Kinetics of the Volatilization Removal of Zinc from Manganese Dust
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Manganese dust which contains significant amounts of manganese, zinc and potassium is collected from the off-gas during manufacturing ferromanganese and silicomanganese alloys at Dongbu Metal Company in Korea. The removal of zinc and potassium from the manganese dust is very important in the process for recycling the dust back into the ferromanganese smelting furnace. This is because the potential accumulation of zinc and potassium in the smelting furnace can cause irregularities in the operation of the smelting furnace. In this study, the reduction-volatilization reaction of the zinc oxide contained in the manganese dust with carbon was examined at reaction temperatures between 923 and 1323 K in nitrogen atmosphere using a thermogravimetric method. The results of experiments on the kinetics of the reaction are presented in this paper. Experimentally, the rate of this reaction was demonstrated by the removal of 99% zinc in 20 min at 1198 K under a carbon addition amount of 9 mass%. The reduction-volatilization reaction started at above 973 K and proceeded very fast at above 1023 K. Furthermore, manganese and iron oxides in the dust was partially reduced during the reaction. The shrinking-core model for a surface chemical reaction control was found to be useful in describing the reduction-volatilization reaction rate, which had an activation energy of 173 kJ/mol (41.3 kcal/mol).Keywords:
Ferromanganese
Volatilisation
Reaction rate
AbstractMost manganese used in the world is consumed as ferroalloys by the steelmaking industry. Submerged arc electric furnace smelting using the manganese-rich slag method is widely used to produce ferromanganese. This process has been modelled using the HSC computational thermodynamics package. It was assumed that higher manganese and iron oxides are reduced to MnO and FeO before entering the zone where molten slag and alloy form and equilibrate. The model predictions were compared to data from Thermit Alloys (P) Limited, an Indian ferroalloy smelter, and the agreement was found to be good. It was then used to examine the affects of changing the amount of carbon reductant and temperature on several performance indicators. The results of this modelling are discussed and it is concluded that the model is useful as an aid to understanding ferromanganese smelting.Keywords: SUBMERGED ARC ELECTRIC FURNACEFERROMANGANESE SMELTINGCOMPUTATIONAL THERMODYNAMICS MODEL
Ferromanganese
Ferroalloy
Slag (welding)
Electric arc furnace
Pyrometallurgy
Ferrochrome
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In this paper the smelting separation of high-alumina rich-manganese ore prepared with selective reduction and magnetic separation was proposed to produce the high carbon ferromanganese alloy (HCFeMn). The rational smelting separation parameters for high-alumina rich-manganese ore included the FC/O of 1.1, the smelting temperature of 1550?C, the smelting time of 60 min, and the basicity of 0.7. The smelting separation of high-alumina rich-manganese ore was achieved successfully. The content of Fe, C, Si and other impurities (P, S) were 12.13%, 6.73%, 0.17% and 0.14, 0.008, respectively. Especially, the recovery and the content of Mn reached 80.47% and 76.76%. The obtained high carbon ferromanganese alloy met the higher standard (FeMn78C8) of ferromanganese alloy, especially the content of Si P and S in the HCFeMn alloy was far below the standard value. Based on the SEM-EDS, XRD and thermodynamic calculation, the smelting and separation mechanisms of high-alumina rich-manganese ore was proposed to more effectively explain the effect of smelting parameters on slag/metal separation behaviors during the process of smelting HCFeMn alloys.
Ferromanganese
Ferroalloy
Magnetic separation
Slag (welding)
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Abstract Manganese minerals, pretreatment of manganese ores, and smelting processes are reviewed. The reduction of manganese ores and the production of high carbon ferromanganese and of silicomanganese are discussed as is the electrolytic production of manganese metal. The safety of ferromanganese production in electric furnaces is presented. Manganese and manganese alloy production is closely tied to the steel industry. Many specialty steels contain significant quantities of manganese. Other important uses of manganese occur in the cast iron and aluminum industries where manganese metal is used as an alloy addition to aluminum that is used for beverage containers.
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The possibility of replacement of the high cost sinter manganese ore by manganese rich slag for the production of high carbon ferromanganese was experimentally demonstrated. The experimental heats were designed and carried out to optimize this replacement through the adjustment of different production parameters. The results of pilot plant experimental heats showed that replacement of 50% of the sinter in the blend (or 25% of the blend) by slag containing 32% Mn and operation under slag basicity 0.9 and low (MgO)/(CaO) ratio of about 0.2‐0.3 are the optimum conditions to attain the highest manganese content in the produced ferromanganese, the highest manganese recovery and the highest metallic yield. The industrial application of reusing manganese slag clarified the economic efficiency of charging manganese slag up to 20‐25% of the blend in reducing the production cost due to reducing the cost of manganese ores. Charging of 20‐25% manganese slag reduces the cost of manganese ores and the total production cost by about 13 and 6% respectively, comparing with the conventional technology (without using manganese slag in the blend).
Ferromanganese
Slag (welding)
Ferroalloy
Carbon fibers
Production cost
High carbon
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This paper studies the possibility and proposed optimal technological scheme of manganese ferroalloys of manganese ores from Usinskoye deposit on the basis of analysis of the concentrates chemical composition and indicators of manganese ferroalloys smelting processes. It is shown that the standard manganese ferroalloys can be produced without attracting the rich content of manganese, low-phosphorous import manganese ore. The solution of this problem is of strategic importance from the standpoint of economic security and import substitution of manganese resources. The authors actualized the direction, allowing to explore opportunities not only to increase the volume of melt in the Russian high-carbon ferromanganese and ferrosilicon manganese, including through the involvement in the domestic production of manganese ore, but also to develop import-substituting technology for the production of refined manganese fer-roalloys – medium and low carbon ferromanganese and manganese metal from these ores.
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Ferromanganese
Ferrosilicon
Carbon fibers
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Chuo Denki Kogyo Co. Ltd. was established for producing low cation ferromanganese in February 1934. Now our company produces some ferromanganese, electrolytic manganese, and inorganic compounds of manganese. The electrolytic manganese is produced at Taguchi Plant of Myokokogen in Niigata.Commercial production begun in 1940 was small, of the order of 15 kg per day, and the process was gradually improved and the pilot plant expanded so that it had a monthly capacity of 300 tons in 1971.Initially native Rhordochrosite (MnCO3) was used as manganese source. But it was changed to calcined ore of manganese dioxide (MnO2) in 1976. The reduction process has been originally studied to develop new sources of the metal. Use of the calcined ore has an advantage to maintain the stability of the operation.
Ferromanganese
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The mineral resources base of manganese ores is sufficiently large in Russia. However, their mining capacity is almost absent. This is due to the low quality of domestic manganese ores and the high content of phosphorus. To date, Russia has been obliged to import the commercial manganese ore, manganese-containing ferroalloys, metallic manganese, and manganese dioxide. To produce the high-carbon ferromanganese the composition of charge was developed. The optimum variant was that where 10–15% of manganese-containing raw materials were changed for waste slag. In this case, the phosphorus content in the high-carbon ferromanganese is lower by approximately 20 rel. % in comparison with the production of ferromanganese only from the manganese-containing raw materials. About 50–60 rel. % of manganese can be extracted from the waste slag of silicon-thermal production. To produce the hot metal, the composition of iron-bearing burden material was developed. The optimum variant was that where 100% of manganese raw materials were changed for the waste slag. In this case, upon production of hot metal, the specific consumptions of manganese raw materials and limestone were decreased by 100 and 20%, respectively. The phosphorus concentration in metal was lower by about 10 rel. % as compared to the production of hot metal only from the manganese raw materials. Up to 55% of manganese can be extracted from the waste slag of silicothermic production, which is irretrievably lost at present.
Keywords: manganese ferroalloys, manganese-containing raw materials, waste slag, hot metal
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Ferroalloy
Slag (welding)
Carbon fibers
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Abstract Manganese minerals, pretreatment of manganese ores, and smelting processes are reviewed. The reduction of manganese ores and the production of high carbon ferromanganese and of silicomanganese are discussed as is the electrolytic production of manganese metal. The safety of ferromanganese production in electric furnaces is presented. Manganese and manganese alloy production is closely tied to the steel industry. Many specialty steels contain significant quantities of manganese. Other important uses of manganese occur in the cast iron and aluminum industries where manganese metal is used as an alloy addition to aluminum that is used for beverage containers.
Ferromanganese
Ferroalloy
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