Utilization of Electrolytic Manganese Residues in Production of Porous Ceramics

Abstract

Electrolytic manganese residues (EMR) are one of industrial by-products generated during the production of electrolytic manganese metal. To reduce the EMR hazard to environment and invent value-added materials, porous ceramics were prepared by the pore-forming method with EMR and various additives. The influences of the incorporation of different additives, sintering temperature, and molding pressure on properties of porous ceramics were investigated. Properties such as apparent porosity, water absorption, bulk density, and compression strength have been measured. The EMR-based porous ceramics were also characterized by XRD, SEM, BET-specific surface area, and BJH pore size distribution measurement. It revealed that the appropriate mode was the sample containing 20 wt% carbon powder, 7.5 wt% dolomite, and 5 wt% kaoline, under which the ceramics with the properties of high apparent porosity (69.70%), high compressive strength (6.97 MPa), and good acidity-alkali stability were obtained successfully. The comprehensive performance of EMR-based porous ceramics makes them advantageous to use as nonhazardous and valuable materials showing promising potential applications, which not only is a promising new approach to improve the resource utilization of EMR but also can promote the manganese industry's sustainable and healthy development and protect and improve ecological environment.

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

“…With increasingly stringent environmental regulations in China, the ability to treat EMR in hazard-free way has become of critical importance and over the last decade, a number of related studies have been carried out (Xin et al, 2011;Du et al 2014;Xu et al, 2014;Yang et al, 2014;Li et al, 2015;Shu et al, 2016b;Shu et al, 2016c;Wu et al, 2016;Li et al, 2018;Shu et al, 2018a;Shu et al, 2019b;Shu et al, 2018b). These investigations can be roughly divided into four main categories:…”

“…EMR has also been used in the preparation of porous ceramics in combination with carbon powder, dolomite and kaolin to obtain material high apparent porosity (~70%), compressive strength (7MPa) and acidity-alkali stability (Wu et al, 2016). Production of quasi-sulfoaluminate cement (Q-SAC) by calcination of EMR (up to 40 wt.…”

Effects of electrolytic manganese residue (EMR) to co‐sintering mechanism of ceramic aggregate

“…As the temperature increases, glaze layer of blocking the passage of water is formed on the surface of aggregate, and the gas generated in the pellet increases the internal pressure that leads to the volume expansion of aggregate, resulting in the increase of true porosity and decrease of bulk density 29 . At 1180°C, the liquid phase is too much and the pressure inside the pellet is greater than the surface tension of the liquid phase, leading to the overflow of internal gas, and the liquid phase fills and destroys the pores generated inside the pellet, resulting in the collapse of the sphere 16 . Therefore, at 1180°C, the 1‐h water absorption and bulk density of aggregate rebounded, and the grain shape coefficient also increased sharply.…”

“…Gel materials prepared by adding cement, lime, and other materials to EMR can absorb soluble harmful substances in EMR, with a compressive strength of 18.85 MPa, and the stability efficiency of NH 4+ and Mn 2+ can achieve more than 95% 12 . Adding waste glass, dolomite and kaolin to EMR and using sawdust and toner as a foaming agent can be used for firing porous ceramics 13–16 . The color of EMR glass–ceramics can be changed by changing the content of Mn 2+ by changing the content of manganese slag, which also plays a certain role in Mn solidification 17,18 .…”

Use of a kaolinitic‐illitic clay from Central African Republic and an organic waste for the production of porous ceramic materials

“…Porous materials appeared of great interest both in everyday life (for example, with the filtration of drinking water) and in the industrial field with the elimination of dust by granular filters in industrial processes requiring high purity of the fluids (liquids or gases). In general, these porous ceramics are suitable candidates for overcoming some environmental and energy issues, 17,18 in the fields of heterogeneous catalysis and chemical separation. The use of organic residues in brick production to obtain porous ceramic bodies with enhanced insulating properties was studied by several authors 4,5,9,11,13,19 .…”