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Magnetite powder and kaolinite derived from waste iron ore tailings for
environmental applications
S.K. Giri a, N.N. Das b,⁎, G.C. Pradhan a
a
Department of Chemistry, Utkal University, Bhubaneswar-751 004, Orissa, India
b
Department of Chemistry, North Orissa University, Baripada-757 003, Orissa, India
a r t i c l e i n f o a b s t r a c t
Article history: The present study demonstrated a feasible approach of utilizing waste iron ore tailings in synthesis of value
Received 22 February 2011 added products for environmental applications. The ferric iron recovered from waste iron ore tailings via acid
Received in revised form 28 August 2011 leaching followed by precipitation as ferric (hydr)oxide was used as feed stock to synthesis magnetite pow-
Accepted 11 September 2011
der by its reductive-roasting with charcoal. Physicochemical characterizations revealed the formation of suf-
Available online 16 September 2011
ficiently pure magnetite powder with ferric (hydr)oxide to charcoal ratio 1:2 and calcined at 1200 °C for 4 h.
Keywords:
The magnetic powder as such or coated with polyacrylic acid, was found efficient for removal of a model dye,
Iron ore tailings methylene blue from its solution within 2 min. The acid insoluble residue, generated after iron recovery from
Ferric (hydr)oxide iron ore tailings, was characterized as kaolinite. The residue with reasonably good surface area (119 m2 g− 1)
Charcoal was also found effective for adsorptive removal of dyes including methylene blue and can find large scale ap-
Reduction roasting plications in wastewater treatment. Moreover the present study provided further inputs for possible alterna-
Acid insoluble residue tive uses of waste iron ore tailings to partly reduce its associated disposal problems.
Dye adsorption © 2011 Elsevier B.V. All rights reserved.
0032-5910/$ – see front matter © 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.powtec.2011.09.017
514 S.K. Giri et al. / Powder Technology 214 (2011) 513–518
2.1. Materials
Iron ore tailings, collected from the tailing ponds of iron ore indus-
tries (Joda-Badbil, Orissa, India), were first screened for their iron
content and one sample with relatively high iron content (~ 40%)
was selected for this study (Table 1). Charcoal containing 96% of car-
bon was used to synthesize the magnetite powder. Methylene blue
(Qualigens) and polyacrylic acid (Merck) were used as received for
adsorption experiments. All other chemicals used in this work were
of AR/GR grades.
2.2. Preparation of magnetite (Fe3O4) from iron ore tailing Fig. 1. Particle size analysis of iron ore tailings.
The particle size distribution of the selected iron ore tailings was
carried out using CILAS (1064 LIQUID). The size analysis (Fig. 1) indi-
cates high degree of fineness of the iron ore tailings with d10 of
4.81 μm, d50 of 13.21 μm and d90 of 20.13 μm. The chemical analyses
for major elements in iron ore tailings, acid insoluble residue,
Table 1
Chemical analyses (in part) of the iron ore tailings (IOT) and acid insoluble residue
(AIR).
Component Wt. % in
IOT AIR
the absorbances at 665 nm (λmax) using UV–vis spectrophotometer concentration (mg L − 1), volume of the solution (L) and amount of
(Systronics, 2204). The amounts of dye adsorbed (qe) and the effi- acid insoluble residue (g), respectively.
ciency (%) of acid insoluble residue were calculated by using Eq. (1): In the case of magnetite powder, both neat as well as in-situ poly-
acrylic acid coated magnetite powder were used for adsorption of
qe ¼ ðCt –Ce ÞV=m ð1Þ methylene blue. In-situ coating of polyacrylic acid with ion exchange
groups on magnetite powder could further increase the adsorption of
cationic methylene blue at alkaline pH [18]. Typically 0.1 g of magne-
where qe, Ci, Ce, V and m represent the amount of methylene blue tite powder, dispersed in 8 ml 4% sodium salt of polyacrylic acid was
adsorbed (mg g − 1), the initial concentration (mg L − 1), the final allowed for 10 min for in-situ coating of polyacrylic acid over
Fig. 3. EPMA compositional map of waste iron ore tailings sample at 20 μm and 5 μm.
516 S.K. Giri et al. / Powder Technology 214 (2011) 513–518
coated samples, was adjusted to ~ 9.0. In comparison to acid insoluble 5 10 900 1.11 ± 0.16 22.20 62.69
residue, the adsorption of methylene blue was quite rapid and the ad- 5 10 1000 1.22 ± 0.23 24.40 64.50
5 10 1100 2.29 ± 0.32 45.80 68.84
sorption equilibrium was attained in about 2 min. As such all the ad-
5 10 1200 2.72 ± 0.11 54.40 71.64
sorption experiments with magnetite powder were performed up to 5 10 1300 2.85 ± 0.20 57.00 71.20
2 min and the concentrations of residual methylene blue, after mag- 6 9 1200 3.50 ± 0.21 58.33 –
netic separation of magnetite powder, were determined spectropho- 7 8 1200 4.09 ± 0.25 58.42 –
tometrically as described above. The adsorption data of acid insoluble 8 7 1200 4.65 ± 0.30 58.13 –
9 6 1200 4.88 ± 0.13 54.22 –
residue and magnetite powder were fitted to Langmuir and Freun-
10 5 1200 5.11 ± 0.17 51.10 –
dlich models to derive various adsorption parameters.
Chemical analyses of the selected iron ore tailings (Table 1) show Among several possible routes for preparation of magnetite pow-
that iron, silica and alumina are the major constituents. More than der using the freshly precipitated ferric (hydr)oxide precursor from
9.0 wt.% loss of ignition of iron ore tailings is primarily due to pres- iron ore tailings, the reduction-roasting method in presence of carbo-
ence of substantial amount of moisture and structural water. The neous material (viz. charcoal) is adopted in this study. As evident
XRD pattern of iron ore tailings (Fig. 2a) also shows the characteristic from XRD (Fig. 2b), the ferric (hydr)oxide precursor is primarily con-
peaks for goethite (JCPDS: 29-0713) along with peaks due to hema- stituted of goethite and hematite. The results of magnetite yields
tite (JCPDS: 33-0664) and magnetite (JCPDS: 19-0629). However, under varying conditions of reduction-roasting of ferric (hydr)oxide
the characteristic peaks of kaolinite (JCPDS: 06-0221) either appeared are presented in Table 2.
as low intensity peaks or overlapped with the peaks of different iron At fixed ferric (hydr)oxide to charcoal ratio (1:2), the yield of
phases. The EPMA of iron ore tailings at 20 μm and 5 μm (Fig. 3) re- magnetite is progressively increased with increase of reduction tem-
veals that the grains are composed of aluminum iron silicate perature from 900 to 1300 °C. The fused metallic mass obtained at
[19,20]. Free quartz grains are occasionally present in the range 4– 1300 °C is, however, difficult to grind. Also the iron content
5 μm in size as indicated with an arrow (viewed on 20 μm). Large alu- (71.20%) of the resulted product is marginally lower than that
minum iron silicate grain was also obtained in which fine iron-rich obtained by reduction-roasting at 1200 °C (71.64%). Moreover, the
particles are clotted (viewed on 5 μm). product obtained by reduction-roasting at 1200 °C is much easier to
In order to establish the optimal conditions for iron recovery from grind. Hence further optimization of ferric (hydr)oxide to charcoal
iron ore tailings, the concentrations of HCl are varied from 15 to 85% ratio is carried out keeping their total mass (15 g) and temperature
(v/v) keeping the temperature and solid:liquid ratio fixed at 80 °C (1200 °C) constant. It is seen that the increase of ferric (hydr)oxide
and 1:6, respectively. The iron recovery increases with increasing to charcoal ratio (w/w) in the mixture (0.66–1.143) results maximum
acid concentration and 100% recovery is observed within 15 min yield (~ 58%) with negligible variation. Further increase of ferric
with 85% HCl while 45 min is required with 50% HCl for same per- (hydr)oxide content in the reducing mixture decreases the magnetite
centage of recovery (Fig. 4). As such, further experiments on iron re- yield in the final product. As such the optimum ferric (hydr)oxide to
covery as FeCl3 are carried out by digesting iron ore tailings with 50% charcoal wt. ratio is kept fixed at 1.143 in all further experiments for
HCl at 80 °C for 1 h. At the end of digestion, the acid insoluble residue synthesis of magnetite powder. This also generates less amount of
of iron ore tailings is separated by filtration, washed and kept for fur- CO2 and satisfies one of the primary requirements for any process in
ther characterization and adsorption studies. respect of release of gaseous pollutants.
The XRD of magnetite powder (Fig. 2d) primarily shows the char-
acteristic peaks of magnetite and is in good agreement with the stan-
dard magnetite phase (JCPDS: 19-0629). The slight broadening of the
Fig. 4. Optimization of iron recovery from waste iron ore tailings using different con-
centration of HCl (a) 15% (b) 30% (c) 50% (d) 65% and (e) 85% HCl. Fig. 5. SEM image of magnetite powder.
S.K. Giri et al. / Powder Technology 214 (2011) 513–518 517
where qe and Ce represent the same as stated above while K and n are
Freundlich constants and considered to be relative indicators of ad-
sorption capacity (mg g − 1) and adsorption intensity, respectively.
The derived adsorption parameters from the least square fittings of
Langmuir and Freundlich equations are given in Table 3 along with
the same reported for other relevant adsorbents. The Freundlich
Fig. 6. Effect of initial methylene blue concentrations on percentage of adsorption and
isotherm is slightly better fitted (R2 = 0.99) in comparison to Langmuir
uptake by magnetite powder, at pH ~ 9 and magnetite powder (1.0 g L− 1).
(R2 = 0.968) indicating the heterogeneous nature of the adsorbent sur-
face. The derived monolayer adsorption capacities for neat magnetite
peaks is more likely due to the poor crystallinity and small crystallite powder (Q0 = 20.74 mg g − 1) and in-situ coated magnetite powder
of magnetite [21]. Appearance of a few low intensity peaks (marked (Q0 = 39.1 mg g− 1) are, however, relatively lower than those observed
with asterisk) in the XRD pattern is presumably due to other iron for polyacrylic acid-bound (Q0 = 199 mg g− 1 [18]) magnetite nanopar-
oxide phases (like Fe2O3) associated with magnetite as impurity. ticles primarily due to bigger size of the magnetite particles in the
Chemical analyses show that the total iron and Fe 2+ contents in the present case. Further studies are required to assess the potential of syn-
prepared sample are 71.64 and 23.74 wt.%, respectively as against thesized magnetite powder as such or coated with different surfactants
theoretically calculated values of 72.46 and 24.15 wt.%, indicating for their practical use wastewater treatment.
the purity of magnetite powder. The SEM of magnetite powder
(Fig. 5) also shows low crystallinity of the material with non- 3.4. Acid insoluble residue and its adsorption characteristics
uniform grain size [22]. Further it shows that the agglomerated mag-
netite powder is in the sub-micrometer range. The chemical analyses show (Table 1) that Si and Al are the major
constituents of acid insoluble residue along with minor amounts of Fe
and P. The XRD pattern of acid insoluble residue (Fig. 2c) primarily
3.3. Adsorption characteristics of magnetite powder exhibits the characteristic peaks of kaolinite (JCPDS: 06-0221) [25].
In order to make the overall process of magnetite powder synthesis
The use of magnetite as adsorbent for wastewater treatment is economically viable, it is desirable to find some potential uses for
one among different possible large scale applications and several acid insoluble residue of iron ore tailings as such or in preparation
studies have been made in recent years [18,23,24]. It is found that of inorganic polymers, ceramic, polymer composites etc. [26, 27]. Al-
the adsorption efficiency of magnetite particles largely depends on though there are reports on the use of acid insoluble residue for pro-
their size and different coating on their surface. Since the magnetite duction of cementitious materials [8, 9], its use as cheap but effective
powder in this study is synthesized through reduction-roasting of fer- adsorbent for water treatment is hardly researched till date. More-
ric (hydr)oxide at high temperature, it is expected to exhibit low ad- over, the residue contains significant amounts of structural water/hy-
sorption capacity for different contaminants in comparison to droxyl groups with kaolinite as the only phase which can exhibit good
magnetite nanoparticle. The results of methylene blue adsorption adsorption properties. In addition the surface area of acid insoluble
with varying methylene blue concentrations (1.6–32 mg L − 1) at residue (119 m 2/g) is relatively higher than those that occurred nat-
pH ~ 9.0 are presented in Fig. 6. Although the percentage of adsorption urally [28]. Keeping these in view, a preliminary adsorption study
decreases with increase of methylene blue concentrations, the overall was carried taking a methylene blue as adsorbent and the results
methylene blue uptake increases from 0.72 to 8.8 mg g − 1 when the are compared with those reported for naturally occurring kaolinite.
concentration of methylene blue increases from 1.6 to 32.0 mg L − 1. The adsorption data at fixed pH ~ 5.0 and acid insoluble residue
To derive different adsorption parameters, the equilibrium methylene dose (2.0 g L − 1) with varying methylene blue concentration (1.6–
blue adsorption data are fitted to widely used Langmuir (Eq. (2)) and 32 mg L − 1) indicates that methylene blue adsorption decreases
Table 3
Adsorption parameters derived from Langmuir and Freundlich isotherms for adsorption of MB on MP and AIR.
Magnetite powder 1.6–32 9.21 20.74 3.59 1.28 0.7345 This work
Magnetite powder (in-situ coated with polyacrylic acid) 1.6–32 9.02 39.1 3.59 3.37 0.637 This work
Polyacrylic acid-bound iron oxide magnetite nanoparticles 50–800 9.0 199 – – – [18]
Acid insoluble residue 1.6–32 5.1 15.98 5.50 5.35 0.224 This work
Raw kaolin 13.99 27.49 14.85 0.151 [30]
Pure kaolin 15.55 91.87 16.39 0.070 [30]
Calcined raw kaolin 7.59 13.44 6.57 0.075 [30]
Calcined pure kaolin 8.88 56.31 9.01 0.061 [30]
518 S.K. Giri et al. / Powder Technology 214 (2011) 513–518
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