Abstract
The recovery of Mn and Al from two industrial waste of ferromanganese and aluminum production processes was investigated via implementing a high temperature smelting—aluminothermic reduction process. The experiments were carried out with or without CaO flux addition, and two dross qualities. It was observed that the prepared mixtures of the materials yield homogeneous metal and slag products in terms of chemical composition and the distribution of phases. However, the separation of produced metal phase from the slag at elevated temperatures occurs when a higher amount of CaO is added. Viscosity calculations and equilibrium study indicated that the better metal and slag separation is obtained when the produced slag has lower viscosity and lower liquidus. It was found that the process yields Al-Mn-Si alloys, and it is accompanied with complete recovery of Mn, Si and Fe and the unreacted Al in the process. Moreover, the quality of metal product was less dependent on the slightly different dross quality, and the concentration of minor Ca in metal is slightly increased with significant increase of CaO in the slag phase.
Highlights
Manganese is an essential element in the production of iron and exists in many steel grades and its primary application is for steelmaking
Evaluation of Aluminothermic Reduction The chemical compositions of the produced metal and slag phases indicate that sig nificant mass transport has been occurred through the contact of Al with the ferromanga
The chemical compositions of the produced metal and slag phases indicate that significant mass transport has been occurred through the contact of Al with the ferromanganese slag and lime oxide mixture
Summary
Manganese is an essential element in the production of iron and exists in many steel grades and its primary application is for steelmaking. Manganese is produced mostly in the form of ferromanganese (FeMn), silicomanganese (SiMn), and in pure form of electrolytic manganese. In 2019, 4.4 million tons of high carbon FeMn, 1.4 million tons of low carbon ferromanganese, 18 million tons of SiMn were produced [1]. The production of ferromanganese is accompanied with the generation of a high MnO-containing slag that is called high-carbon ferromanganese slag (HCFeMn slag) that has 20–45 wt% MnO. This slag can be fed into the SiMn production furnace as a part of the charge to supply the Mn of the SiMn product, and valorize the significant among of the Mn in HCFeMn slag [2]. The valorization of FeMn to recover Mn is important
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