Magnesium recovery from ferrochrome slag: kinetics and possible use in a circular economy

The ever-increasing demand for ferrochrome alloys has resulted in a substantial accumulation of ferrochrome slag by-products in many mining areas. On the other hand, the ferrochrome slag has been identified as one waste material that is rich in magnesium (Mg) and has not been effectively exploited. Beneficiating of ferrochrome slag (FCS) waste material is envisaged as a means of achieving sustainable recovery of Mg. Previous studies have used sulphuric acid as a lixiviant for leaching FCS at moderate temperatures to recover Mg. In this study, the recovery of Mg from ferrochrome slag was investigated using hydrochloric acid (HCl) as the lixiviant at low temperatures. Previous studies have shown that various metal oxides have been proven to be more amenable to leaching using HCl. This study examined the effects of acid content, leaching temperature, and reaction time on the recovery of Mg from FCS. Kinetic and thermodynamic analysis of the leaching process were also investigated as these are critical factors for maximum extraction of the Mg. The results showed that the highest recovery of Mg of 88.2% was obtained from FCS using 5 M HCl with a solid to liquid ratio of 1:10, mixing intensity of 250 rpm, reaction time and temperature of 150 min and 70 °C, respectively. The shrinking core model (SCM) was used in kinetic analysis to find the experimental data's best fit. A linear relationship was obtained with the coefficient of determination for the chemical reaction model (K(c)) of >0.9 which indicates a good fit. The activation energy obtained for the diffusion and chemical reaction models were 95.44 and 41.45 kJ/mol, respectively, demonstrating that the rate-limiting phase is the one involving the chemical reaction.