Enhanced recovery of high-purity Fe powder from iron-rich electrolytic manganese residue by slurry electrolysis

Abstract

Iron-rich electrolytic manganese residue (IREMR) is an industrial waste produced during the processing of electrolytic metal manganese, and it contains certain amounts of Fe and Mn resources and other heavy metals. In this study, the slurry electrolysis technique was used to recover high-purity Fe powder from IREMR. The effects of IREMR and H₂SO₄ mass ratio, current density, reaction temperature, and electrolytic time on the leaching and current efficiencies of Fe were studied. According to the results, high-purity Fe powder can be recovered from the cathode plate, and the slurry electrolyte can be recycled. The leaching efficiency, current efficiency, and purity of Fe reached 92.58%, 80.65%, and 98.72wt%, respectively, at a 1:2.5 mass ratio of H₂SO₄ and IREMR, reaction temperature of 60°C, electric current density of 30 mA/cm², and reaction time of 8 h. In addition, vibrating sample magnetometer (VSM) analysis showed that the coercivity of electrolytic iron powder was 54.5 A/m, which reached the advanced magnetic grade of electrical pure-iron powder (DT4A coercivity standard). The slurry electrolytic method provides fundamental support for the industrial application of Fe resource recovery in IRMER.

Keywords

iron-rich electrolytic manganese residue / slurry electrolysis / high-purity iron powder / leaching efficiency / current efficiency

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