Recovery Of Manganese Research Articles

A novel process on the recovery of zinc and manganese from spent alkaline and zinc-carbon batteries

Spent alkaline and zinc-carbon batteries contain valuable elements (notably, Zn and Mn), which need to be recovered to keep a circular economy. In this study, the black mass materials from those spent batteries are pyrometallurgically treated via a series of process steps in a pilot-scale KALDO furnace to produce an Mn–Zn product, a ZnO product, and an MnO (manganese monoxide) product, toward applications of Mn–Zn micronutrient fertilizer, zinc metal, and manganese alloy, respectively. After an oxidative roasting step, an Mn–Zn product, containing 43% Mn, 22% Zn, and negligible amounts of toxic elements (notably, Cd, Hg, and Pb), could be produced, being suitable for the micronutrient fertilizer application. After a reductive roasting step, a ZnO product and an MnO product are produced. The attained ZnO product, containing up to 84.6% ZnO, is suitable for zinc metal production when the leaching steps are taken to remove most of the Cl and F in the product. The attained MnO product, containing up to 91.7% MnO, is of premium quality for manganese alloy production, preferably for SiMn alloy production due to its low phosphorus content. The proposed application scenarios could substantially improve the recovery efficiency of those spent batteries.

Extraction of manganese through baking-leaching technique from high iron containing manganese sludge

The growing demand for manganese and environmental regulations had made it increasingly important to develop a process for the recovery of manganese from manganese sludge before dumping. This article explores the possibility of extracting manganese from manganese sludge containing 10% manganese and 15.5% iron. Detailed physico-chemical characterization was carried out by using X-ray diffraction (XRD), Scanning electron microscopy (SEM), X-ray fluorescence (XRF), Atomic absorption spectrometer (AAS) and conventional analytical tools. The manganese present in the form of Mn+4 is stable in acid or alkaline oxidizing condition. So the recovery of manganese must be carried out under reducing condition. Sulfation roasting in the presence of proper reductant followed by water leaching process was developed to recover manganese. Different processes parameters such as roasting temperature, reductant mass, sulfuric acid concentration were studied and optimized to give more than 98% dissolution of manganese. The leached sulphate solution is purified further and precipitated as manganese carbonate (>95%) in the presence of ammonium carbonate. The precipitate was dried and calcined at 350 °C to produce chemical manganese dioxide (CMD). The products were characterized by using XRD and SEM.

Non-reductive acidic leaching as a method for recovery of zinc and manganese from Zn-C and Zn-MnO2 battery waste

Non-reductive acidic leaching as a method for recovery of zinc and manganese from Zn-C and Zn-MnO2 battery waste

Recovery of Cobalt and Manganese from Spent Lithium-ion Batteries using a Phosphonium-based Ionic Liquid

Recovery of Cobalt and Manganese from Spent Lithium-ion Batteries using a Phosphonium-based Ionic Liquid

Optimization of Production of Blast Furnace Ferromanganese in Conditions of Non-Integrated Iron Works

Production of high carbon blast furnace ferromanganese (HC FeMn) in conditions of Russian non-integrated iron works stipulates use of various combinations of permanently changed sorts of manganese ores with different mineralogy, manganese content and granulometric composition. Operation complexity is caused by challenge to satisfy with customers’ stringent requirements specific to percentage of manganese, silicon and maximum permissible content of tramp elements in produced alloy as well as by necessity to recycle fine fraction formed at the stage of crushing of solidified large-sized ferromanganese. Fluxless technological regime is defined as a most efficient mode to achieve high technical and economic indices. Special attention is given to methods of increase of manganese recovery in every stage of technological process. The largest losses of manganese are related to losses with slag and top gas, and developed techniques to minimize these losses are described with taking ecological aspects into consideration.

Optimization of Manganese Recovery from a Solution Based on Lithium-Ion Batteries by Solvent Extraction with D2EHPA

Manganese is a critical metal for the steelmaking industry, and it is expected that its world demand will be increasingly affected by the growing market of lithium-ion batteries. In addition to the increasing importance of manganese, its recycling is mainly determined by trends in the recycling of iron and steel. The recovery of manganese by solvent extraction has been widely investigated; however, the interaction of different variables affecting the process is generally not assessed. In this study, the solvent extraction of manganese from a solution based on lithium-ion batteries was modeled and optimized using factorial designs of experiments and the response surface methodology. Under optimized conditions (O:A of 1.25:1, pH 3.25, and 0.5 M bis(2-ethylhexyl) phosphoric acid (D2EHPA)), extractions above 70% Mn were reached in a single extraction stage with a coextraction of less than 5% Co, which was mostly removed in two scrubbing stages. A stripping product containing around 23 g/L Mn and around 0.3 g/L Co can be obtained under optimized conditions (O:A of 8:1, 1 M H2SO4 and around 13 min of contact time) in one stripping stage.

Simultaneous recovery of copper and manganese from exotic copper ore in acid chloride media using cane molasses as the reducing agent

Chile is host to one of the most considerable Cu resources in the world. The primary source of Cu is from porphyry deposits. However, associated “exotic-Cu” deposits are also significant in the Atacama Desert of northern Chile. The critical processing issue for these ores is that they are refractory to dissolution under acidic and oxidative conditions, and consequently their dissolution kinetics are relatively slow. This paper reports a study on the extraction of copper and manganese from exotic-Cu ores using cane molasses as a reducing agent in the presence of chloride ions and diluted sulfuric acid media. The effects of concentrations of cane molasses, chloride ion, and sulfuric acid are discussed. Leaching tests on ground ore in shake flasks were studied, as well as the agglomeration and curing stages of a coarse ore sample. The dissolution of the exotic copper ore is enhanced when 50 g/L of NaCl and 60 g/L of cane molasses are added to the leaching solution. The dissolution of copper associated with copper wad appears independent of the Mn dissolution. Tests with the ore agglomerated with acid, chloride ions, and cane molasses showed enhanced dissolution of manganese contained in the copper wad, but not copper. It is thus confirmed that cane molasses is a suitable reductant in the leaching of Mn, especially in the presence of chloride ions. The behavior and fate of the wad-associated copper requires further investigation.

An overview on potential hydrometallurgical processes for separation and recovery of manganese

With rapid economic progress worldwide, the search for new resources for materials has become a priority due to mineral resource depletion. Enhanced requirements for manganese alloys and compounds for several commercial applications created a desperate demand for manganese recovery technologies from primary as well as secondary resources. The future demand for manganese alloys and compounds is expected to increase. The growing need of electrolytic manganese dioxide (EMD) for different battery usage in automobile and energy sectors could create a gap in the supply and demand of manganese. There is an urgent necessity for eco-friendly and efficient technologies to boost the production of manganese from low-grade ores as well as post-consumer products. The framework of effective leaching processes and proper solvent extraction techniques for the recovery of manganese could be a novel pathway to get a clean, green and healthy environment for a sustainable future in the automotive and energy segment where this metal has a significant contribution.

Optimization of manganese recovery from groundwater treatment sludge for the production of highly-efficient Cu(II) and Pb(II) adsorbents

Manganese is one of the main components of groundwater treatment sludge. Meanwhile, copper (Cu) and lead (Pb) ions are usually present in various metal plating spent rinse waters and their removal prior to effluent release is of great importance to mitigate the adverse effects of these metals on human health and the environment. In this study, manganese recovery from groundwater treatment sludge by reductive acid leaching was optimized to produce manganese dioxide adsorbents for the competitive removal of Cu(II) and Pb(II) from simulated electroplating wastewaters. Box–Behnken design was used to optimize manganese recovery and analyze the two-parameter interactions of reductive leaching parameters for manganese recovery from the sludge, namely: sulfuric acid concentration, hydrogen peroxide dosage and sludge mass. Results showed that manganese recovery via reductive acid leaching was found to be more dependent on sludge mass than on sulfuric acid concentration and hydrogen peroxide dosage. Analysis of the elemental adsorbent composition revealed a 72.47: 27.53 manganese-to-oxygen ratio, while the evaluation of the adsorbent surface functional groups confirmed the presence of hydroxides and manganese oxides. Adsorbent point-of-zero-charge was determined at pH 6.0. Adsorption capacities for Pb(II) and Cu(II) reached 177 and 118 mg g−1, respectively. Metal uptake for both adsorbates conformed with the extended Langmuir isotherm, implying monolayer adsorption, while film diffusion was the rate-limiting mechanism. Overall, the findings of this study demonstrate high manganese recovery from groundwater treatment sludge and the production of highly-efficient adsorbents for the treatment of heavy metal-containing industrial effluents.

Recovery of manganese from the mother liquor after vanadium precipitation during vanadium extraction with calcified roasting and acid leaching process

Recovery of manganese from the mother liquor after vanadium precipitation during vanadium extraction with calcified roasting and acid leaching process

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.

Hydrometallurgical Process and Economic Evaluation for Recovery of Zinc and Manganese from Spent Alkaline Batteries

An innovative, efficient, and economically viable process for the recycling of spent alkaline batteries is presented herein. The developed process allows for the selective recovery of Zn and Mn metals present in alkaline batteries. The hydrometallurgical process consists of a physical pre-treatment step for separating out the metal powder containing Zn and Mn, followed by a chemical treatment step for the recovery of these metals. Sulfuric acid was used for the first leaching process to dissolve Zn(II) and Mn(II) into the leachate. After purification, Mn was recovered in the form of MnO2, and Zn in its metal form. Furthermore, during the second sulfuric acid leaching, Na2S2O5 was added for the conversion of Mn(IV) to Mn(II) (soluble in the leachate), allowing Mn to be recovered as MnCO3. Masses of 162 kg of Zn metal and 215 kg of Mn (both in the form of MnO2 and MnCO3) were recovered from one ton of spent alkaline batteries. The direct operating costs (chemicals, labor operation, utilities, energy) and indirect costs (amortization, interest payment) required for a plant treating 8 tons of spent batteries per day was calculated to be $CAD 726 and $CAD 534 per ton, respectively, while the total revenue from the sale of the metals was calculated at $CAD 1359.6 per ton of spent batteries. The development of this type of cost-effective industrial process is necessary for a circular economy, as it contributes to addressing environment- and energy-related issues, and creates opportunities for the economic utilization of metals.

Manganese Problem in Russian Metallurgy

The main manganese consumer is ferrous metallurgy. The global volume of manganese ferroalloys production is ~1% of the volume of steel production. After the collapse of the Soviet Union, Russia was cut off from a manganese ore base. Currently, only high-carbon ferromanganese and ferrosilicomanganese are smelted in Russia from imported ore in a limited amount. The mineral resource base of manganese ores in Russia is quite large: the balance reserves of manganese ores are about 230 million tons (~2% of the world), the projected resources are more than 1 billion tons. The quality of the manganese ores in Russia is lower than that of manganese ores in most of the main producing countries. The average manganese content in Russian ores is 9–23%. The mineral resource base of the manganese ores is made up of carbonate ores, which account for more than 77%. Recovery of manganese ores in Russia is carried out irregularly and does not exceed 66 thousand tons/year. The demand of Russian ferroalloy plants producing manganese ferroalloys for manganese ores and concentrates is covered by imports. The acceleration of the creation of the domestic manganese ore base from the standpoint of economic security is quite a pressing issue. It is necessary to solve a number of issues related to the following: the treatment of poor manganese ores, the development of effective technologies for smelting manganese ferroalloys from concentrates obtained after the treatment of these ores, as well as the creation of more advanced methods for dephosphorization of manganese concentrates. In the production of manganese ferroalloys from ore to finished alloys, about 50% of manganese extracted from the subsoil is lost, a large amount of by-products is formed (treatment sludge, slags, screenings of fine fractions of ore raw materials and finished products, sludge from the smelting process and dust), its utilization makes it possible not only to reduce the consumption of raw mineral materials, but also to increase the efficiency of the main production, as well as to reduce environmental pollution. Additional recovery of manganese from industrial waste and improvement of technological processes for smelting manganese ferroalloys are ways to increase the through manganese recovery.

Countercurrent leaching of Ni, Co, Mn, and Li from spent lithium-ion batteries

This study focuses on a countercurrent leaching process (CLP) for the dissolution of high-value metals from cathode active material of spent lithium-ion batteries (LIBs). Its main aim is to improve the effective utilization of acid during leaching and allow for the continuous operation of the entire CLP by adjusting the process parameters. The overall recovery of lithium (Li), cobalt (Co), nickel (Ni), and manganese (Mn) was 98%, 95%, 95%, and 92%, respectively; the acid utilization of the leaching process exceeded 95% under optimum conditions. The optimum conditions for first stage leaching were 70 g/L solid-liquid (S/L) ratio at 40°C for 30 minutes, and 2.0 M sulfuric acid, 100 g/L S/L ratio, 7 g/L starch, at 85°C for 120 minutes for second stage leaching. After five bouts of circulatory leaching, more than 98% Li, 95% Co, 95% Ni, and 92% Mn were leached under the same leaching conditions. Furthermore, we introduced the Avrami equation to describe metal leaching kinetics from spent LIBs, and determined that the second stage leaching process was controlled by the diffusion rate. In this way, Li, Ni, Co, and Mn can be recovered efficiently and the excess acid in the leachate can be reused in this hydrometallurgical process, potentially offering economic and environmental benefits.

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

A combined low-temperature-roasting and water-washing process is investigated as a hazard-free method to treat electrolytic manganese residue (EMR) and recover manganese. In this study, the phase transformation characteristics and a thermodynamics analysis of the low temperature roasting process of EMR are evaluated. In addition, the effects of temperature and time on the phase transformation of EMR in the roasting process and the washing characteristics of roasted EMR samples are also investigated. Results reveal that some unstable phases within EMR are transformed into more stable phases depending on the treatment time/temperature conditions used and EMR roasted for 60 min at 600 °C (R60min/600°C) exhibit the highest rate of manganese recovery, 67.12 %. After 25 min of deionized water washing, the concentration of manganese in solution from R60min/600°C material become stable, whereas after 6 washing cycles the concentration of manganese in the solution is < 0.005 g/L. The R60min/600°C material with three wash cycles results in a manganese-water solution concentration that is suitable for use in electrolytic manganese metal production. Finally, toxicity leaching tests show that the concentrations of ions present in the leaching solution are all lower than the regulatory limits mandated by the Chinese Integrated Wastewater Discharge Standard GB 8978−1996.

Hydrometallurgical recovery of manganese, gold and silver from refractory Au-Ag ore by two-stage reductive acid and cyanidation leaching

In this study, a refractory Au-Ag ore from Beiya (Yunnan, China) was characterised and the occurrence states of low-grade gold and silver were clarified. The results revealed that the gold in the ore mainly occurred as visible native gold, which can be leached easily via cyanidation, whereas the visible silver minerals occurred as native silver, acanthite, chlorargyrite, acanthite, pyrargyrite, andorite and polybasite. Nevertheless, most of the silver occured as invisible silver in manganese oxide ore with the form of isomorphs and could not be leached via direct cyanidation. A pretreatment of reductive acid leaching using sodium sulphite as a reductant successfully leached the manganese and liberated the silver, which was very beneficial for the cyanidation of silver. The manganese was enriched in the leaching solution at a concentration of 16.51 g/L with an average leaching percentage of 70.27% after five-stage cyclic reductive acid leaching under optimised conditions of 1.0 mol/L of H2SO4, 20 g/L of Na2SO3, a liquid-solid ratio of 5:1, and stirring speed of 300 r/min at room temperature (28 ± 1 °C) for 1.0 h. We could easily recover 99.90% copper and 99.80% manganese from the leaching solution via iron powder reduction and sodium carbonate precipitation. Following the leaching of manganese, the cyanidation leaching percentages of gold and silver were to 87.37% and 80.19% respectively. In summary, we developed a novel process for the hydrometallurgical recovery of manganese, gold, and silver from refractory Au-Ag ore.

An innovative technology for full component recovery of iron and manganese from low grade iron-bearing manganese ore

Low grade iron-bearing manganese ore is a potential solid waste resource. In this study, an innovative technology of suspension reductive roasting and magnetic separation (SRMS) was used to treat the iron-bearing manganese ore for comprehensive recovery of iron and manganese. The phase transformation of minerals in roasting process was systematically investigated by X-ray diffraction analyzer (XRD) and high-resolution transmission electronic microscope (HRTEM). The results show under the optimum conditions of reduction temperature 680 °C, reduction time 30 min, CO concentration 20% and particle size −0.9 mm, iron concentrate with iron grade 67.38% and iron recovery 87.14% and manganese concentrate with manganese grade 30.51% and manganese recovery 87.02% were obtained respectively. Magnetite converted from hematite was enriched in the concentrate of magnetic separation, while manganosite transformed from pyrolusite and braunite was enriched in the tailings of magnetic separation. SRMS can achieve full component utilization of iron-bearing manganese without residues.

Selective Recovery of Manganese from Anode Sludge Residue by Reductive Leaching

Manganese-containing anode sludge is a common side-product in the electrowinning of zinc. The anode sludge consists mainly of oxidized manganese, but also lesser amounts of lead, calcium, and other minor metals. The impurities present in the anode sludge mandate new recycling strategies for its efficient use. This work demonstrates a novel method for selective manganese recovery from lead- and calcium-bearing manganese oxide solid residue. Leaching with sulfuric acid in the presence of a selected reducing agent, such as hydrogen peroxide or citric acid, yields a concentrated MnSO4 solution with high selectivity over calcium and lead. Manganese yields up to 98% can be obtained. Minimization of calcium and lead in final manganese product can be accomplished with the correct choice of leaching conditions. Alongside manganese sulfate solution, leaching residue with high content of lead and silver was also formed.

Optimization of Cu and Mn Dissolution from Black Coppers by Means of an Agglomerate and Curing Pretreatment

Black coppers are mineraloids with a high content of Cu and Mn. These have an amorphous crystalline structure that makes them refractory to conventional leaching processes. For this reason, these mineral resources are not incorporated in industrial leaching heap processes and are taken to dumps. In the present study, an agglomerate pretreatment process incorporating NaCl is evaluated, and a curing stage, followed by acid-reducing leaching for Cu and Mn dissolution from a high-grade black copper mineral. For this, an experimental design was developed both to evaluate the impact of the dependent variables on the response, to generate analytical models that represent the copper and manganese recoveries under the set of sampled conditions. The models indicate that the curing time and the NaCl concentration have a primary effect on the recovery of both elements. In contrast, the optimization model suggests that the optimal operating levels are reached at relatively high levels of time (&gt;130 h) and of NaCl concentration (&gt;22 kg/t).

Microwave Processing of Electrode Active Materials for the Recovery of Cobalt, Manganese, and Lithium

The limited lifespan, ever-growing demand, and significant lithium and cobalt content are responsible factors for the immediate recycling of discarded lithium-ion batteries. Discharged batteries were dismantled, segregated, and size reduced to recover cathode and anode material. The active cathode material comprises LiCoO2 (65.8%) and LiMn2O4 (34.2%) and was carbothermal reduced with recovered graphite in a microwave furnace followed by water leaching and magnetic separation. A Box Behnken statistical experimental design is used for process optimization. Both cobalt and manganese report to magnetic fraction, whereas graphite and lithium carbonate report to non-magnetic fraction and solution crystal respectively. The final product comprises of cobalt 73% and manganese of 14% with process yield of 36% and saturation magnetization of 76 emu/g.