RU2441086C1 | 2012-01-27 | |||
CN105296745A | 2016-02-03 | |||
CN1238534C | 2006-01-25 | |||
CN104817116A | 2015-08-05 | |||
CN105002380A | 2015-10-28 |
ZHANG XIUFENG ET AL: "Recovery of Manganese Ore Tailings by High-Gradient Magnetic Separation and Hydrometallurgical Method", JOM: JOURNAL OF METALS, SPRINGER NEW YORK LLC, UNITED STATES, vol. 69, no. 11, 16 August 2017 (2017-08-16), pages 2352 - 2357, XP036427172, ISSN: 1047-4838, [retrieved on 20170816], DOI: 10.1007/S11837-017-2521-5
Claims 1. A process for extracting manganese from manganese-bearing ore, the process including roasting a feed admixture of particulate manganese-bearing ore, comprising Mn and Fe, and ammonium sulphate at a first temperature T1 to provide a sulphonated admixture comprising MnSO4(s) and FeSO4(s); roasting the sulphonated admixture at a second temperature T2, which is higher than the first temperature T1, to form a leachable admixture comprising MnSO4(s) and Fe2O3(s); and leaching the MnSO4(s) in preference to the Fe2O3(s) from the leachable admixture to provide a leachate rich in dissolved MnSO4. 2. The process according to claim 1, which includes include preventing or at least inhibiting ingress of oxygen into an atmosphere within which the feed admixture is roasted. 3. The process according to claim 1 or claim 2, wherein the MnSO4(s) is leached from the leachable admixture using an aqueous leachant or aqueous solvent. 4. The process according to any of claims 1 to 3, wherein the first temperature T1 is in a range between 300°C and 550°C. 5. The process according to claim 4, wherein the first temperature T1 is between 350°C and 500°C, or between 375 °C and 475°C. 6. The process according to any of claims 1 to 5, wherein the second temperature T2 is in a range between 550°C and 750°C. 7. The process according to claim 6, wherein the second temperature T2 is between 600°C and 725°C, or between 650°C and 700°C. 8. The process according to any of claims 1 to 7, wherein the feed admixture and the sulphonated admixture are roasted in a roasting stage employing a roaster, with the roaster having a continuum of roasting temperatures increasing from a feed inlet roasting temperature to a leachable admixture discharge temperature, with at least one zone of the roaster having roasting temperatures corresponding with the range of temperatures for the first temperature T1, and at least one zone of the roaster having roasting temperatures corresponding with the range of temperatures for the second temperature T2. 9. The process according to claim 8, wherein the roaster has at least one zone with a roasting temperature Tinitial below the range of temperatures for the first temperature T1, the roasting temperature Tinitial being in the range of between 225°C and 375°C. 10. The process according to claim 9, wherein the roasting temperature Tinitial is between 250°C and 350°C. 11. The process according to claim 9, wherein the roasting temperature Tinitial is between 275°C and 325°C, with the understanding that the temperature Tinitial employed is lower than the first temperature T1 employed. 12. The process according to any of claims 1 to 11, wherein the particulate manganese- bearing ore and the ammonium sulphate are present in the feed admixture in a mass ratio of ore : ammonium sulphate of between 1 : 1 and 1 : 4. 13. The process according to claim 12, wherein the particulate manganese-bearing ore and the ammonium sulphate are present in the feed admixture in a mass ratio of ore : ammonium sulphate of between 1 : 2 and 1 : 3. 14. The process according to any of claims 1 to 13, which includes precipitating Mn(OH)2 from the leachate using NH4OH or NH3(g), producing an Mn(OH)2 precipitate and an (NH4)2SO4 solution. 15. The process according to claim 14, which includes producing (NH4)2SO4 crystals or powder from the (NH4)2SO4 solution, and recycling (NH4)2SO4 crystals or powder, i.e. (NH4)2SO4(s), obtained from the (NH4)2SO4 solution, to form part of the feed admixture. 16. MnSO4 or Mn(OH)2 or MnO2 produced by a manufacturing process which includes a process as claimed in any of claims 1 to 15. |
Table 1 250g of the manganese-bearing ore of Table 1 was milled to -106 µm. Similarly, 250g of (NH 4 ) 2 SO 4 was milled to -106 µm. Both powders at -106 µm were then blended to form an admixture, with the admixture being added to an open SiC crucible. The admixture was fired at 400°C for 30 minutes, soon providing an atmosphere inside the crucible substantially free of oxygen as a result of the evolution of gases that replaced the air, then 450°C for 1 hour, 500°C for 1 hour and lastly 670°C for 1 hour. A red powder of 323.5g was recovered. 500 ml water was added to the red power to form a suspension and the temperature of the suspension was raised to 60 - 70°C. After 15 minutes of stirring, the suspension was filtered and washed. 600ml MnSO 4 leachate was collected (refer to Table 1 for the composition of the leachate). The Mn units collected = 87100 mg/l x 0.6 l = 52.26g from a theoretical amount of 2.5 x 42.7 = 106.75g Mn. Thus a 49% Mn recovery was achieved. It can be seen from Table 1 that not only does the Fe concentration diminish in the leachate but also some other deleterious elements. The Mn/Mg mass ratio virtually remains the same. The experiment was repeated with 1 part milled ore : 2 parts milled (NH 4 ) 2 SO 4 and a Mn recovery of 76% was achieved. By altering experimental conditions, e.g. by further increasing the mass ratio of manganese-bearing ore : ammonium sulphate, it was proven that a Mn recovery of >95% can be obtained. Referring to the drawing, reference numeral 10 generally shows one embodiment of a continuous process in accordance with the invention for extracting manganese from manganese-bearing ore. The process 10 generally includes a roasting stage comprising a slightly inclined externally heated or indirectly heated rotary kiln 12 (often referred to as a rotary calciner), a cooler 14, a leaching stage comprising a leach vessel 16, a first filter 18, a precipitator 20 and a second filter 22. The rotary kiln 12 is provided with an ammonium sulphate feed line 24 and a particulate manganese-bearing ore feed line 26. An off-gas withdrawal line 28 is provided adjacent a discharge end of the rotary kiln 12. A leachable admixture transfer line 30 leads from the rotary kiln 12 to the cooler 14, and from the cooler 14 to the leach vessel 16. The leach vessel 16 is a stirred vessel provided with a mechanical agitator and is also provided with a water feed line 32. A slurry transfer line 34 leads from the leach vessel 16 to the first filter 18, which is provided with a tailings withdrawal line 36 and a filtrate transfer line 38. The filtrate transfer line 38 leads into the precipitator 20, which is also provided with an NH 3 (g) feed line 40 and a slurry transfer line 42. The slurry transfer line 42 leads to the second filter 22, which is provided with a Mn(OH) 2 precipitate withdrawal line 44 and an ammonium sulphate solution withdrawal line 46. In order to extract manganese from manganese-bearing ore which also includes iron, a powder of the manganese-bearing ore with a D90 particle size of about 106 μm is continuously fed by means of the particulate manganese-bearing ore feed line 26 into the rotary kiln 12. Simultaneously, a powder of ammonium sulphate with a D90 particle size of about 106 μm is continually fed by means of the ammonium sulphate feed line 24 into the rotary kiln 12. A mass ratio of the powdered manganese-bearing ore to the ammonium sulphate powder being fed into the rotary kiln 12 depends on the composition of the manganese-bearing ore. For the ore shown in Table 1, the mass ratio would be about 1 : 2.4. The mass ratio required, for the manganese-bearing ore of Table 1, can be determined as follows (based on a 100 gram of manganese-bearing ore): Fe 13.2% = 0.236 mol x 1.5 = 0.354 mol SO3 required to form Fe2(SO3)3 Ca 5.3% = 0.133 mol x 1 = 0.133 mol SO3 required to form CaSO4 Mg 0.4% = 0.017 mol x 1 = 0.017 mol SO3 required to form MgSO4 Mn 42.7% = 0.776 mol x 1 = 0.776 mol SO3 required to form MnSO4 Ba 1.36% = 0.010 mol x 1 = 0.01 mol SO3 required to form BaSO4 (Ba not shown in Table 1) Total SO3 required= 1.29 mol It follows that 100g feed of the manganese-bearing ore requires 1.29 mol (NH4)2SO4 x 132 g/mol = 170.28g + 15% excess used experimentally = approximately 200g (NH4)2SO4, i.e. a manganese-bearing ore : ammonium sulphate mass ratio of about 1 : 2. Experimentally an efficiency or Mn yield of about 80% was achieved. By using 20% more (NH4)2SO4 it is believed that the sulphonation reactions will proceed almost to completion. This provides a required manganese-bearing ore : ammonium sulphate mass ratio of about 1 : 2x1.2 = 1 : 2.4. NH 3 (g) will always be present in excess as 2 mol NH 3 (g) is released for every mol of SO 3 (g) released inside the rotary kiln 12 (see Equation 1 + Equation 4). The particulate manganese-bearing ore and the ammonium sulphate are fed from hoppers (not shown) through inlet seals (not shown, and typically used only if the hoppers do not provide adequate sealing against air ingress) so as to inhibit the introduction of air into the rotary kiln 12. In the rotary kiln 12, the particulate manganese-bearing ore and the ammonium sulphate powder are admixed as a result of the rotary action of the rotary kiln 12 and a resultant admixture is roasted, in an atmosphere substantially free of oxygen over most of the length of the rotary kiln 12, as the admixture travels through the rotary kiln 12 as a result of the rotation of the rotary kiln 12 and as a result of the slight inclination of the rotary kiln 12 to the horizontal. In an inlet zone 12.1 of the rotary kiln 12, the admixture is roasted or subjected to pyrolysis conditions (i.e. in an atmosphere substantially free of oxygen) at a roasting temperature Tinitial which typically ranges between about 300°C and about 350°C, for a period of about 60 minutes. As the admixture progresses towards a discharge end of the rotary kiln 12, the admixture is roasted in an intermediate zone 12.2 at a first temperature T1, which typically is in a range of about 400°C to about 500°C, for a period of about 180 minutes. Thereafter, the admixture enters an end zone 12.3 of the rotary kiln 12 adjacent a discharge end of the rotary kiln 12. In the end zone 12.3, the admixture is roasted at a second temperature T2, which typically is in a range of about 550°C to about 675°C, for a period of about 120 minutes. The total residence time of material passing through the rotary kiln 12 is thus typically about 360 minutes. In the inlet zone 12.1, the ammonium sulphate decomposes in an atmosphere substantially free of oxygen to form ammonia gas in situ presumably in accordance with Equation 1 hereinbefore described, with the gaseous ammonia then reacting with manganese oxides and iron oxides to reduce these oxides presumably in accordance with Equations 2 and 3 hereinbefore described. Nitrogen gas and water vapour evolve, and these gases are withdrawn through the off-gas withdrawal line 28, together with any unreacted ammonia gas. In the intermediate zone 12.2, in an atmosphere still substantially free of oxygen, more gaseous ammonia, and sulphur trioxide, are produced presumably in accordance with Equation 4 hereinbefore described, and MnO(s) and FeO(s) react with the sulphur trioxide to form, it is believed, MnSO 4 (s) and FeSO 4 (s) presumably in accordance with Equation 5 hereinbefore described. The FeSO 4 (s) reacts further with the sulphur trioxide, it is believed, presumably in accordance with Equation 6 hereinbefore described, to form Fe 2 (SO 4 ) 3 (s). In the end zone 12.3, it is believed the Fe 2 (SO 4 ) 3 (s) is decomposed presumably in accordance with Equation 7 hereinbefore described, producing Fe 2 O 3 (s), SO 2 (g) and gaseous oxygen. The SO 2 (g) and oxygen, water vapour and any unreacted sulphur trioxide from the zones 12.2 and 12.3 are also withdrawn by means of the off-gas withdrawal line 28. As will be appreciated, instead of employing a single rotary kiln 12 with multiple temperature zones, separate rotary kilns or other roasters can be used to roast the feed admixture and the sulphonated admixture at different temperatures. As will be appreciated, one advantage of using separate rotary kilns or other roasters is that it would be easier to eliminate oxygen from the atmosphere within which the feed admixture is roasted, as the atmosphere within which the feed admixture is roasted can be separated from the atmosphere withing the Fe2(SO4)3(s) is decomposed and which may thus include oxygen released by the decomposition of the Fe2(SO4)3(s). The leachable admixture is withdrawn from the rotary kiln 12 through a discharge seal (not shown) and transferred by means of the leachable admixture transfer line 30 to the cooler 14, where the leachable admixture is cooled using plant cooling water in an indirect heat transfer arrangement to a temperature of about 30°C, before being transferred to the leach vessel 16 by means of the leachable admixture transfer line 30. Instead of, or in addition to using a separate cooler 14, the rotary kiln 12 may have an integral cooling zone. Water is fed by means of the water feed line 32 into the leach vessel 16 and is admixed with the leachable admixture using the mechanical stirrer of the leach vessel 16. Typically, leaching of the leachable admixture in the leach vessel 16 with water as leachant or solvent is effected at a temperature of about 60°C to 70°C. If necessary, the leach vessel 16 can thus be a heated vessel. Alternatively, the leachable admixture and the water fed into the leach vessel 16 may be at a sufficiently high temperature to ensure that leaching takes place at the desired temperature. In the leach vessel 16, the water leaches MnSO 4 (s) from the leachable admixture. The leachable admixture has a residence time of about 60 minutes in the leach vessel 16 and is then transferred as a slurry by means of the slurry transfer line 34 to the first filter 18. In the first filter 18, leach residue or tailings is separated from the slurry and withdrawn by means of the tailings withdrawal line 36. A leachate or filtrate rich in dissolved manganese sulphate is withdrawn from the first filter 18 and is transferred to the precipitator 20. As will be appreciated, as manganese sulphate is quite soluble in water, in contrast to FeSO3(s) which is substantially insoluble in water, the leach residue or tailings which is withdrawn by means of the tailings withdrawal line 36 is depleted in manganese sulphate, whereas the leachate or filtrate transferred by means of the filtrate transfer line 38 to the precipitator 20 is enriched in manganese sulphate, with most of the FeSO3(s) reporting to the leach residue or tailings. In the embodiment of the process of the invention illustrated in the drawing, Mn(OH)2 is precipitated from the leachate fed to the precipitator 20. This is achieved by feeding gaseous ammonia by means of the NH3(g) feed line 40 into the precipitator 20 and allowing Mn(OH)2 to precipitate. Although not shown, the precipitator 20 may be a stirred vessel. A slurry of the Mn(OH)2 precipitate is transferred by means of the slurry transfer line 42 to the second filter 22, where the Mn(OH)2 precipitate is separated from an ammonium sulphate solution and withdrawn by means of the Mn(OH)2 precipitate withdrawal line 44. The ammonium sulphate solution is withdrawn by means of the withdrawal line 46. The withdrawn ammonium sulphate solution can be treated to produce ammonium sulphate crystals or powder, e.g. by membrane separation and evaporation with the ammonium sulphate crystals or powder then being recycled to the rotary kiln 12 as part of the ammonium sulphate in the ammonium sulphate feed line 24. The Mn(OH) 2 withdrawn by means of the Mn(OH) 2 precipitate withdrawal line 44 can be treated to convert the Mn(OH) 2 to very pure MnO 2 . The resultant MnO 2 can be reacted with sulphuric acid to produce manganese (II) sulphate monohydrate of exceptional purity suitable, for example, for use in an electrochemical cell. The process 10, as illustrated, advantageously does not require digesting of a roasted manganese-bearing ore or concentrate with sulphuric acid. The process 10, as illustrated, advantageously also does not require alkaline precipitation of soluble impurities such as Fe. Importantly, the process 10, as illustrated, also allows for recycling of a bulk reagent (ammonium sulphate). Manganese-bearing ore typically includes significant concentrations of Ca and Mg (see for example Table 1). In the process of the invention, as illustrated, so-called dead burnt gypsum or dead burnt plaster is advantageously formed. Thus, although anhydrous CaSO4 is formed in the process of the invention, the CaSO4 does not rehydrate to form CaSO4·2H20 when leached with water. This greatly facilitates aqueous leaching, as CaSO4·2H20 acts as a sponge that would undesirably capture valuable MnSO4. A similar issue in conventional processes arises because of the formation of silica gel, which is difficult to remove by filtration, but advantageously in the process of the invention, as illustrated, SiO2 is formed which is easily removed by filtration.