Microwave pyrolysis of walnut shell for reduction process of low-grade pyrolusite

Closed-loop recovery of molybdenum and value-added reuse of tungsten from alloy waste in additive manufacturing

As metal additive manufacturing (MAM) technology is booming in the aerospace sector, alternatives to the traditional production methods of metals such as mining, processing, and refining with severe emissions are urgently needed. This study proposed a closed-loop route for efficient recovery of molybdenum (Mo) and value-added reuse of tungsten (W) from Cr-Co-Ni-Mo-W alloy waste in MAM. The results showed that the leaching efficiency of Mo and W reached 99.3% and 99.9%, respectively, using the dual chemical-physical means of mixed-alkali roasting and leaching by microwave heating, while the discharge of waste liquor containing Cr6+ was reduced. Leaching kinetic studies revealed that the metal leaching process was controlled by chemical reaction mechanism. Moreover, the 10%N1923 (primary amine)-5%TRPO (tri-alkyl phosphine oxide)-kerosene extraction system exhibited a synergistic extraction effect on Mo and W. After purification, Mo was recovered as Mo powder for MAM. Simultaneously, the recovered product of W, MnWO4, was applied as a photocatalytic material with excellent degradation of methylene blue dye. Ultimately, the proposed method obtained recovery efficiencies of 98.4% and 99.3% for Mo and W, respectively, achieving efficient and environmentally-friendly reuse of these key metals.

Co-recovery of Mn and Fe from pyrolusite and copper slag with hydrometallurgy process: Kinetics and leaching mechanisms

With the shortage of high-quality raw materials and increasingly strict environmental regulations, the recovery of metals from copper slag and pyrolusite has become a research hotspot. A novel method for simultaneously extracting Mn and Fe from pyrolusite and copper slag has been proposed. Under the optimal conditions (Copper slag / Pyrolusite = 2, H2SO4 = 2 M, liquid-solid ratio = 10, T = 90 ℃, holding time = 60 min), the leaching efficiencies of Mn and Fe can reach 98.28% and 99.04%, respectively. In addition, the treated residue containing 60.04 wt% SiO2 can be used as a raw building material. Through chemical kinetics and mineralogical transformation analyses, Fe2SiO4 in copper slag decomposes to release Fe2+, which can reduce and leach Mn from pyrolusite. The unreacted shrinkage nuclear reaction model under the control of the surface chemical reaction is the most suitable model to describe the process, and when the apparent activation energy is 35.50 kJ/mol, the apparent rate equation is: [Formula: see text].

Conventional and microwave-assisted acid pretreatment of tea waste powder: analysis of functional groups using FTIR

Tea waste powder (TWP) is one of the potential biomass waste to recover valuable chemicals and materials. The prime objective of this work is to investigate the role of acid pretreatment on TWP. Diluted acids (HCl, H₃PO₄, CH₃COOH, and H₂SO₄) were used to soak the TWP to understand the role of acids on bond cleavage and chemicals formation. One gram of TWP was soaked in 100 mL of diluted acids for 24 h. The soaked samples were further subjected to a hot air oven (temperature: 80 °C, duration: 6 h), orbital shaking (shaking speed: 80-100 rpm, duration: 6 h), and microwave irradiation (microwave power: 100 W, duration: 10 min) to understand the synergistic effects of acids and mode of exposure. The pretreated solid samples and liquid samples were analyzed using FTIR to understand the presence of functional groups. The mass loss of TWP after treatment significantly varied with the type of acid and exposure mode used. In the orbital shaker, the mass loss was varied in the following order: H₂SO₄ (36%) > CH₃COOH (32%) > H₃PO₄ (22%) > HCl (15%). In hot air oven, high mass loss was observed compared to orbital shaking [HCl (48%) > CH₃COOH (37%) > H₂SO₄ (35%) > H₃PO₄ (33%)]. The mass loss in microwave irradiation is lower (19 to 25%) with all acids compared to orbital shaking. In the solid samples, O-H stretching, C-H stretching, C=O stretching, C=C stretching, -C-O-, and -C-OH- functional groups were noticed. Similarly, C=O and C=C peaks and C-O and -C-OH peaks were noticed in liquid samples. Interestingly, microwave irradiation showed promising results in 10 min of pretreatment, whereas orbital shaking and hot air oven pretreatments require 6 h to achieve the same result.

Microwave drying method investigation for the process and kinetics of drying characteristics of zinc-leaching residue

Due to the high moisture content in the zinc-leaching residue, it is easy to cause safety problems when directly entering the kiln. Microwave drying can minimize particle agglomeration and promote cracks on the mineral surface, which benefits the subsequent recovery and smelting of zinc-leaching residue. The results showed that increasing microwave power and particle size range could improve the maximum drying rate and reduce the drying time. The maximum drying rate of 20 g zinc-leaching slag with a microwave power of 700 W, a particle size of 1-10 mm, and a moisture content of 20% can be higher than 0.365%/s and reach complete drying within 120 s. The drying results were fitted and statistically analyzed using nine common kinetic models of drying, the surface diffusion coefficient changes were further analyzed at four levels, and the reaction activation energy (E_a) was calculated. According to Fick's second law, when the average particle size increased from 0.044 to 5.5 mm, the surface diffusion coefficient increased from 6.2559 × 10^-9 to 3.8604 × 10^-6 m²/s, which showed that the effect of particle size change on microwave drying process was significant. The E_a of the drying reaction was 18.1169 kJ/mol. This method provides an idea for efficiently treating secondary resources containing valuable metals.

Analysis of pyrolysis index and reaction mechanism in microwave-assisted ex-situ catalytic co-pyrolysis of agro-residual and plastic wastes

Catalytic and non-catalytic microwave-assisted co-pyrolysis of biomass with plastics was performed to understand the interactions. An ex-situ configuration was adopted for performing catalytic co-pyrolysis experiments with ZSM-5 as a catalyst. Co-pyrolysis promoted cracking of vapors resulting in enhanced gas yields. ZSM-5 further enhanced the secondary cracking which resulted in low oil yields. The oil fraction collected from the pyrolysis of plastics was rich in hydrocarbons, whereas biomass pyrolysis led to the formation of oxygenated compounds in the oil. A plausible reaction mechanism scheme is proposed to understand the formation of major pyrolysis products via different pathways during different pyrolysis processes investigated. Also, a new parameter, the pyrolysis index is introduced to understand the pyrolysis intensity by utilizing the feedstock conversion, pyrolysis time, heating value, mass of feedstock, and energy consumption. The value of the pyrolysis index was found to be higher for plastics pyrolysis than biomass pyrolysis. Co-pyrolysis further increased the pyrolysis index due to the synergistic interactions.

The preparation and properties of iron-walnut shell powder microelectrolytic spherical fillers

In order to solve the issues of caking, loss, and effluent color reversion in the application of traditional microelectrolysis, the iron-walnut shell powder microelectrolytic spherical filler was developed in this paper. The filler was prepared by walnut shell powder, iron powder, sodium silicate, and sodium humate activated by ZnCl₂ as raw materials and calcined at high temperature. The effects of the mass ratios of Fe to walnut shell powder, sodium silicate content, sodium humate content, calcination temperature, and time on the removal rate of methylene blue by the spherical fillers were investigated, so as to determine the optimal preparation conditions of the spherical fillers. The pore-forming structure and the composition of the spherical fillers were also analyzed by an X-ray diffractometer (XRD), a scanning electron microscope (SEM), and an energy spectrometer (EDS). The results show that the optimal preparation conditions for the spherical fillers of 5 mm are as follows: the mass ratio of iron powder to walnut shell powder treated by 15% ZnCl₂ is 1:1, sodium silicate is 15%, sodium humate is 20%, the calcination temperature is 800 °C, and the calcination time is 3 h. Compared with the conventional microelectrolysis, the removal rate of methylene blue by the spherical fillers can finally reach the same level as it did, and the phenomena of the filler hardening and clogging can be avoided.

Study on the mechanism and kinetics of manganese release from waste manganese ore waste rock under rainfall leaching

Manganese released from the piled manganese ore wastes is a great threat to the local ecosystem and human health. The mechanism and dynamic characteristics of manganese release from the manganese ore wastes were studied based on the static and dynamic experiments. The concentration of manganese in the leaching solution under the intensive state is twice that resulted from the static state; the manganese release from the waste rock increased with the increase of the solid-liquid ratio and reached 922.3 mg/L when the solid-liquid ratio was 1:5. When the particle size of waste rock was less than 180 μm, the release amount of manganese was the largest and reached 491.3 mg/L. When the pH was 7 and the rainfall intensity was 80 mL/h, the increase of leaching time contributed to the rapidly decreased amount of manganese released, and the leaching process reached equilibrium gradually. The cumulative release of manganese increased with the increase of rainfall duration. In the dynamic leaching process, the change of pH and EC of the leachate had nothing to do with the initial pH of leaching agent but has a close relationship with the hydrolysis of minerals in waste. According to the experimental results, it was found that the double constant equation model fitted the kinetic process of release process better. The purpose of this study was to provide a scientific basis for the assessment and control of manganese pollution in soil and groundwater in manganese mining area.

Replacing Fossil Carbon in the Production of Ferroalloys with a Focus on Bio-Based Carbon: A Review

The production of ferroalloys and alloys like ferronickel, ferrochromium, ferromanganese, silicomanganese, ferrosilicon and silicon is commonly carried out in submerged arc furnaces. Submerged arc furnaces are also used to upgrade ilmenite by producing pig iron and a titania-rich slag. Metal containing resources are smelted in this furnace type using fossil carbon as a reducing agent, which is responsible for a large amount of direct CO2 emissions in those processes. Instead, renewable bio-based carbon could be a viable direct replacement of fossil carbon currently investigated by research institutions and companies to lower the CO2 footprint of produced alloys. A second option could be the usage of hydrogen. However, hydrogen has the disadvantages that current production facilities relying on solid reducing agents need to be adjusted. Furthermore, hydrogen reduction of ignoble metals like chromium, manganese and silicon is only possible at very low H2O/H2 partial pressure ratios. The present article is a comprehensive review of the research carried out regarding the utilization of bio-based carbon for the processing of the mentioned products. Starting with the potential impact of the ferroalloy industry on greenhouse gas emissions, followed by a general description of bio-based reducing agents and unit operations covered by this review, each following chapter presents current research carried out to produce each metal. Most studies focused on pre-reduction or solid-state reduction except the silicon industry, which instead had a strong focus on smelting up to an industrial-scale and the design of bio-based carbon for submerged arc furnace processes. Those results might be transferable to other submerged arc furnace processes as well and could help to accelerate research to produce other metals. Deviations between the amount of research and scale of tests for the same unit operation but different metal resources were identified and closer cooperation could be helpful to transfer knowledge from one area to another. Life cycle assessment to produce ferronickel and silicon already revealed the potential of bio-based reducing agents in terms of greenhouse gas emissions, but was not carried out for other metals until now.

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.

Bioleaching of manganese from a low-grade pyrolusite ore using Aspergillus niger: Process optimization and kinetic studies

Low-grade metal resources generated during different mineral processing activities are increasing while there are not many economic and environmentally friendly techniques to manage them. There is no viable technique for the manganese extraction from low-grade ores as the conventional procedures are costly and environmentally unfriendly. In this research, the D-optimal response surface methodology has been used to optimize the bioleaching parameters. Varied contact methods (one-step, two-step, and spent medium), nutrition sources (sucrose and glucose), and pulp densities (1 g.L^-1 to 10 g.L^-1) were used in different experiments having been done in 30 days using Aspergillus niger. A maximum recovery of over 80% of Mn was achieved based on the acidolysis, complexolysis, and redoxolysis leaching of the organic acids produced by the fungi under the optimum condition; a two-step approach, in a glucose medium, and with a pulp density of 1 g.L^-1. A kinetic study was also performed and revealed that the leaching mechanism was a mixed one which consisted of two stages (diffusion through the liquid film and a chemical reaction) for the first 12 day period, and a mechanism of diffusion through the product layer for the rest of the experiment.

Enhanced leaching of manganese from low-grade pyrolusite using ball milling and electric field

In this study, electric field and ball milling were used to leach Mn²⁺ from low-grade pyrolusite (LGP). The effects of current density, reaction time, reaction temperature, ball-to-powder weight ratio, and ball milling time on the leaching efficiency of Mn²⁺ from LGP as well as the leaching mechanism were systematically studied. The results showed that the combined use of electric field and ball milling enhanced the leaching of Mn²⁺ from LGP. The leaching efficiency of Mn²⁺ reached 97.79% under the optimum conditions of LGP-to-pyrite mass ratio of 1:0.18, current density of 30 mA/cm², LGP-to-H₂SO₄ mass ratio of 1:0.4, liquid-to-solid ratio of 5:1, ball-to-powder weight ratio of 1:1, ball milling time of 2 h, temperature of 80 °C, and leaching duration of 120 min. This value was 25.95% higher than that attained without ball milling and 41.45% higher than that attained when neither ball milling nor electric field was employed. Pyrite was fully oxidized to generate additional SO₄^2- and Fe³⁺, and was further hydrolyzed to form jarosite (KFe₃(SO₄)₂(OH)₆) and hydronium jarosite (Fe₃(SO₄)₂(OH)₅·2H₂O) via ball milling and electric field application. Moreover, the electric field changed the surface charge distribution of the mineral particles and promoted collisions between them as well as the collapse of the crystal lattice, further improving the leaching efficiency of Mn²⁺ from LGP. This study provided a new method for leaching Mn from LGP.

Kinetics characteristics and microwave reduction behavior of walnut shell-pyrolusite blends

Combining biomass pyrolysis with microwave heating technologies provides a novel and efficient approach for low-grade pyrolusite reduction. The microwave reduction behavior and pyrolysis kinetic characteristics of walnut shell-pyrolusite blends were explored. Results indicated the optimal reduction parameters were: reduction temperature of 650 °C, holding time of 30 min, M_bio/M_ore of 1.8:10, and microwave power of 1200 W. The co-pyrolysis characteristics of the blends included four stages: dehydration, pre-pyrolysis, intense pyrolysis and reduction, and slow pyrolysis and reduction. Fitting analysis based on Coats-Redfern method revealed that chemical reaction was the control step of the process of reducing pyrolusite by biomass, which the finding matched to the isothermal kinetic analysis results determined through unreacted shrinking nuclear model. The activation energies and pre-exponential factors were determined at 5.62 kJ·mol^-1-16.69 kJ·mol^-1 and 0.0426 min^-1-0.515 min^-1. The work provides sound references for promoting the industrial application of the combined method on minerals reduction.

Investigations on the microwave absorption properties and thermal behavior of vanadium slag: Improvement in microwave oxidation roasting for recycling vanadium and chromium

Vanadium slag contains high contents of vanadium and chromium with complex and dense structures, hence microwave heating instead of conventional methods is expected to destroy the dense structure and further to improve the extraction rate of vanadium and chromium, and exploring its dielectric properties is the prerequisite work. Microwave absorption properties and thermal behavior of vanadium slag were investigated. Results indicated that vanadium slag endowed excellent microwave absorption properties, with minimum ε_r' value of 34.447 (F/M). Dielectric properties of vanadium slag varied with temperature, which changing trend was matched to the three stages of microwave heating characteristics identified by heating rates. Meanwhile, the changing process of dielectric properties also corresponded to the three processes of thermogravimetric characteristics: dehydration stage (30 °C-280 °C), oxidation decomposition of olivine phase and normal spinel phase (280 °C-650 °C), and oxidation decomposition of vanadium chromium spinel (650 °C-950 °C). Moreover, the maximum dielectric constant and highest microwave heating rate of vanadium slag both appeared at the temperature regime of 500 °C-550 °C, which was also the main temperature regime for oxidation decomposition of olivine phase and normal spinel phase in vanadium slag, demonstrating the appropriate process temperature for microwave heating technology to recycle vanadium slag.

High-temperature dielectric properties and pyrolysis reduction characteristics of different biomass-pyrolusite mixtures in microwave field

Exploring the dielectric properties of mineral-biomass mixtures is fundamental to the coupled application with biomass pyrolysis and microwave technology to mineral reduction. In this work, the microwave dielectric properties of five pyrolusite-biomass mixtures were measured by resonant cavity perturbation technique and the pyrolysis reduction characteristics were systematically investigated, including poplar, pine, ageratina adenophora, rapeseed shell and walnut shell. Results indicated that the dielectric properties commonalities of five mixtures with temperature represented by increasing firstly, dropping intensely and finally rising slightly, with excellent responsiveness to microwaves; which the change trend was mainly attributed to the crystal transformation of amorphous MnO₂ and pyrolusite reduction reactions by biomass pyrolysis. Meanwhile, the heating characteristics successfully matched the dielectric properties of the mixtures, and the pyrolusite reduction process by biomass can be divided into two stages: biomass pyrolysis and pyrolusite reduction. The work highlights the universal feasibility of the novel coupled method for mineral reduction.