Detailed Project Report on ferro alloy (silicon manganese)

FERRO ALLOY (SILICON MANGANESE)

[CODE NO.3806]  

Silico manganese is a metallic ferroalloy composed principally of manganese, silicon, and iron.  It is produced in a number of grades and sizes and is consumed in bulk form primarily in the production of steel as a source of both silicon and manganese, although some silicomanganese is used as an alloying agent in the production of iron castings.  Manganese, intentionally present in nearly all steels, is used as a steel desulfurizer and deoxidizer.  By removing sulfur from steel, manganese prevents the steel from becoming brittle during the hot rolling process.  In addition, manganese increases the strength and hardness of steel.  Silicon is a deoxidizer, aiding in making steels of uniform chemistry and mechanical properties.  As such, it is not retained in the steel, but forms silicon oxide, which separates from the steel as a component of the slag.  Silicomanganese generally contains 65 to 68 percent manganese and about 17 percent silicon

Silico-manganese (Si-Mn) is a metallic ferro alloy which is being used to add both silicon (Si) and manganese (Mn) as ladle addition during steelmaking. Because of its lower carbon (C) content, it is a preferred ladle addition material during making of low carbon steels.

Si-Mn is a ferroalloy composed principally of Mn, Si, and Fe (iron), and normally contains much smaller proportions of minor elements, such as C, phosphorus (P), and sulphur (S). The ferroalloy is also sometimes referred to as ferro-silicon-manganese.

Both Mn and Si play an important role in the manufacturing of steel as deoxidizing, desulphurizing, and alloying agents. Si is the primary and more powerful deoxidizer. Mn is a milder deoxidizer than Si but enhances the effectiveness of the latter due to the formation of stable manganese silicates and aluminates. It also serves as desulphurizer. Mn is used as an alloying element in almost all types of steel. Of particular interest is its modifying effect on the iron-carbon (Fe-C) system by increasing the hardenability of the steel.

There are two families of Mn alloys one is called Si-Mn while the other is known as ferro-manganese (Fe-Mn). Si-Mn adds additional silicon in liquid steel which is a stronger deoxidizer and which also helps to improve some mechanical properties of steel. In each family, content of C can be controlled and lowered when producing low C grades. Around 93 % of all the Mn produced is in the form of Mn ferroalloys consists of the Fe-Mn grades and the Si-Mn grades.

The Fe-Mn grades are high carbon (HC), medium carbon (MC), low-carbon (LC) and very low carbon (VLC), whereas the Si-Mn grades include medium carbon (MC) and low carbon (LC). The steel industry is the only consumer of these alloys. However as the average consumption of Mn in one ton of steel is around 7 kg, the requirement of these two ferro alloys amounts to considerable tonnages.

To cover the need for Mn and Si, the steelmaker has the choice of a blend of Si-Mn, HC Fe-Mn and Fe-Si governed of by specifications on C, Si, and Mn. Normally earlier a mixture of HC Fe-Mn and Fe-Si was used, but now a trend towards more use of Si-Mn is seen at the expense of the two others. This is primarily for economic reasons.

Si-Mn is produced in a number of grades and sizes and is consumed in bulk form primarily in the production of steel as a source of both Si and Mn, although some Si-Mn is also used as an alloying agent in the production of iron castings. Mn, which is intentionally present in nearly all steels, is used as a steel desulphurizer and deoxidizer. By removing S from steel, Mn prevents the steel from becoming brittle during the hot rolling process. In addition, Mn increases the strength and hardness of steel. Si is a deoxidizer, aiding in making steels of uniform chemistry and mechanical properties. As such, it is not retained in the steel, but forms SiO2, which separates from the steel as a component of the slag.

Effects of the addition of Si-Mn to steel depend on the amount added and the combined effect with other alloying elements. Both Si and Mn have an important influence on the properties of steel since both of them have a strong affinity for oxygen (O), and act as deoxidizers. Deoxidation with Si-Mn results in cleaner steel, as the liquid manganese silicate formed coagulates and separates easier from the melt, compared to solid SiO2 formed during Fe-Si deoxidation. Use of Si-Mn adds less C to steel compared to combination of standard Fe-Si and HC Fe-Mn. Computational fluid dynamics calculations show that the yield of Si from Si-Mn is higher than that of standard Fe-Si.

Si-Mn normally contains around 65 % to 68 % Mn and around 17 % Si. Various national and international standards for Si-Mn, designates different grades, differentiated by their Si and C contents. All standard grades of Si-Mn are generally acceptable for most uses and they are readily interchangeable.

Si-Mn is added to steel in small quantities, hence it accounts for only a small share of the total cost of end use steel mill products. No single product can substitute for Si-Mn. Steelmakers can and do substitute a combination of high C Fe-Mn and Fe-Si for Si-Mn, although not all steelmakers can make this substitution. In small plants, the facilities for storing and handling material are not sufficient to handle a combination of inputs, so only Si-Mn is used these plants efficiently.

Silicon manganese is a ferro alloy obtained by carbothermic reduction with slag coke from the production of high carbon ferro manganese or manganese ore together with silica as a flux usually in submerged electric arc furnaces, manganese silicon contains between 65%-68% mn, 16%-21%si and approximately 1.5%-2% of carbon. Manganese silicon manufacturing is more energy intensive than the ferro manganese due to the energy requirements for the reduction of the silica to silicon metal. The world’s largest producers are China-which is far above all others, representing more than 50% of the world’s production -India, Ukraine, Norway and Kazakhstan.   

There are basically three types of silicon manganese which are a function of silicon and carbon content:

Element Grade A      Grade B      Grade C

        Mn      65.0-68.0     65.0-68.0      65.0-68.0

        Si      18.5-21.0     16.0-18.5      12.5-16.0

      C, Max.        1.5        2.0         3.0

      P, Max        0.20       0.20        0.20

      S, Max        0.04       0.04        0.04

Properties

PHYSICAL STATE Solid

COLOUR Silvered gray

ODOUR Odourless

MELTING POINT 1,050°C-1,290°C

BOILING POINT       -

SPECIFIC GRAVITY 6.1g/cm³

Both silicon and manganese, besides its deoxidizing and desulphurizing effects, increase the hardenability of the steels.

The product is stable under normal conditions. Its contact with moisture, acids or alkalis causes the formation of extremely flammable (hydrogen) and very toxic gases (arsine and phosphine). 

Silicon manganese is not classified as a dangerous product according to the relevant European legislation. 

Silicon manganese is not classified as a hazardous good for transportation.

Si-Mn is produced by carbo-thermic reduction of oxidic raw materials in a three-phase, alternating current (AC), submerged arc furnace (SAF) which is also being used for the production of Fe-Mn. Operation of the process for the Si-Mn production is often more difficult than the Fe-Mn production process since higher process temperature is needed. The process of manufacturing Si-Mn is more energy intensive than the process of producing Fe-Mn due to the energy requirements for the reduction of the silica to silicon metal.

Si-Mn is produced by smelting sources of Si, Mn, and Fe, along with reducing agents (usually coke or coal). The raw materials used in Si-Mn production mainly consist of Mn ore, high C Fe-Mn slag, quartzite, coke and coal, and fluxes (dolomite or calcite). The main source of Mn in raw materials for Si-Mn production is Mn-ore and Mn-rich slag from the high C Fe-Mn production. For Si-Mn production in SAF, C (coke and coal) is used as a reducing agent while the heat is supplied by the electric power.

The raw materials are combined in a ‘charge’ and introduced into the furnace where an electrical transformer system delivers high?current, low?voltage electric power to the charge through carbon electrodes. The charge is then heated. Impurities from the ore and other Mn sources are released and form slag. Following smelting, molten Si-Mn and the slag are separated. The molten Si-Mn is cooled and cast. Once the molten Si-Mn is hardened, it is crushed and sized for packing and dispatch.

A process temperature in the range of 1600 deg C to 1650 deg C is needed to obtain Si-Mn alloy with sufficiently high content of Si and for generation of the discard slag with low MnO.

Low carbon Si-Mn with around 30% Si is produced by upgrading standard alloy by addition of Si wastes from the Fe-Si alloy industry.

COST ESTIMATION

Plant Capacity                                              45 MT/Day

Land & Building (88,202 sq.mt.)                  Rs. 13.36 Cr

Plant & Machinery                                        Rs. 1.81 Cr

Working Capital for 2 Months                     Rs. 10.40 Cr

Total Capital Investment                             Rs. 27.20 Cr

Rate of Return                                              44%

Break Even Point                                          57%

• INTRODUCTION
• PROPERTIES
• PROPERTIES
• LUMPS OF SILICO-MANGANESE
• USES AND APPLICATION
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• MANUFACTURING PROCESS
• ZONES OF A SILICO-MANGANESE FURNACE
• CRUSHING AND GRINDING OF THE ORE:
• CONCENTRATION OR BENEFICIATION OF THE ORE:
• MAGNETIC SEPARATION OF IMPURITIES:
• THE EQUILIBRIUM IS DETERMINED BY THE FOLLOWING REACTION
• CHARGING:
• SMELTING:
• TAPPING/POURING:
• METAL RECOVERY PLANT:
• CRUSHING AND SCREENING:
• SEPARATION OF METAL FROM SLAG:
• RE-CRUSHING OF MIDDLING:
• PLANT AND MACHINERY FOR MANGANESE METAL
• DETAILS OF 9MVA SUB-MERGED ARC FURNACE
• 1. FURNACE SHELL
• 2. EXHAUST HOOD
• 3. CONNECTING DUCT AND CHIMNEY
• 4. ELECTRODE SYSTEM
• 5. SUSPENSION FRAME
• 6. MANTLE FRAME/ COOLING SHIELD
• 7. PRESSURE RING
• 8. REFRECTORIES
• 9. COPPER WATER
• 10. HYDRAULIC POWER PACK
• 11. SLIPPING MECHANISM
• 12. TAPPING ARRANGEMENTS (OPTIONAL)
• 13. CONTROL PANEL
• 14. SUB STATION
• 15. BATCHING SYSTEM
• 15 (A) WEIGHING & BATCHING OPERATION
• 15 (B) FURNACE FEEDING SYSTEM
• 16. FINISHING PRODUCT HANDLING
• 17. FURNACE TRANSFORMER
• 18. MISC.
• 19. POLLUTION CONTROL EQUIPMENT
• 20. PUMP ROOM
• (1) SUBMERGED ELECTRIC ARC FURNACE
• THE 1ST LAYER
• THE 2ND LAYER
• THE 3RD LAYER
• SUBMERGED ARC FURNACE
• SUBMERGED ARC FURNACE PROFILE
• PRINCIPLE AND CHARACTERISTICS OF SAF
• FEATURES OF SAF
• THE MAJOR NORMAL FEATURES OF AC BASED FURNACES ARE AS FOLLOWS
• (2) DESCRIPTION OF VIBRATING FEEDER
• CHARACTERISTIC OF VIBRATE FEEDING:
• (3) JAW CRUSHER:
• STRUCTURE OF JAW CRUSHER:
• FEATURES OF JAW CRUSHER:
• OPERATING PRINCIPLE OF JAW CRUSHER:
• (3) DESCRIPTION OF VIBRATING SCREEN:
• WORK PRINCIPLE OF VIBRATING SCREENS:
• FEATURES OF VIBRATING SCREEN:
• (4) INTRODUCTION OF BALL MILL:
• WORKING PRINCIPLE OF BALL MILL:
• APPLICATION OF BALL MILL:
• (5) MAGNETIC SEPARATOR
• APPLICATION OF MAGNETIC SEPARATOR:
• ADVANTAGES OF MAGNETIC SEPARATOR:
• (6) FLOATATION MACHINE:
• (7) INTRODUCTION OF SPIRAL CLASSIFIER:
• (8) INTRODUCTION OF BELT CONVEYOR:
• WORKING PRINCIPLE OF BELT CONVEYOR:
• MARKET POSITION
• ROLE OF FERRO ALLOYS
• DEMAND DRIVERS OF FERRO ALLOYS
• TYPES OF FERRO ALLOYS
• FERRO ALLOYS AS DE-OXIDANT FOR STEELMAKING
• GROWTH OF THE FERROALLOY INDUSTRY IN INDIA:
• MAJOR PRODUCERS OF FERRO ALLOYS IN INDIA
• NEW PROJECTS & EXPANSIONS
• RAW MATERIALS FOR BULK FERRO ALLOYS
• USEFULNESS OF CHROMIUM ORE
• CONTRIBUTION OF FERRO ALLOY INDUSTRY TO INDIA'S ECONOMY
• ELECTRICITY GENERATION
• HELPED INDUSTRIALIZATION OF MANY SATES.
• EMPLOYMENT TO THE PEOPLE.
• MAJOR RECOMMENDATIONS OF IFAPA FOR DEVELOPMENT OF THE INDIAN FERRO ALLOY INDUSTRY.
• THE GOVERNMENT SHOULD DEVISE A MECHANISM FOR MAKING FUNDS AVAILABLE
• CONCLUSION
• INDUSTRY, PRODUCTION, DEVELOPMENT AND CONSUMPTION
• TABLE – 1: CAPACITY OF FERRO-ALLOYS INDUSTRY IN INDIA
• BULK FERRO-ALLOYS
• FERRO-MANGANESE/SILICO-MANGANESE
• FERRRO-CHROME/CHARGE-CHROME
• FERRO-SILICON
• NOBLE FERRO-ALLOYS
• OTHERS
• TABLE – 3: STATEWISE, PLANTWISE CAPACITY AND SPECIFICATIONS OF PRINCIPAL FERRO-ALLOYS PRODUCED IN INDIA
• ENVIRONMENTAL ASPECTS AND FUTURE SCOPE
• WORLD REVIEW
• FUTURE OUTLOOK
• PLANT LAYOUT
• MANUFACTURERS/SUPPLIERS OF LOW CARBON SILCO MANGANESE
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF MANGANESE ORE
• SUPPLIERS OF PEARL COKE
• SUPPLIERS OF DOLOMITE
• SUPPLIERS OF QUARTAZ POWDER
• SUPPLIERS OF HDPE BAGS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF MANGANESE BENEFICIATION PLANT
• SUPPLIERS OF SUBMERGED ARC FURNACE
• SUPPLIERS OF DG SETS
• SUPPLIERS OF EOT CRANES
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF ELECTRIC MOTOR
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF SHOT BLASTING MACHINE
• SUPPLIERS OF JIGS AND FIXTURE
• SUPPLIERS OF SUBMERSIBLE WATER PUMP

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)