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

Investigation of waste alkali-activated cementing material using municipal solid waste incineration fly ash and dravite as precursors: Mechanisms, performance, and on-site application

The proper treatment of municipal solid waste incineration fly ash (MSWIFA) is a crucial concern due to its hazardous nature and potential environmental harm. To address this issue, this study innovatively utilized dravite and black liquor to solidify MSWIFA. The semi-dry pressing method was employed, resulting in the production of waste alkali-activated cementing material (WACM). This material demonstrated impressive compressive and flexural strength, reaching 45.89 MPa and 6.55 MPa respectively, and effectively solidified heavy metal ions (Pb, Cr, Cu, Cd, and Zn). The leaching concentrations of these ions decreased from 27.15, 10.36, 8.94, 7.00, and 104.4 mg/L to 0.13, 1.05, 0.29, 0.06, and 12.28 mg/L, respectively. The strength of WACM increased by 3 times compared to conventionally produced materials. Furthermore, WACM exhibited excellent long-term performance, with acceptable heavy metal leaching and minimal mechanical degradation. Experimental and theoretical analyses revealed the heavy metal solidification mechanisms, including chemical binding, ion substitution and physical encapsulation. Finally, the on-site application of WACM confirmed its feasibility in meeting both environmental and strength requirements.

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

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

Study of microscopic properties and heavy metal solidification mechanism of electrolytic manganese residue-based cementitious materials

Electrolytic manganese residue (EMR) is a solid waste that contains a significant amount of soluble manganese and ammonia nitrogen, which can pose risks to human health if improperly disposed of. This study aimed to prepare cementitious materials containing abundant ettringite crystals by mixing EMR with various proportions of granulated blast furnace slag (GBFS) and alkaline activators (CaO, Ca(OH)2, clinker, NaOH). The resulting cementitious material not only utilized a substantial amount of EMR but also exhibited comparable strength to ordinary Portland cement. The optimal ratios were determined through mechanical testing. Additionally, the leaching toxicity of cementitious materials was assessed using ICP-MS (inductively coupled plasma mass spectrometer) tests. The microscopic properties, hydration, and mechanism of heavy metal solidification in the cementitious materials were evaluated using XRD (X-ray diffraction), SEM (scanning electron microscope), EDS (energy-dispersive spectrometer), FTIR (Fourier transform infrared spectroscopy), and TG (thermogravimetric) techniques. The results showed that the optimal ratio for the cementitious materials was 60% EMR, 36% GBFS, and 4% Ca(OH)2. The hardened mortar exhibited compressive strengths of 34.43 MPa, 41.3 MPa, and 50.89 MPa at 3 days, 7 days, and 28 days, respectively, with an EMR utilization rate of 60%. The hydration products of EMR-based cementitious materials were C-(A)-S-H, AFt, and ferromanganese compounds, which contribute to the mechanical strength. The Mn2+ and NH4+-N contents of raw EMR were 1220 and 149 mg/L, respectively. Nonetheless, the leaching of Mn2+ and NH4+-N in the alkali-EMR-GBFS system was significantly below the limits set by the Chinese emission standard GB8978-1996. Within this system, C-(A)-S-H and AFt could physically adsorb and displace heavy metals, Ca6Mn2(SO4)2(SO3)2(OH)12·24H2O could replace Al ions with Mn ions, and ferromanganese compounds Fe2Mn(PO4)2(OH)2·(H2O)8 and MnFe2O4 could chemically precipitate Mn2+.

Remediation of arsenic contaminated water and soil using mechanically (ball milling) activated and pyrite-amended electrolytic manganese slag

With the development of industry, heavy metal (HM) pollution of soil has become an increasingly serious problem. Using passivators made of industrial by-products to immobilize HMs in contaminated soil is a promising in-situ remediation technology. In this study, the electrolytic manganese slag (EMS) was modified into a passivator (named M-EMS) by ball milling, and the effects of M-EMS on adsorption of As(V) in aquatic samples and on immobilization of As(V) and other HMs in soil samples were investigated under different conditions. Results demonstrated that M-EMS had a maximum As(V) adsorption capacity of 65.3 mg/g in the aquatic samples. Adding M-EMS to the soil reduced the leaching of As (from 657.2 to 319.8 μg/L) and other HMs after 30 d of incubation, reduced the bioavailability of As(V) and improved the quality and microbial activity of the soil. The mechanism for M-EMS to immobilize As in the soil are complex reactions, ion exchange reaction with As and electrostatic adsorption. This work provides new ideas of using waste residue matrix composites for sustainable remediation of Arsenic in the aquatic environment and soil.

Effect of soluble salts in electrolytic manganese residue on its geotechnical characteristics

Electrolytic Manganese Residue (EMR) is a solid waste containing soluble sulfate, discharged by electrolytic manganese industries. The accumulation of EMR in ponds poses a significant hazard to both safety and the environment. This study utilized innovative geotechnical test techniques to conduct a series of tests, investigating the effect of soluble salts on the geotechnical characteristics of EMR. The results revealed that soluble sulfates had a significant impact on the geotechnical characteristics of the EMR. In particular, the infiltration of water leached away the soluble salts, causing a non-uniform particle size distribution and decreasing the shear strength, stiffness, and liquefaction resistance of the EMR. Nevertheless, an increase in the stacking density of EMR could improve its mechanical characteristics and inhibited the dissolution of soluble salts. Therefore, increasing the density of stacked EMR, ensuring the effectiveness and non-obstruction of the water interception facilities, and reducing rainwater infiltration could be effective measures to enhance the safety and reduce the environmental hazard of EMR ponds.

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.

Study on phase evolution and promoting the pozzolanic activity of electrolytic manganese residue during calcination

Electrolytic manganese residue (EMR) is a harmful by-product in the electrolytic manganese industry. Calcination is an efficient method for disposing EMR. In this study, thermogravimetric-mass spectrometry (TG-MS) combined with X-ray diffraction (XRD) was used for analysing the thermal reactions and phase transitions during calcination. The pozzolanic activity of calcined EMR was determined by the potential hydraulicity test and strength activity index (SAI) test. The leaching characteristics of Mn were determined by TCLP test and BCR SE method. The results showed that MnSO₄ was converted into stable MnO₂ during calcination. Meanwhile, Mn-rich bustamite (Ca_0.228Mn_0.772SiO₃) was converted into Ca(Mn, Ca)Si₂O₆. The gypsum was transformed into anhydrite and then decomposed into CaO and SO₂. Additionally, the organic pollutants and ammonia were completely removed following calcination at 700 °C. The leaching concentration of Mn decreased from 819.9 mg L^-1 to 339.6 mg L^-1 following calcination at 1100 °C. The chemical forms of Mn were transformed from acid-soluble fraction to residual fraction. The pozzolanic activity tests indicated that EMR1100-Gy maintained a complete shape. The compressive strength of EMR1100-PO reached 33.83 MPa. Finally, the leaching concentrations of heavy metals met the standard limits. This study provides a better understanding for the treatment and utilization of EMR.

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.

Submicron tourmaline enhanced the solidification of municipal solid waste incineration fly ash by chemical structure reorganization and stabilized heavy metals

Municipal solid waste incineration fly ash (MSWIFA) exsits in large quantitities and contains pollutants such as heavy metal. While solidification is one of the most effective methods for treating MSWIFA, this application is limited by cost, subsequent treatment, and simultaneous immobilization of anions and cations. This research demonstrated that under a certain initial pressure (20 MPa), a gelation reaction involving ball milling-modified tourmaline powder, a small amount of cement clinker, and MSWIFA forms a stable consolidated body and significantly reduces the risk of heavy metal dissolution. The consolidated MSWIFA can easily be formed into unfired bricks in large-scale pilot production, and a response surface model was used to optimize the experimental parameters. When the mass ratio of tourmaline: cement clinker: MSWIFA was 15:15:200 (mixed with a moisture content of 13 to 15 %), the compressive strength of the consolidated body reached 13 MPa, and the amounts of Cr and Pb leached decreased from 12 mg/L to 0.1 mg/L and 25 mg/L to 0.3 mg/L, respectively. The consolidated form contained a new mineral phase (Ca₃Si₂O₇·3H₂O, Ca₁₀Mg_0.8(SiO₄)_0.6O₂Cl, and CaCl₂∙Ca(OH)₂·H₂O) with a high compressive strength. Notably, the soluble PbSO₄ in the MSWIFA was converted into relatively stable PbSiO₃, and Cr(VI) was lattice-wrapped. This study was the first to demonstrate that tourmaline synchronously passivates Pb(II) and Cr(VI) in fly ash in the solid phase, with a low cost and requires no subsequent treatment. This study provided a novel technical path for recycling MSWIFA. Eventually, leaching of the heavy metals Pb, Cr, Cu, Cd, and Zn from the solids achieved concentrations less than 0.25, 1.5, 0.5, 0.15, and 100 mg/L.

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.