄⁺-N from electrolytic manganese residue (EMR) using MgO and different phosphate resource. The characteristics of EMR NH₄⁺-N and Mn²⁺ S/S behavior, S/S mechanisms, leaching test and economic analysis, were investigated. The results show that the S/S efficiency of Mn²⁺ and NH₄⁺-N could reach 91.58% and 99.98%, respectively, and the pH value is 8.75 when the molar ratio of Mg:P is 3:1 and the dose of PM (MgO and Na₃PO₄·12H₂O) is 8wt%. In this process, Mn²⁺ could mainly be stabilized in the forms of Mn(H₂PO₄)₂·2H₂O, Mn₃(PO₄)₂·3H₂O, Mn(OH)₂, and MnOOH, and NH₄⁺-N in the form of NH₄MgPO₄·6H₂O. Economic evaluation indicates that using PM process has a lower cost than HPM and HOM process for the S/S of Mn²⁺ and NH₄⁺-N from EMR at the same stabilization agent dose. Leaching test values of all the measured metals are within the permitted level for the GB8978-1996 test suggested when the dose of PM, HPM and HOM is 8wt%.

Solidification/stabilization of electrolytic manganese residue using phosphate resource and low-grade MgO/CaO

In this study, P-LGMgO (low-grade MgO and NaH2PO4·2H2O), P-CaO (CaO and NaH2PO4·2H2O), and P-MgCa (low-grade MgO, CaO and NaH2PO4·2H2O) were used for the solidification/stabilization (S/S) of electrolytic manganese residue (EMR). Relevant characteristics such as ammonia nitrogen and manganese stabilization behavior, unconfined compressive strength (UCS), probable S/S mechanisms, and EMR leaching test were investigated. The results demonstrate that using P-LGMgO had higher stabilization efficiency than P-CaO and P-MgCa for the S/S of EMR at the same stabilization agent dose. The stabilization efficiency of ammonia nitrogen and manganese in the EMR were 84.0% and 99.9%, respectively, and the UCS of EMR was 5.1MPa using P-LGMgO process after curing for 28 days when the molar ratio of Mg:P was 5:1 and dose of stabilization agent was 12wt%. In this process, ammonia nitrogen was stabilized by struvite (NH4MgPO4·6H2O), and manganese by bermanite (Mn3(PO4)2(OH)2·4H2O) and pyrochroite (Mn(OH)2). The leaching test results show that the values of all the measured metals on the 28th day were within the permitted level for the GB8978-1996 test suggested by China's environmental protection law and the concentration of ammonia nitrogen can be reduced from 504.0mgL(-1) to 76.6mgL(-1).

Immobilization of Mn and NH4 (+)-N from electrolytic manganese residue waste

The objective of this work was the immobilization of soluble manganese (Mn) and ammonium nitrogen (NH4 (+)-N) leached from electrolytic manganese residue (EMR). Immobilization of Mn was investigated via carbonation using carbon dioxide (CO2) and alkaline additives. NH4 (+)-N immobilization was evaluated via struvite precipitation using magnesium and phosphate sources. Results indicated that the immobilization efficiency of Mn using CO2 and quicklime (CaO) was higher than using CO2 and sodium hydroxide (NaOH). This higher efficiency was likely due to the slower release of OH(-) during CaO hydrolysis. The immobilization efficiency of Mn was >99.99 % at the CaO:EMR mass ratio of 0.05:1 for 20-min reaction time. The struvite precipitation of NH4 (+)-N was conducted in the carbonated EMR slurry and the immobilization efficiency was 89 % using MgCl2 · 6H2O + Na3PO4 · 12H2O at the Mg:P:N molar ratio of 1.5:1.5:1 for 90-min reaction time. A leaching test showed that the concentrations of Mn and NH4 (+)-N in the filtrate of the treated EMR were 0.2 and 9 mg/L, respectively. The combined immobilization of Mn and NH4 (+)-N was an effective pretreatment method in the harmless treatment of the EMR.