Microwave Production of Manganese from Manganese (IV) Oxide using Postconsumer Polypropylene as Reductant
Keywords:
Microwave irradiation, Polypropylene, Calcination, Reduction, MnO2, Mn3O4, MnO, ManganeseAbstract
This work investigates the production of manganese metal from MnO2 by microwave irradiation using postconsumer polypropylene (PP) as reductant. Reagent grade MnO2 was first calcined to Mn3O4 followed by reduction with pulverised postconsumer PP in a domestic microwave oven (Pioneer, Model PM-25 L, 1000 W, 2.45 GHz) in a recorded temperature range 900-1200 °C. Calcined and reduced products were characterised by XRD, XRF and SEM/EDX. The results showed that microwave irradiation is effective at calcining MnO2 to Mn3O4, evidenced by the complete disappearance of peaks of MnO2 and appearance of peaks of Mn3O4 after 40 minutes. SEM/EDX analysis revealed that calcined Mn3O4 was first transformed to MnO and later to manganese metal. The range of temperature achieved in the microwave oven was below the equilibrium temperature for MnO reduction by solid carbon and accordingly solid carbon produced from PP cannot be wholly responsible for the production of manganese metal. It is therefore concluded that the large scale production of manganese metal observed in this investigation was effected with CH4 (generated from the thermal decomposition of PP) and solid amorphous carbon as the predominant reductants, with solid amorphous carbon providing the heat energy required for the reduction. Microwave reduction of manganese oxides is therefore a potential route for diverting postconsumer plastics from landfill sites as well as decrease the amount of expensive metallurgical coke currently used in the ferromanganese process.
References
Abdel Halim, K. S. (2007), “Isothermal Reduction behaviour of Fe2O3-MnO Composite Materials with Solid Carbon†Mater. Sci. Eng. A, Vol. A452-A453, pp. 15-22.
Abdel Halim, K. S., Bahgat, M., Morsi, M. B. and El-Barawy, K. (2011), “Pre-reduction of Manganese Ores for Ferromanganese Industryâ€, Ironmaking Steelmaking, Vol. 38(4), pp. 279-284.
Akdogan, G. and Eric, R. H. (1993), “Solid State Carbothermic Reduction of Manganese Oresâ€, Int. J. Mater. Prod. Technol., Vol. 8, pp. 29-42.
Akdogan, G. and Eric, R. H. (1994), “Carbothermic Reduction Behaviour of Wessel Manganese Oresâ€, Miner. Eng., Vol. 7(5-6), pp. 633-645.
Akdogan, G. and Hurman, R. (1995), “Kinetics of the Solid-State Carbothermic Reduction of Wessel Manganese Oresâ€, Metall. Mater. Trans. B, Vol. 26B, pp. 13-24.
Anacleto, N., Ostrovski, O., Ganguly, S. (2004), “Reduction of Manganese Oxides by Methane-Containing Gas†ISIJ Int., Vol. 44(9), pp. 1480-1487.
Blagus, A. V., Dankwah, J. R. and Sahajwalla, V. H. (2013), “Interfacial Reactions between Coke/HDPE Blends and High Carbon Ferromanganese Slagâ€, ISIJ International, Vol. 53(1), pp. 41-47.
Berg, K. L., Olsen, S. E. (2000), Kinetics of Manganese Ore Reduction by Carbon Monoxide†Metall. Trans. B, Vol. 31B, pp. 477-490.
Dankwah, J. R., Koshy, P., Saha-Chaudhury, N. M., O'Kane, P., Skidmore, C., Knights, D. and Sahajwalla, V. (2011), “Reduction of FeO in EAF Steelmaking Slag by Blends of Metallurgical Coke and Waste Plasticsâ€, ISIJ Int., Vol.51, No. 3, pp. 498-507.
Dankwah, J. R., Koshy, P., O’Kane, P. and Sahajwalla, V. (2012), “Reduction of FeO in EAF Steelmaking Slag by Blends of Metallurgical Coke and End-of-Life Tyresâ€, Steel Research International, Vol. 83, No.8, pp. 766-774.
Dankwah, J. R., Koshy P. and Sahajwalla, V. H. (2013), “Reduction of FeO in EAF Steelmaking Slag by Blends of Metallurgical Coke and End-of-Life Polyethylene Terephthalateâ€, Ironmaking and Steelmaking, Vol. 41, No. 6, pp. 401-409.
Dankwah, J. R. and Asamoah D. N. (2013), “Utilisation of Postconsumer Plastics in Pre-reduction of Higher Manganese Oxides in Ferromanganese Processâ€, Ironmaking and Steelmaking, Vol. 40(2), pp. 138-146.
Dankwah, J. R., and Koshy, P. (2014a), “Reduction of FeO in EAF Steelmaking Slag by Blends of Metallurgical Coke and Waste Polypropyleneâ€. High Temperature Materials and Processes, Vol. 33, No. 2, pp. 107-114.
Dankwah, J. R. and Koshy, P. (2014b), “Effect of HDPE addition on the Pre-reduction of Mn3O4 to MnO by Metallurgical Cokeâ€, High Temperature Materials & Processes Vol. 33, Issue 4, pp. 345-353.
Dankwah, J. R., Fosu, A. Y., Fosu, N. and Koshy, P. (2015), “Carbothermal Upgrading of the Awaso Bauxite Ore using Waste Pure Water Sachets as Reductantâ€, Ghana Mining Journal, Vol. 15, No. 1, pp. 64-72.
De Bruijn T. J. W., Soerawidjaja, T. H., De Jong, W. A., Van Den Berg, P. J. (1980), “Modelling of the Reduction of Manganese Oxides with Hydrogen†Chem. Eng. Sci. Vol. 35, pp. 1591-1600.
Eric, R. H. and Burucu, E. (1992), “The Mechanism and Kinetics of the Carbothermic Reduction of Mamatwan Ore Finesâ€, Miner. Eng., Vol. 5, pp. 795-815.
Gao, Y. B., Kim, H. G. and Sohn, H. Y. (2012), “Kinetics of Pre-reduction of Manganese Ore by COâ€, Miner. Process. Extr. Metal., Vol. 121(2), pp. 109-116.
Holta, O. and Olsen, S. E. (1986), “Composite Briquettes of Manganese Ore and Coalâ€, Proc. Electric Furnace Conf., Iron and Steel Society, Warrendale, PA, Vol. 43, pp. 273-279
Ishak, R. and Tangstad, M. (2007), “Degree of Pre-reduction without Coke Consumption in Industrial Furnacesâ€, INFACON XI Proceedings, New Delhi, India, pp. 268-280.
Knacke, O., Kubaschewski, O., and Hasselmann, K. (1991), Thermochemical Properties of Inorganic Substances I, Springer Verlag, 2nd Ed., 129 pp.
Kononov, R., Ostrovski, O. and Ganguly, S. (2007), “Carbothermal Solid State Reduction of Manganese Oxideâ€, Innovations in the Ferro Alloy Industry - Proceedings of the XI International Conference on Innovations in the Ferro Alloy Industry, INFACON XI, pp. 258-267.
Kononov, R., Ostrovski, O. and Ganguly, S. (2008), “Carbothermal Reduction of Manganese Oxide in Different Gas Atmospheresâ€, Metall. Mater. Trans. B, Vol. 39B, pp. 662-668.
Kononov, R., Ostrovski, O., Ganguly, S. (2009a), “Carbothermal Solid State Reduction of Manganese Ores: 2. Non-isothermal and Isothermal Reduction in Different Gas Atmospheres†ISIJ Int., Vol. 49(8), pp. 1107-1114.
Kononov R.; Ostrovski O.; Ganguly S. (2009b), “Carbothermal Solid State Reduction of Manganese Ores: 3. Phase Developmentâ€, ISIJ Int., Vol. 49, no. 8, pp. 1115-1122.
Kor, G. J. W. (1978), “The Thermal Decomposition of Mn2O3 and the Reduction of Mn3O4 by C and CO†Metall. Trans. B, Vol. 9B, pp. 307-311.
Kumar, M., Ranganathan, S., Sinha, S. N. (2007), “Kinetics of Reduction of Different Manganese Oresâ€, INFACON XI Proceedings, New Delhi, India, pp. 241-246.
Matsuda, T., Hasegawa, M., Ikemura, A., Wakimoto, K., and Iwase, M. (2008), “Utilization of Waste Plastic for Production of Metallic Iron, Hydrogen and Carbon Monoxide without Generating Carbon Dioxideâ€, ISIJ Int., Vol. 48, No. 9, pp. 1186-1196.
Murakami, T., Akiyama, T. and Kasai, E., (2009), “Reduction Behaviour of Hematite Composite containing Polyethylene and Graphite with Different Structures with Increasing Temperatureâ€, ISIJ Int., 49(6), pp. 809-814
Murakami, T., and Kasai, E., (2011), “Reduction Mechanism of Iron Oxide-carbon Composite with Polyethylene at Lower Temperatureâ€, ISIJ Int., 51(1), pp. 9-13
Nishioka, K., Taniguchi, T., Ueki, Y., Ohno, K., Maeda, T., and Shimizu, M. (2007), “Gasification and Reduction Behaviour of Plastic and Iron Ore Mixtures by Microwave Heatingâ€, ISIJ Int., Vol. 47, No. 4, pp. 602-607.
Ostrovski, O. and Webb, T. (1995), “Reduction of Siliceous Manganese Ore by Graphite†ISIJ Int., Vol. 35(11), pp. 1331-1339.
Ostrovski, O., Anacleto, N., Ganguly, S. (2004), “Reduction of Manganese Ores by Methane-Containing Gas†INFACON Proceedings, Cape Town, South Africa, pp. 173-183
PACIA (2012), National Plastics Recycling Survey for July 2011- June 2012.
Peretyagin, V. A., Pavlov, A. V., (2003), “Aspects of the High-Temperature Reduction of Manganese Ores by Coalâ€, Metallurgist, Vol. 47(9-10), pp. 419-423.
Ueki, Y., Ohno, K., Maeda, T., Nishioka, K., and Shimizu, M. (2008), “Reaction Behaviour during Heating Waste Plastic Materials and Iron Oxide Compositesâ€, ISIJ Int., Vol. 48, pp. 1670-1675.
Walkiewicz, J. W., Kazonich, G. and McGill, S. L. (1988), “Microwave Heating Characteristics of Selected Minerals and Compoundsâ€, Minerals and Metallurgical Processing, Vol. 48, pp. 39-42.
Downloads
Published
Issue
Section
License
Copyright © 2021 University of Mines and Technology (UMaT), Tarkwa. Ghana
