Resource Recycling of Mn-Rich Sludge: Effective Separation of Impure Fe/Al and Recovery of High-Purity Hausmannite

Groundwater treatment sludge is a Fe/Mn-rich waste generated in mass production in a groundwater treatment plant for potable water production. The conventional disposal of sludge, such as direct discharge into river/lake, sea, and landfill, is not environmentally sustainable. Herein, a novel method was proposed to effectively separate Fe/Al and recover Mn via a combined hydrochloric acid leaching and hydrothermal route. The sludge contained 14.6% Fe, 6.3% Mn, and 11.5% Al and was first dissolved in 5 M HCl to prepare a leaching solution. Second, the leaching solution was hydrothermally treated, in which 97.1% Fe and 94.8% Al were precipitated as hematite and boehmite and more than 98% Mn was kept. Increasing the reaction temperature to 270 °C was beneficial for Fe/Al removal. With the consumption of abundant H+, the reaction of added glucose and nitrate accelerated as the temperature increased. An optimal pH was utilized for Fe/Al hydrolysis and crystallization, leading to extensive removal of Fe/Al. Third, the residual solution was adjusted to pH 8.3 with NaOH, and approximately, 99.2% Mn was removed as hausmannite with a Mn content of 63.6%. This method exhibited efficient separation of impure Fe/Al from Mn-rich groundwater treatment plant iron mud, and the recycled high-purity hausmannite was a marketable active pharmaceutical ingredient.