Chlorination roasting-coupled water leaching process for potash recovery from waste mica scrap using dry marble sludge powder and sodium chloride

Sandeep Kumar Jena; Jogeshwar Sahu; Geetikamayee Padhy; Swagatika Mohanty; Ajit Dash

doi:10.1007/s12613-020-1994-3

Volume 27 Issue 9

Sep. 2020

Turn off MathJax

Article Contents

Article Navigation > International Journal of Minerals, Metallurgy and Materials > 2020 > 27(9): 1203-1215

Sandeep Kumar Jena, Jogeshwar Sahu, Geetikamayee Padhy, Swagatika Mohanty, and Ajit Dash, Chlorination roasting-coupled water leaching process for potash recovery from waste mica scrap using dry marble sludge powder and sodium chloride, Int. J. Miner. Metall. Mater., 27(2020), No. 9, pp. 1203-1215. https://doi.org/10.1007/s12613-020-1994-3

Cite this article as:

Sandeep Kumar Jena, Jogeshwar Sahu, Geetikamayee Padhy, Swagatika Mohanty, and Ajit Dash, Chlorination roasting-coupled water leaching process for potash recovery from waste mica scrap using dry marble sludge powder and sodium chloride, Int. J. Miner. Metall. Mater., 27(2020), No. 9, pp. 1203-1215. https://doi.org/10.1007/s12613-020-1994-3

Citation:

PDF( 2218 KB)

Research Article

Chlorination roasting-coupled water leaching process for potash recovery from waste mica scrap using dry marble sludge powder and sodium chloride

+ Author Affiliations

Corresponding author:
Sandeep Kumar Jena E-mail: sandeepjena@immt.res.in;sandeepimmt@gmail.com
Received: 23 October 2019; Revised: 11 December 2019; Accepted: 1 February 2020; Available online: 11 February 2020

Abstract

Abstract

The present paper reports the effective utilization of marble sludge powder (MSP) for the recovery of potash values from waste mica scrap using chlorination roasting–water leaching method. Characterization studies indicated the presence of dolomite as the major mineral phase in MSP, whereas muscovite and quartz were observed in the mica sample. The acid leaching studies suggest a maximum of 22% potash recovery under conditions: 4 M H₂SO₄ acid, particle size of ~100 μm, stirring speed of 600 r/min, leaching temperature of 75°C, and leaching time of 90 min. The chlorination roasting–water leaching process was adopted to achieve the lowest level of 80%–90% potash recovery. The optimum conditions for the recovery of ~93% potash from mica (~8.6wt% K₂O) requires 900°C roasting temperature, 30 min roasting time, and 1:1:0.75 mass ratio of mica : MSP : NaCl. The roasting temperature and amount of NaCl are found to be the most important factors for the recovery process. The reaction mechanism suggests the formation of different mineral phases, including sylvite (KCl), wollastonite, kyanite, and enstatite, during roasting, which were confirmed by X-ray diffraction (XRD) analyses and scanning electron microscopy (SEM) morphologies. The MSP-blended NaCl additive is more effective for potash recovery compared with the other reported commercial roasting additives.
- potash recovery;
- mica scrap;
- marble sludge powder;
- chlorination roasting;
- water leaching

FullText(HTML)

Supplements(0)

References(72)

References

[1]	H.A. El-Sayed, A.B. Farag, A.M. Kandeel, A.A. Younes, and M.M. Yousef, Characteristics of the marble processing powder waste at Shaq El-Thoaban industrial area, Egypt, and its suitability for cement manufacture, HBRC J., 14(2018), No. 2, p. 171. doi: 10.1016/j.hbrcj.2016.06.002
[2]	R.S. Kori, P. Jagan, and S.K. Meena, Guidlines for Management and Handling of Marble Slurry Generated from Marble Processing Plants in Rajasthan, Central Pollution Control Board, Bhopal [2019-07-09]. https://www.scribd.com/document/410211989/Draft-guidelines-for-M-H-of-Marble-slurry-generated-from-marble-processing-plants-in-Rajasthan-pdf
[3]	K. Shreyas, Impact of marble dust on cement concrete, Int. J. Sci. Technol. Eng., 4(2017), No. 6, p. 6.
[4]	M. Wijayasundara, P. Mendis, and R.H. Crawford, Net incremental indirect external benefit of manufacturing recycled aggregate concrete, Waste Manage., 78(2018), p. 279. doi: 10.1016/j.wasman.2018.02.042
[5]	The Countries with the Largest Marble Exports in 2017 [2018-12-31]. https://stonenews.eu/countries-largest-marble-exports-2017/
[6]	Indian Bureau of Mines, Indian Minerals Yearbook 2015 (Part-III: Mineral Reviews), 54th ed., Government of India, Ministry of Mines, Indian Bureau of Mines [2016-11-20]. http://ibm.nic.in/writereaddata/files/11232016170046IMYB2015_Marble_23112016_Adv.pdf
[7]	M. Yavuz Çelik and E. Sabah, Geological and technical characterization of Iscehisar (Afyon-Turkey) marble deposits and the impact of marble waste on environmental pollution, J. Environ. Manage., 87(2008), No. 1, p. 106. doi: 10.1016/j.jenvman.2007.01.004
[8]	A. Pappu, M. Saxena, and S.R. Asolekar, Solid wastes generation in India and their recycling potential in building materials, Build. Environ., 42(2007), No. 6, p. 2311. doi: 10.1016/j.buildenv.2006.04.015
[9]	M.A. Montero, M.M. Jordán, M.S. Hernández-Crespo, and T. Sanfeliu, The use of sewage sludge and marble residues in the manufacture of ceramic tile bodies, Appl. Clay Sci., 46(2009), No. 4, p. 404. doi: 10.1016/j.clay.2009.10.013
[10]	E.K. Shirazi, Reusing of stone waste in various industrial activities, [in] 2011 2nd International Conference on Environmental Science and Development, Singapore, 2011, p. 217.
[11]	G. Rego, C. Martínez, A. Quero, T.P. Blanco, and J.M.F. Borque, Efectos del polvo inhalado en los trabajadores de la industria de pizarras, Med. Clínica, 116(2001), No. 8, p. 290. doi: 10.1016/S0025-7753(01)71802-7
[12]	G. Angotzi, L. Bramanti, D. Tavarini, M. Gragnani, L. Cassiodoro, L. Moriconi, P. Saccardi, I. Pinto, N. Stacchini, and M. Bovenzi, World at work: Marble quarrying in Tuscany, Occup. Environ. Med., 62(2005), No. 6, p. 417. doi: 10.1136/oem.2004.018721
[13]	M. El-Gammal, M.S. Ibrahim, E.A. Badr, S.A. Asker, and M. El-Galad, Health risk assessment of marble dust at marble workshops, Nat. Sci., 9(2011), No. 11, p. 144.
[14]	MSME-Development Institute, Status Report on Commercial Utilization of Marble Slurry in Rajasthan, Government of India, Ministry of Micro, Small & Medium Enterprises, Jaipur [2019-07-07]. https://www.pdffiller.com/jsfiller-desk12/?projectId=492304325#df10e63ea090407894eb1d43d40fb651
[15]	N. Careddu, G. Siotto, R. Siotto, and C. Tilocca, From landfill to water, land and life: The creation of the centre for stone materials aimed at secondary processing, Resour. Policy, 38(2013), No. 3, p. 258. doi: 10.1016/j.resourpol.2013.05.001
[16]	F.J. Aukour, Incorporation of marble sludge in industrial building eco-blocks or cement bricks formulation, Jordan J. Civ. Eng., 3(2009), No. 1, p. 58.
[17]	S.D. Kore and A.K. Vyas, Impact of marble waste as coarse aggregate on properties of lean cement concrete, Case Stud. Constr. Mater., 4(2016), p. 85.
[18]	F. Faleschini, M.A. Zanini, C. Pellegrino, and S. Pasinato, Sustainable management and supply of natural and recycled aggregates in a medium-size integrated plant, Waste Manage., 49(2016), p. 146. doi: 10.1016/j.wasman.2016.01.013
[19]	E. Tugrul Tunc, Recycling of marble waste: A review based on strength of concrete containing marble waste, J. Environ. Manage., 231(2019), p. 86. doi: 10.1016/j.jenvman.2018.10.034
[20]	A. Rana, P. Kalla, and L.J. Csetenyi, Sustainable use of marble slurry in concrete, J. Cleaner Prod., 94(2015), p. 304. doi: 10.1016/j.jclepro.2015.01.053
[21]	R. Rodrigues, J. de Brito, and M. Sardinha, Mechanical properties of structural concrete containing very fine aggregates from marble cutting sludge, Constr. Build. Mater., 77(2015), p. 349. doi: 10.1016/j.conbuildmat.2014.12.104
[22]	M. Singh, A. Srivastava, and D. Bhunia, An investigation on effect of partial replacement of cement by waste marble slurry, Constr. Build. Mater., 134(2017), p. 471. doi: 10.1016/j.conbuildmat.2016.12.155
[23]	K. Vardhan, R. Siddique, and S. Goyal, Strength, permeation and micro-structural characteristics of concrete incorporating waste marble, Constr. Build. Mater., 203(2019), p. 45. doi: 10.1016/j.conbuildmat.2019.01.079
[24]	H. Al-Hamaiedh, Reuse of marble sludge slime in ceramic industry, Jordan J. Civ. Eng., 4(2010), No. 3, p. 264.
[25]	J. Carneiro, D.M. Tobaldi, M.N. Capela, R.M. Novais, M.P. Seabra, and J.A. Labrincha, Synthesis of ceramic pigments from industrial wastes: Red mud and electroplating sludge, Waste Manage., 80(2018), p. 371. doi: 10.1016/j.wasman.2018.09.032
[26]	S.K. Amin, E.M. Abdel Hamid, S.A. El-Sherbiny, H.A. Sibak, and M.F. Abadir, The use of sewage sludge in the production of ceramic floor tiles, HBRC J., 14(2018), No. 3, p. 309. doi: 10.1016/j.hbrcj.2017.02.002
[27]	G. Tozsin, Inhibition of acid mine drainage and immobilization of heavy metals from copper flotation tailings using a marble cutting waste, Int. J. Miner. Metall. Mater., 23(2016), No. 1, p. 1. doi: 10.1007/s12613-016-1204-5
[28]	S. Elabbas, L. Mandi, F. Berrekhis, M.N. Pons, J.P. Leclerc, and N. Ouazzani, Removal of Cr(III) from chrome tanning wastewater by adsorption using two natural carbonaceous materials: Eggshell and powdered marble, J. Environ. Manage., 166(2016), p. 589. doi: 10.1016/j.jenvman.2015.11.012
[29]	S.E. Ghazy and A.H.M. Gad, Lead separation by sorption onto powdered marble waste, Arabian J. Chem., 7(2014), No. 3, p. 277. doi: 10.1016/j.arabjc.2010.10.031
[30]	M.R. Lasheen, A.M. Ashmawy, H.S. Ibrahim, and S.M. Abdel Moniem, Immobilization technologies for the management of hazardous industrial waste using granite waste (case study), Korean J. Chem. Eng., 33(2016), p. 914. doi: 10.1007/s11814-015-0187-7
[31]	N. Bilgin, H.A. Yeprem, S. Arslan, A. Bilgin, E. Günay, and M. Marşoglu, Use of waste marble powder in brick industry, Constr. Build. Mater., 29(2012), p. 449. doi: 10.1016/j.conbuildmat.2011.10.011
[32]	G. Tozsin, A.I. Arol, T. Oztas, and E. Kalkan, Using marble wastes as a soil amendment for acidic soil neutralization, J. Environ. Manage., 133(2014), p. 374. doi: 10.1016/j.jenvman.2013.12.022
[33]	M. Dasgupta, S.D. Gupta, R. Mukhopadhyay, and A. Bandyopadhyay, Derivation of a new compounding ingredient for rubber from waste marble powder and study on its suitability in an inner liner compound of tubeless tyres, Prog. Rubber Plast. Recycl. Technol., 32(2016), No. 2, p. 55. doi: 10.1177/147776061603200201
[34]	G. Marras and N. Careddu, Sustainable reuse of marble sludge in tyre mixtures, Resour. Policy, 59(2018), p. 77. doi: 10.1016/j.resourpol.2017.11.009
[35]	T. Thenepalli, A.Y. Jun, C. Han, C. Ramakrishna, and J.W. Ahn, A strategy of precipitated calcium carbonate (CaCO₃) fillers for enhancing the mechanical properties of polypropylene polymers, Korean J. Chem. Eng., 32(2015), No. 6, p. 1009. doi: 10.1007/s11814-015-0057-3
[36]	T. Chaize, Potash [2010-03-14]. http://www.dani2989.com/gold/potashgb.htm
[37]	B. Mukherjee, Uses of Potassium [2019-07-05]. https://biologywise.com/potassium-uses
[38]	D.A.C. Manning, Mineral sources of potassium for plant nutrition. A review, Agron. Sustainable Dev., 30(2010), p. 281. doi: 10.1051/agro/2009023
[39]	P. Heffer and M. Prud’homme, Short-term fertilizer outlook 2015 – 2016, [in] International Fertilizer Industry Association Strategic Forum, Paris, 2015.
[40]	S.M. Jasinski, Mica, [in] Mineral Commodity Summaries 2018, U.S. Geological Survey (USGS), p. 108 [2019-07-10]. https://s3-us-west-2.amazonaws.com/prd-wret/assets/palladium/production/mineral-pubs/mcs/mcs2018.pdf
[41]	Indian Bureau of Mines, Mineral reviews, [in] Indian Minerals Yearbook 2018, Vol. III [2019-06-22]. https://ibm.gov.in/index.php?c=pages&m=index&id=1347
[42]	W.X. Liu, X.S. Xu, X.H. Wu, Q.Y. Yang, Y.M. Luo, and P. Christie, Decomposition of silicate minerals by Bacillus mucilaginosus in liquid culture, Environ. Geochem. Health, 28(2006), p. 133. doi: 10.1007/s10653-005-9022-0
[43]	Z. Luo, J. Yang, H.W. Ma, M.T. Liu, and X. Ma, Recovery of magnesium and potassium from biotite by sulfuric acid leaching and alkali precipitation with ammonia, Hydrometallurgy, 157(2015), p. 188. doi: 10.1016/j.hydromet.2015.08.018
[44]	T.M. Bhatti, J.M. Bigham, A. Vuorinen, and O.H. Tuovinen, Weathering of phlogopite in simulated bioleaching solutions, Int. J. Miner. Process., 98(2011), No. 1-2, p. 30. doi: 10.1016/j.minpro.2010.10.004
[45]	C. Varadachari, An investigation on the reaction of phosphoric acid with mica at elevated temperatures, Ind. Eng. Chem. Res., 31(1992), No. 1, p. 357. doi: 10.1021/ie00001a048
[46]	N.N. Xue, Y.M. Zhang, T. Liu, J. Huang and Q.S. Zhang, Effects of hydration and hardening of calcium sulfate on muscovite dissolution during pressure acid leaching of black shale, J. Cleaner Prod., 149(2017), p. 989. doi: 10.1016/j.jclepro.2017.02.152
[47]	C. Varadachari, Potash fertilizer from biotite, Ind. Eng. Chem. Res., 36(1997), No. 11, p. 4768. doi: 10.1021/ie970220u
[48]	P. Meng, Z.L. Huang, Z.Q. Li, M.W. Hu, C.L. Chen, and R. Chi, Conditions and mechanism for extracting potassium from muscovite in potassium-bearing shale by the barium ion-exchange method, Int. J. Miner. Process., 142(2015), p. 107. doi: 10.1016/j.minpro.2015.01.006
[49]	A. Kumar, Y.P. Singh, G. Pradhan, and N. Dhawan, Utilization of mica for potassium recovery, Mater. Today:Proc., 5(2018), No. 9, p. 17030. doi: 10.1016/j.matpr.2018.04.108
[50]	A.A.S. da Silva, J.A. Sampaio, A.B. da Luz, S.C.A. França, and C.M. Ronconi, Modeling controlled potassium release from phlogopite in solution: Exploring the viability of using crushed phlogopitite rock as an alternative potassium source in Brazilian soil, J. Braz. Chem. Soc., 24(2013), No. 8, p. 1366.
[51]	S.K. Jena, N. Dhawan, D.S. Rao, P.K. Misra, B.K. Mishra, and B. Das, Studies on extraction of potassium values from nepheline syenite, Int. J. Miner. Process., 133(2014), p. 13. doi: 10.1016/j.minpro.2014.09.006
[52]	S.K. Jena, N. Dash, and S.S. Rath, Effective utilization of lime mud for the recovery of potash from mica scraps, J. Cleaner Prod., 231(2019), p. 64. doi: 10.1016/j.jclepro.2019.05.231
[53]	S. Shekhar, D. Mishra, A. Agarwal, and K.K. Sahu, Physico–chemical treatment of glauconitic sandstone to recover potash and magnetite, J. Cleaner Prod., 147(2017), p. 681. doi: 10.1016/j.jclepro.2017.01.127
[54]	S.K. Jena, P.K. Misra, and B. Das, Studies on extraction of potassium from feldspar by roast–leach method using phosphogypsum and sodium chloride, Miner. Process. Extr. Metall. Rev., 37(2016), No. 5, p. 323. doi: 10.1080/08827508.2016.1218869
[55]	M.T. Serdengeçti, H. Baştürkcü, F. Burat, and M.O. Kangal, The correlation of roasting conditions in selective potassium extraction from K-feldspar ore, Minerals, 9(2019), No. 2, p. 109. doi: 10.3390/min9020109
[56]	B. Yuan, C. Li, B. Liang, L. Lü, H.R. Yue, H.Y. Sheng, L.P. Ye, and H.P. Xie, Extraction of potassium from K-feldspar via the CaCl₂ calcination route, Chin. J. Chem. Eng., 23(2015), No. 9, p. 1557. doi: 10.1016/j.cjche.2015.06.012
[57]	S.K. Jena, N. Dash, A.K. Samal, and P.K. Misra, Competency of chlorination roasting coupled water leaching process for potash recovery from K-feldspar: Mechanism and kinetics aspects, Korean J. Chem. Eng., 36(2019), No. 12, p. 2060. doi: 10.1007/s11814-019-0393-9
[58]	S.K. Jena, N. Dhawan, S.S. Rath, D.S. Rao, and B. Das, Investigation of microwave roasting for potash extraction from nepheline syenite, Sep. Purif. Technol., 161(2016), p. 104. doi: 10.1016/j.seppur.2016.01.039
[59]	A.K. Mazumder, T. Sharma, and T.C. Rao, Extraction of potassium from glauconitic sandstone by the roast–leach method, Int. J. Miner. Process., 38(1993), No. 1-2, p. 111. doi: 10.1016/0301-7516(93)90068-L
[60]	L.S. Darken and R.W. Gurry, Physical Chemistry of Metals, CBS Publishers and Distributers, Delhi, 1987.
[61]	L. Li, S.M. Lei, Y.Y. Liu, and H.H. Luo, Extraction and reaction mechanism of potassium from associated phosphorus and potassium ore, J. Wuhan Univ. Technol. -Mater. Sci. Ed., 31(2016), No. 6, p. 1255. doi: 10.1007/s11595-016-1522-5
[62]	M. Kumanan, G. Sathya, V. Nandakumar, and L.J. Berchmans, Extraction of potash from k-feldspar mineral by acid and molten salt leaching processes, IASET Int. J. Metall. Mater. Chem. Eng., 7(2016), p. 1.
[63]	W.O. Santos, E.M. Mattiello, A.A. Pacheco, L. Vergutz, L.F. da Silva Souza-Filho, and D.B. Abdala, Thermal treatment of a potassium-rich metamorphic rock in formation of soluble K forms, Int. J. Miner. Process., 159(2017), p. 16. doi: 10.1016/j.minpro.2016.12.004
[64]	E.M.M. Ewais, Y.M.Z. Ahmed, A.A.M. El-Amir, and H. El-Didamony, Cement kiln dust/rice husk ash as a low temperature route for wollastonite processing, J. Silic. Based Compos. Mater., 66(2014), No. 3, p. 69.
[65]	M. Lin, Z.Y. Pei, and S.M. Lei, Mineralogy and processing of hydrothermal vein quartz from Hengche, Hubei Province (China), Minerals, 7(2017), No. 9, p. 161. doi: 10.3390/min7090161
[66]	Z.Y. Pei, M. Lin, Y.Y. Liu, and S.M. Lei, Dissolution behaviors of trace muscovite during pressure leaching of hydrothermal vein quartz using H₂SO₄ and NH₄Cl as leaching agents, Minerals, 8(2018), No. 2, p. 60. doi: 10.3390/min8020060
[67]	O. Palchik, J.J. Zhu, and A. Gedanken, Microwave assisted preparation of binary oxide nanoparticles, J. Mater. Chem., 10(2000), No. 5, p. 1251. doi: 10.1039/a908795h
[68]	M. Olszak-Humienik and M. Jablonski, Thermal behavior of natural dolomite, J. Therm. Anal. Calorim., 119(2015), No. 3, p. 2239. doi: 10.1007/s10973-014-4301-6
[69]	T.N. Chernykh, A.V. Nosov, and L.Y. Kramar, Dolomite magnesium oxychloride cement properties control method during its production, IOP Conf. Ser:Mater. Sci. Eng., 71(2015), art. No. 012045. doi: 10.1088/1757-899X/71/1/012045
[70]	H.W. Day, The high temperature stability of muscovite plus quartz, Am. Mineral., 58(1973), p. 255.
[71]	J.A. Schramke, D.M. Kerrick, and A.C. Lasaga, The reaction muscovite + quartz = andalusite + K-feldspar + quartz. Part I. Growth kinetics and mechanism, Am. J. Sci., 287(1987), No. 6, p. 517. doi: 10.2475/ajs.287.6.517
[72]	L. Shi and H.J. Luo, Preparation of soil nutrient amendment using white mud produced in ammonia–soda process and its environmental assessment, Trans. Nonferrous Met. Soc., 19(2009), No. 5, p. 1383. doi: 10.1016/S1003-6326(08)60454-9