Sameepa Banerjee

FLOW CHART OF SILICO MANGANESE PRODUCTION

Use of PLC Telfar
Vehicle BIN HOUSE WH-1,2&3 CHUT-1 TO 8
RM YRD Skip
BIN-1-12
Belt

SUB STATION

Gas & Smoke

PC UNIT FURNACE
TRANSFORMER

FINISH YARD

Metal Size &

Packing PUMP HOUSE
METAL SLAG
Ready for CI Pans Sand Bed
Despatch
1. Slag use of ground feeling
2. Separate metal & slag by
MIX using gravitational force
MRP MELT
RAW MATERIALS

 Manganese Ores: Commonly used ores include pyrolusite (MnO₂),

rhodochrosite (MnCO₃), and other manganese oxides.
 Silicon Ores: Typically quartz (SiO₂) or sand.Carbonaceous Reducing Agent:
Coke, coal, or charcoal are used to facilitate the reduction reactions.
PRODUCTION PROCESS
 Preparation and Sizing of Raw Materials : Manganese ores are crushed and screened to
obtain the desired particle size.Silicon ores are similarly processed to achieve the required
size.The carbonaceous reducing agent is also prepared by crushing and screening.
 Mixing and Batching: The raw materials are weighed and mixed in specific
proportions. The typical charge for the furnace consists of manganese ore, silicon
ore (quartz), and a carbonaceous reducing agent.
 Smelting in Electric Arc Furnace (EAF) : The mixed charge is fed into an electric arc
furnace.An electric arc is struck between electrodes, generating high temperatures
(approximately 1600–1700°C).Under these conditions, the manganese oxides and
silicon dioxide are reduced by the carbonaceous material.
 Reduction Reactions : Manganese oxide reacts with carbon to form manganese metal
and carbon monoxide:
𝑀𝑛𝑂2 + 2𝐶 → 𝑀𝑛 + 2𝐶𝑂𝑀𝑛𝑂2 + 2𝐶 → 𝑆𝑖 + 2𝐶𝑂𝑆𝑖𝑂2 + 2𝐶 → Si+2CO
Silicon dioxide reacts with carbon to form silicon metal and carbon monoxide:
𝑆𝑖𝑂2 + 2𝐶 → 𝑆𝑖 + 2𝐶𝑂𝑆𝑖𝑂2 + 2𝐶 → 𝑆𝑖 + 2𝐶𝑂
Iron, present in the ores, is also reduced and combines with manganese and silicon to
form the silicon manganese alloy.
 Tapping and Casting : The molten silicon manganese alloy is tapped from the furnace into
molds. The slag, which is a by-product of the smelting process, is also tapped off
separately.
 Cooling and Solidification: The alloy cools and solidifies in the molds. The ingots or lumps
are then broken down into smaller sizes suitable for transportation and use in
steelmaking.
 Quality Control and Storage : Samples of the silicon manganese alloy are analyzed
for their composition to ensure they meet the required specifications.The final
product is stored and shipped to customers, primarily for use in steelmaking.
CHEMICAL REACTION

 The main chemical reaction involved in the production of silicomanganese are :

1. Reduction of Manganese Oxide:
𝑀𝑛𝑂2 + 2𝐶 ⟶ 𝑀𝑛 + 2𝐶𝑂
2. Reduction of Silicon Dioxide:
𝑆𝑖𝑂2 + 2𝐶 → 𝑆𝑖 + 2𝐶𝑂
3. Formation of Alloy:
𝑀𝑛 + 𝑆𝑖 + 𝐹𝑒 → (𝐹𝑒𝑀𝑛𝑆𝑖)𝑎𝑙𝑙𝑜𝑦
IMPORTANT CONSIDERATIONS

 Energy Consumption: The EAF consumes significant amounts of electricity, making

energy efficiency crucial in the production process. Environmental Impact: The
process generates carbon monoxide and other emissions. Implementing proper
environmental controls and emission treatment systems is essential to minimize the
environmental impact. Material Handling: High temperatures and reactive
materials require specialized handling and safety measures to protect
workers and equipment.
 APPLICATIONS

 Steelmaking: Manganese is a critical component in steel production, where it

acts as a deoxidizer and an alloying element to improve the strength, toughness,
and hardness of steel.