Mn-Zn Ferrite Composite from Waste Residues via Stepwise Purification
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Solution Overview
Problem
Current methods for recycling manganese-containing and zinc-containing industrial waste residues face challenges such as high recovery costs, energy consumption, environmental pollution, and low purification efficiency, which hinder the effective preparation of soft magnetic manganese-zinc ferrite composites suitable for electronic devices.
Innovation Solution
A multi-step method involving crushing, roasting, acid treatment, and multi-stage purification using a flux composed of KZrF5 and Na3AlF6, followed by reduction and filtration to produce high-purity manganese and zinc sulfate solutions, which are then mixed and roasted to form a manganese-zinc ferrite composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wet reduction method is used to extract manganese from marine manganese nodules, then leaching rate of Mn is improved, but consumption of acid and alkali increases and environmental protection becomes more challenging
Solution Approach 1:
The patent changes the chemical parameters by using a specific reducing agent (aromatic amine) instead of traditional acid/alkali systems, and controls reaction conditions (temperature, pH, concentration) to achieve high leaching rates with reduced environmental impact
Solution Approach 2:
The patent introduces aromatic amine as an intermediary reducing agent that facilitates the reduction of Mn(IV) to Mn(II) without requiring large amounts of acid and alkali, thereby mediating between the need for high leaching rates and environmental protection
2Use of energy by moving object
If fire reduction method is used for manganese ore smelting, then energy consumption is reduced, but a large amount of Mn-rich residue is produced requiring complicated and long subsequent treatment
Solution Approach 1:
The patent extracts and removes impurities (Si, Al, Ca, Mg) from the manganese-containing waste residue through selective leaching and precipitation processes, separating the valuable manganese from the problematic residue components
Solution Approach 2:
The patent divides the treatment process into multiple sequential stages (roasting, leaching, purification, precipitation) to systematically address different aspects of residue treatment, making the overall process more manageable and efficient
3Productivity
If marine manganese nodules are ground to very fine particle size (less than 0.074 mm) to improve Mn extraction efficiency, then leaching rate increases, but material mixing process time increases and extraction efficiency becomes unstable
Solution Approach 1:
The patent changes the particle size parameter to a moderate range (0.5-5 mm) rather than very fine sizes, and compensates by optimizing other parameters (reducing agent concentration, reaction temperature, mixing intensity) to maintain high extraction efficiency without excessive processing time
4Adaptability or versatility
If industrial waste residues are used as raw materials for manganese-zinc ferrite, then resource recycling is improved, but impurity removal becomes difficult and recovery cost increases
Solution Approach 1:
The patent converts the harmful impurities in industrial waste residues into removable forms through controlled roasting and leaching processes, where impurities like Si, Al, and Ca are transformed into soluble or separable compounds that can be efficiently removed
Solution Approach 2:
The patent performs preliminary roasting and pre-leaching treatments on the industrial waste residues before main processing, which simplifies subsequent purification steps and reduces overall manufacturing complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves leaching rates above 99% for both manganese and zinc, produces high-purity raw materials for manganese-zinc ferrite, reduces energy consumption, and shortens processing time, addressing the limitations of existing technologies.
Implementation Method 1
heating up to 390° C. such that the flux begins to melt and gradually penetrates into the zinc-containing waste residue
Implementation Method 2
the flux begins to melt and gradually penetrates into the zinc-containing waste residue
Implementation Method 3
adding excess sulfuric acid according to the manganese content in the solid-phase sediments; in vacuum or in the presence of an inert gas, at room temperature, adding a reducing agent to reduce manganese dioxide in the manganese slurry into low-valent manganese which reacts quickly with excess sulfuric acid to convert all manganese into a manganese sulfate solution
Implementation Method 4
adding a reducing agent to reduce manganese dioxide in the manganese slurry into low-valent manganese which reacts quickly with excess sulfuric acid
Implementation Method 5
adding 1% to 2% ammonium sulfide to further remove remaining metal ions from the tertiary purification solution of manganese sulfate
Implementation Method 6
decomposing in a decomposing furnace the co-precipitated powder into ferric oxide, manganese tetroxide and zinc oxide
Implementation Method 7
coprecipitating the mixed purification solution with ammonium bicarbonate
Data Source
AI summary
Provided is a method for preparing a soft magnetic manganese-zinc ferrite composite by removing impurities from industrial waste step by step. Manganese-containing waste residue is crushed and dried, and then mixed with a flux in a muffle furnace and roasted at a temperature below 1000° C. till solid-liquid stratification; then, multi-step impurity removal is performed to obtain a high-purity quaternary purification solution of manganese sulfate. Similarly, zinc residue is melted to remove impurities, and then multi-step impurity removal is performed to obtain a high-purity quaternary purification solution of zinc sulfate. According to a manganese-zinc-iron ratio required for the manganese-zinc ferrite, the two purification solutions are mixed, and ferrous sulfate is added. The mixed purification solution is coprecipitated with ammonium bicarbonate, washing is performed, and co-precipitated powder is decomposed into ferric oxide, manganese tetroxide and zinc oxide which are then roasted to obtain the manganese-zinc ferrite composite.