A Novel Titanium-Based Dimensionally Stable Anode toward Energy-Efficient and Clean Electrowinning of Metallic Manganese

High energy consumption and significant anode slime emissions pose major challenges in manganese metallurgy. Although dimensionally stable anodes (DSAs) offer a potential solution, their high cost and limited lifespan in harsh environments restrict their broader use. Here, we report a novel Ti/IrO2–RuO2–SiO2 (T/IRS) anode that is both high-efficiency and eco-friendly, designed to reduce energy consumption and address the issue of anode slime in manganese electrowinning. The phase composition and morphology of the IrO2–RuO2–SiO2 coating were characterized. The electrochemical properties of the T/IRS anode were assessed, demonstrating superior electrocatalytic activity and electrode stability compared to traditional Pb alloy anodes. The findings indicate that MnO2 deposition on the T/IRS anode, despite decreasing oxygen evolution activity and slightly increasing anodic potential, substantially improves corrosion resistance, as demonstrated by an increase in corrosion potential from 0.240 to 0.663 V. The dense MnO2 layer formation also effectively prevents anode slime production. Galvanostatic electrowinning confirmed that the T/IRS anode reduces energy consumption and eliminates anode slime, maintaining an average cell voltage 0.22 V lower than that of the Pb-0.5%Ag anode at a cathodic current density of 350 A m–2. Consequently, the T/IRS anode presents great potential for energy saving and waste reduction, making it a viable option for cleaner and sustainable manganese production.