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<p>The sustainable valorization of electrolytic manganese residues (EMR) necessitates innovative strategies to recover valuable metals while mitigating environmental impacts. In this study we demonstrate a biomass driven carbothermic reduction-magnetic separation process that replaces conventional coke-based methods, enabling simultaneous recovery of high purity iron oxides and manganese enrichment. Through integrated thermodynamic modeling, in-situ X-ray diffraction (XRD), X-ray fluorescence spectroscopy (XRF), Raman spectrum, Fourier transform infrared spectroscopy (FTIR) spectrum, and kinetic analysis, we elucidate the phase evolution mechanisms: iron sulfides (FeS/FeS<sub>2</sub>) undergo oxidation to Fe<sub>2</sub>O<sub>3</sub>, followed by carbothermal reduction to magnetically separable Fe<sub>3</sub>O<sub>4</sub>, while MnO<sub>2</sub> progresses through sequential reduction (MnO<sub>2</sub> → Mn<sub>2</sub>O<sub>3</sub> → Mn<sub>3</sub>O<sub>4</sub> → MnO) under controlled oxygen fugacity modulated by biomass char. Optimal conditions (800&#xa0;°C, 2&#xa0;h, 10% biomass char) yield 92.4% Fe recovery as Fe<sub>3</sub>O<sub>4</sub> (95.1 wt% purity) and elevate Mn content in residual clinker to 28.6 wt%, facilitating downstream recycling. Biomass char not only suppresses Mn volatilization but also enhances reduction kinetics, achieving near complete Fe<sub>3</sub>O<sub>4</sub> formation and MnO dominance (&gt; 90%). This study investigates the utilization of renewable reductants in metallurgical processes to transform hazardous EMR into functional materials. The approach highlights a feasible pathway for industrial solid waste valorization, contributing to circular economy strategies and supporting efforts toward industrial decarbonization.</p>

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Biomass-Assisted Roasting for Fe3O4 and MnO Recovery from Electrolytic Manganese Residues: Unraveling Phase Evolution and Metal Mobility

  • 期刊论文

  • 发表日期：

    2025年10月31日

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  • Xiping Chen,
  • Ningning Sun,
  • Muhammad Suliman Khan,
  • Hao Liu,
  • Fangheng Tang,
  • Usman Hamid,
  • Chao Lian

摘要

The sustainable valorization of electrolytic manganese residues (EMR) necessitates innovative strategies to recover valuable metals while mitigating environmental impacts. In this study we demonstrate a biomass driven carbothermic reduction-magnetic separation process that replaces conventional coke-based methods, enabling simultaneous recovery of high purity iron oxides and manganese enrichment. Through integrated thermodynamic modeling, in-situ X-ray diffraction (XRD), X-ray fluorescence spectroscopy (XRF), Raman spectrum, Fourier transform infrared spectroscopy (FTIR) spectrum, and kinetic analysis, we elucidate the phase evolution mechanisms: iron sulfides (FeS/FeS2) undergo oxidation to Fe2O3, followed by carbothermal reduction to magnetically separable Fe3O4, while MnO2 progresses through sequential reduction (MnO2 → Mn2O3 → Mn3O4 → MnO) under controlled oxygen fugacity modulated by biomass char. Optimal conditions (800 °C, 2 h, 10% biomass char) yield 92.4% Fe recovery as Fe3O4 (95.1 wt% purity) and elevate Mn content in residual clinker to 28.6 wt%, facilitating downstream recycling. Biomass char not only suppresses Mn volatilization but also enhances reduction kinetics, achieving near complete Fe3O4 formation and MnO dominance (> 90%). This study investigates the utilization of renewable reductants in metallurgical processes to transform hazardous EMR into functional materials. The approach highlights a feasible pathway for industrial solid waste valorization, contributing to circular economy strategies and supporting efforts toward industrial decarbonization.