Sameepa Banerjee

FLOW CHART OF SILICO MANGANESE PRODUCTION

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

SUB STATION

Gas & Smoke

PC UNIT FURNACE
TRANSFORMER
Wa
W te r in
ate
FINISH YARD ro
ut
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 using
MIX gravitational force
MRP MELT
 RAW MATERIALS

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

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:

Silicon dioxide reacts with carbon to form silicon metal and carbon monoxide:

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.
1. Raw Material Preparation: Manganese ore, quartz, and coke are the primary raw
materials. They are blended and preheated to remove moisture.

2. Reduction of Manganese Oxides:

• Low-Temperature Reduction(800-1000°C):
MnO₂ + C → MnO + C​O₂
• Mid-Temperature Reduction(1000-1200°C):
Mn3​O4 ​+ C → 3MnO + CO
• High-Temperature Reduction(1200-1400°C):
MnO + C → Mn + CO

3. Silicon Reduction: Silicon dioxide(SiO₂) is reduced bycarbon at higher temperatures

(1600-1800°C).
SiO₂ ​+ 2C → Si + 2CO

4. Formation of Silico Manganese Alloy: The Manganese and Silicon formed in the previous
steps combine to form Silico Manganese (SiMn).

Mn + Si → SiMn
 CHEMICAL REACTION

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

1. Reduction of Manganese Oxide:

2. Reduction of Silicon Dioxide:

3. Formation of 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.