INDUSTRIAL MANGANESE ORES OF THE USSR

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP82-00039R000200140011-3
• Release Decision: RIPPUB
• Original Classification: R
• Document Page Count: 26
• Document Creation Date: December 22, 2016
• Document Release Date: March 26, 2012
• Sequence Number: 11
• Publication Date: September 11, 1952
• Content Type: REPORT

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Industrial Manganese Ores of the USSR
By: A. G? Vetekhtin
Promyshlennye Margenteovye Rudy USSR, Moscow/Leningrad, 1946
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CHEMICAL REQUIREMENTS FROM ORES
The constant utilization of manganese in the production of
steel is due to its exceptional qualities. In the first place,
manganese, as an active de-oxidizer, extracts from the melt all the
oxygen, eliminates from the steel iron oxides, and contributes pro-
duction of sound pigs. In addition, manganese is an excellent de-
sulfurizer as it extracts from the melt all the sulfur which even
when present in insignificant amounts (0.02 percent) is one of the
causes of steel brittling and breaking when heated red-hot. Final-
ly, manganese is of primary importance as an alloy constituent and
can replace, in a number of cases, more expensive and rare metals
in the production of high grade steels. Even an insignificant ad-
dition of it to steel sharply increases its mechanical properties
such as hardness, forging, toughness, and resistance to wear, play-
ing a tremendous part in the production of rollings, band, punch-
ings? in the production of rust-resistant, heat-resistant, struc-
tural and other grades of steel. In other words, without manganese
the highly developed steel casting industry cannot exist, particu-
larly since all attempts to find a readily available and cheap subyd
stitute have not yet been successful.
Depending on their quality, particularly their chemical coma.
position, manganese ores utilized in the ferrous metallurgy are
used for the following purposes:
1. High grade manganese ores, poor in iron and phosphorus
content) are used in blast furnaces and electric furnaces to pro-
duce standard grades of ferro-manganese which isimad as an addit-
ion agent in the production of special grades of steel*
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Silico-manganese, which is important in the manufacture of
certain grades of steel) is also produced in insignificant quantit-
ies.
2. Iron-manganese ores, depending on their manganese to iron
ratio, are used for the production of non-standard grades of ferro-
manganese, popularly known as Spiegel) and silicospiegel. All of
these ferrous alloys are substitutes for the high-grade alloys of
ferromanganese used in the manufacture of ordinary and common
grades of steel.
3. Iron-manganese ores) relatively free of phosphorus) are
used in the production of manganese pigs (with a manganese content
of 5 to 10 percent) which are utilized as additions for the re-car-
burization and preliminary de-oxidation of steel in order to d
crease the amount of ferro-manganese used for this purpose.
?
4. Siliceous ores, poor in manganese and iron, not suitable
for the production of the above named special ferrous alloys, may
be used only as a charge in the production of ordinary pig iron
from iron ores, which contain little or no manganese. Green) rich
in manganese slag) obtained during the production of ferro-mangany?
ese may also be used successfully for this purpose.
5. On the other hand as tests have shown) calcium ores)
?
poor in manganese and iron) are very valuable raw material being
utilized as basic manganese fluxes in the production of steel in
Martin furnaces. In a number of cases, these ores may replace to
an appreciable degree the expensive ferromanganese used in the
production of common grades of steel.
6, Finally, it should be pointed out that ores rich in man
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ganese areksed in a raw form in the production of steel, being ad-
ded at the last stage of production to increase the manganese con-
tent in the refined metal. The most desirable ores for this pur-
pose are self-fluxing ores, namely, those containing important quan-
tities of calcium oxide and magnesium oxide (type of ore originat-
ing in the Sapalsk area).
Besides the indicated purposes, manganese is used in the prep-
aration of special rustproof and heat resistant manganese steels,
Godfield steels, structural and other steels.
In the non-ferrous metallurgy, alloys of manganese and cop-
per are of the greatest importance in th nufacture of corrosion-
resistant metal reservoirs, ship propellers, other alloys with alu-
minum for the aviation industry, alloys of copper with manganese
and nickel having great electrical resistance, and others.
The specifications of manganese ores for the production of
ferro-manganese as well as for other alloys are dictated primarily
by metallurgical considerations of which the most important are
summed up as follows:
1. While iron in the presence of manganese oxides is almost
complete. reduGed.d:olning.neltingi-the-reduction of manganese var-
4
ies from 75 to 50 percent. (The reduction process of manganese ox-
ides to metal is accomplished in the lower part of the blast fur-
nace (behind the boshes). As the coke burns and settles down) the
higher oxides gradually pass into a combination of lower oxides
(4n024 Mn203--)04n304-414n0). A part of manganese oxide combined
with silica) forms a silicate melt as may be seen from a microscopm
to study of slags (in particular) the formation of tephroite Mn2SiO4
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and others). In a reaction with calcium, with the formation of
calcium silicates, the manganese is reduced to the metallic states
However, in the smelting of rich ores, poor in silica, the main
mass of manganese is reduced apparently with the aid of carbon ox-
ide (CO) and manganese oxide, which may also be noted under the mi-
croscope in tephroite slags in the form of mineral manganosite (MnO)
while in the case of poorer ores the reduction declines to 40-35
percent, depending on the quality of the raw material (chiefly on
the silica content of the ores and the correlation of slag forming
components in the charge), on the smelting conditions necessary to
obtain a certain grade of ferro alloys, and on a series of other
causes. Only in smelting silico spiegel and siliceous manganese
rich in silica, that is, in converting appreciable quantities of
siliceous ore into pig iron does the degree of reduction reach
80 to 95 percent.
Thus, in the production of manganese alloys with iron and
small quantities of silicon, the manganese losses reach 25 to 65
percent (without taking into account the loss of small particles if
the blast is strong),
2. These losses are as follows:
In slags, where 7 to 20 percent or more of the entire man-
ganese.Nt J,11 the charge, depending on the quantity of the slag,
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appears in the form of manganese sdaiates.
Losses in the form of volatile manganese oxides leaving the
furnace with the escaping gases at high temperatures at the rate
of 12 to 20 percent or more depending on the melting temperature
(The melting temperatures of ferromanganese and spiegel are between
1600 and 1700 degrees; the melting of ordinary pigs is carried out
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at temperatures from 1350 to 1500 degrees) particularly when melt-
ing in electric furnaces, and finally,
Losses in the form of dust and small ore particles during
hard blowing? Depending on the content of dust and small partic-
les content of the ore and on the degree of friability) or rather
on the ability of the ore to withstand crushing and pulverization
in the process of moving the charge in the blast furnace) these
losses may vary from 5 to 10 percent and sometimes reach 30 per-
cent (for small grain ores), A more accurate picture of mangan-
ese losses of the first 2 types may be obtained from the following
data (Table 5)0
TABLE 5
LOSSES IN MANakNESE DURING SMELTING OF SPECIAL AND COMMON PIG IRON
(in Percent)
Absorbed by
Product Volatilize pigs slags
Ferromanganese 10 75-80 10-15
Spiegel 5 75-80 15-20
Foundry pig iron o 7o.75 2.5,030
Bessemer pig iron 0 60-70 30-40
Martin and Thomas Converter pig iron 0 50-60 40-50
Foundry and converted pig iron on
charcoal 0 4O-50 50.2o
3. The presence of large quantities of silica with a low c.
tent of alkaline earths compels to add to the charge appreciable
quantities of limestone in order to flux the silica and aluminum
oxide as well as to create the most favorable conditions for the re-
duction of manganese. Consequently, the smelting of ores richer in
silica even with coke rich in ashes will result in obtaining large
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quantities of slag with a great loss of manganese and conversely
with a lower extraction of metal under an unfavorable ratio of
manganese to iron. For example, calculations indicate that from
ore containing 140 percent manganese and 25 percent silica it is
possible to obtain almost twice as much metal as from ore contain-
ing 30 percent manganese and 35 percent silica although the man-
ganese content decreased by one quarter only. It is clear from
this that it is not possible to smelt high grade manganese alloys
from ores very rich in silica,
From this point of view it is absolutely inadvisable to mix
rich ores (with a 40-45 percent manganese content) with poor ores
containing 20-25 percent manganese, as is the practice in some
mines, for increasing the weight of ores delivered to the plant.
It is fully clear that such imeasures, based on lack of knowledge,
are very harmful.
In addition, the metallurgical practice also shows that in
order to combat large losses of manganese in slags, it is necessary
to observe the following conditions: (1) increase the basicity of
the slag by increasing the amounts of calcium oxide and magnesium
oxide, and (2) heat the blast to a maximum temperature (not under
800 degrees) and increase the amount of coke while maintaining the
hottest temperature in the furnace, which may be controlled by ob-
serving the silicon content of the metal.
4.
.00
Fully satisfactory smelting results are achieved with slag
having a ratio of Si02/ CaO se 0.8 to 009. For ores containing ap-
preciable quantities of manganese (above 10 percent) this ratio may
be reduced even to 0.7 since manganese ores have a greater fluid-
ity than the purely calcareous ores.
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4. The amount of manganese and iron in the obtained melt
represents 90 percent, the remainder is carbon (up to 5 to 7 per-
cent) silicon and phosphorus. In the process, because of its al-
most complete oxidization, the iron content increases 2 to 4 times
(while there is a simultaneous important loss in manganese) as com-
pared with the original content in the ore (depending on how rich
the ore is in manganese).
This is easily demonstrated by the following simple calcu-
lation. (The material balance calculations for blast furnace
charges for a given final product involve complicated mathematical
and graphic methods.) Suppose we have a richer ore in lumps con-
taining 50 percent manganese and 5 percent iron. Assuming the rate
of reduction of manganese to be 75 percent and the amount of iron
and manganese in the pig iron to be 90 percent, the calculation will
show approximately the following composition of ferromanganese: Mn
about 80 percent and Fe about 10.5 percent (that is more than twice
as much as compared with the initial content in the ore).
It is clear from this that in order to produce high quality
grades of ferromanganese the iron content of the ores must be at a
minimum. The ratio of manganese to iron in the rich ores should
not be lower than 70 In extreme cases it can be reduced to 6
(provide8 4,4-re-btalAluznAge is in excellent working order).
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S. In the smelting of special grades of ferromanganese from
manganese ores, extreme attention must be paid to the phosphorus
a
cortant which is considered as/harmful ingredient. Phosphorus, as
well as iron, during the smelting process pass into ferro alloys
if not completely at least in the amount of 95.75 percent of the
original ore content. During the smelting of steel) when ferro-
.7.
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manganese is added the phosphorus is almost completely absorbed.
Inasmuch as the ferromanganese, as a reducer, is added to the tank
at the very end of the steel smelting process before the steel is
poured, it is clear that the phosphorus content in ferromanganese
should not exceed established limits if the required special grades
of steel are to be obtained. It is also necessary to bear in mind
that the phosphorus is transmitted not only by the ores, but durig
smelting by the flux and coke cinders, which also mast be of a cer-
tain standard.
The phosphorus content in ores is usually calculated not in
absolute figures but in parts of 1 percent manganese.
It is self evident that if the ores are subjected to a con-
centration and during this process there is a partial reduction in
phosphorus content, by the elimination of rock containing not any
metal, as it is often the case, then the limits of acceptable phos-
phorus content (as well as other ore components) should be revised
in evaluating the obtained concentrates.
With respect to the sulphur content in ores as a harmful in-
gredient, it is of no great importance in the smelting of manganese
ores inasmuch as sulphur passes on easily to the slag in the form
of MnS (Alabandite) and CaS (Olahamite).
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If there is another harmful ingredient,Jx.the mbliganese ores
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arsenic (which is seldom the case) it volatilizes to an impor-
tant degree with the escaping gases in the hot furnace, although
some parts are retained in the pigs.
6. Sometimes alloys of useful metals may be found in the man-
ganese ores) usually in insignificant quantities (cobalt) nickel,
al 8
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vanadium) which are almost fully reducible. Only vanadium partly
(up to 10-40 percent depending upon the performance of the furnace)
passes on to the slag. It should be borne in mind, in this con-
nection, that the addition of ferromanganese, during the convers-
ion of pig iron, is carried out in very small quantities. There-
fore, the presence of these elements in manganese ores or in con-
centrates within the limits of a few hundredth or tenth parts of
1 percent will practically have no influence on the purity of the
manufactured steels. This is also applicable to those manganese
ores which are used as furnace charge in the production of ordin-
ary pig iron.
If the ores contain copper, this also is completely reduced.
Zinc partly passes on to the slag or is volatilized, and partly
forms a crust. Lead accumulates on the bottom of the furnace and
has a harmful influence on the layer, penetrating into the joints.
From the viewpoint of metallurgical economics, it is impor-?
tant that manganese ores and concentrates Obtained from them should
have a sufficiently high manganese content (or total manganese and
iron), to be poor in silica and rich in alkaline earth components,
and finally contain a minimum quantity of phosphorus*
The requirements which the metallurgical manganese ores
must meet, depending on the purpose for which they are to be used,
may be summed up as follows,
?
Ores for the Smelting of Ferromanganese
Ferromanganese of standard grades of all alloys of manganese
and iron is of the greatest importance in the production of steel.
A high manganese content in the alloys decreases the amount of ad'
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ditions and simplifies the process of steel production.
In accordance with the general standards of the Soviet Union
(GOST 805-41) blast furnace ferromanganese is produced in 2 grades:
FM-1, FM2, each one subdivided in classes A and B depending on the
content in phosphorus (Table 6).
TABLE 6
ELEFENT CONTENT IN FERROMkNGANESE ACCORDING TO
GUST 805-41
Element Content (in percent)
Grade Silicon Manganese Phosphorus
Class A Class B
FM-1 2.00 75.1 0.35 0,145
FM-2 2.00 70.0-75.0 o035 o40145 0,03
Sulphur
0.03
In addition to the above cited grades of ferromanganese, non-
standard grades of ferromanganese are produced from lower quality
manganese ores containing 50-60-70 percent manganese and up to 0.6
to 0.8 percent phosphorus. These alloys are used to a large extent
in the production of common grades of steel.
With respect to silicomanganese which is used in Western Eur-
ope as a reducer in the production of soft steels, no special grades
have been established either in the USSR or in foreign countries.
In foreign countries alloys have been made containing 55-75 percent
manganese, 20-25 percent silica and 5-20 percent iron. As already
indicated in the smelting of silicomanganese, although important
quantities of silicon pass into the metal, the reduction of the
manganese itself i46,ppreciably increased. Because of this, the
percentage content in phosphorus in the alloy is much lower than
in ferromanganese produced from the same ores.
N. 10 116
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Considering the requirements of metallurgy and the\eblemical-
mineralogical characteristics of common types of manganese and some
iron-manganese ores) it is necessary to distinguish the following
grades:
Grade I -- with a content in the raw ores or in the concen-
trates of over 40 percent manganese and under 15 percent of silica.
Grade II-- with a manganese content of 40-35 percent and sil-
ica 15-25 percent.
It is important to break dawn the ares of Grade I according
to silica content: I-A with a content of Si02 up to 9 percent) and
I-B with a content in Si02 of 9 to 15 percent,
The ratio of manganese to iron in the ores of type I-A should
not be lower than 6-7 and for the ores of type IB not lower than 8-10.
The phosphorus content of rich ores should not exceed 000030
to 000035 percent of 1 percent of manganese provided the smelting
is done with coke of low phosphorus content, (At the end of the
book a table of calculations will be found (see appendix II).) In
the production of lower quality) non-standard grades of ferroman-
ganese) if such are used in cases of necessity) the upper limit of
phosphorus content may be increased to 0.0045 percent of 1 percent
of manganese.
Thus) the classification of manganese ores (or concentrates)
suitable for the production of ferromanganese generally may be
summed up as f9pws (Table 7)0
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TABLE 7
REQUIREMENTS FOR MANGANESE ORES (AND CONCENTRATES)
SUITABLE FOR THE PRODUCTION OF FERROMANGANESE
Type Mn SiO2 Mn: Fe P
I-A over 50% up to 9% not under 6-7 up to 0.17-0.20%
I-B 40-50 9-15 it tt 7-10 It II 0.14-0.17
II 35-40 15-25 tit II 3-4 ii ti 0018
III 30.35 25-35 it ti 4-5 II II o.15
It is necessary to point out that the ores of Type I in the
above classification are earmarked for the extraction of standard
grades of ferromanganese. Ores of Types II and III are used for
this purpose in cases of extreme necessity only) provided the iron
and phosphorus (The ratio Mn: Fe should not be lower than 12-15 and
the phosphorus content not over 000035 percent per 1 percent Mn.)
content are very low. If this is not the case these ores may b
used only as charge in the smelting of spiegel or converted and
foundry pigs from iron ores. Ores with a high content of alkaline
earths (oxides of calcium and magnesium) may be an exception to
the rule.
Generally) it is necessary to emphasize that the presence of
appreciable quantities of calcium and magnesium in manganese ore is
extremely desirable as this will permit to decrease the addition of
? , . ?
limestone anddDlomite to the charge. It should not be forgotten
that each 5 percent of calcium and magnesium oxides permit the use
of ores with a silica content of LI percent above the limit. There-
fore) in sampling deposits it is necessary to test the content of
calcium and magnesium oxides in the ores. It was already indica-
ted that the best ores are self-fluxing ores rich in manganese and
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alkaline earths but poor in phosphorus, the content of which is nat
to exceed the above indicated limits. Such ores may be used in the
production of standard grades of ferromanganese. The manganese con-
tent requirements for such ores may be lowered to 32 to 35 percent.
Such are, for example, the ores of the Sapal deposits and some lay-
ers of silicate-carbonate ores of the USSR in deposits* Similar di-
vergencies may be encountered among ordinary carbonaceous sedimen-
tary ores rich in phosphorus.
For the production of silicomanganese, ores may be used that
are hard to concentrate and are richer in silica than indicated for
Types II and III* Therefore, the requirements for phosphorus con-
tent in ores are also lowered if the manganese reduction is high
and in addition if an appreciable quantity of silica passes on to
the metal. In such case, up to 0.006 percent of phosphorus per 1
percent of manganese may be acceptable.
.912.11:132.2_5111eltirlualall_And S.L122.giegel
These alloys are substitutes for ferromanganese in the pro-
_
duction of a series of solid, medium and high carbon grades of
steel* For this purpose, iron manganese ores are usually used.
Spiegel, depending on the
3 grades, in accordance with the
2-4 with a content of 2001-2500%
Z-2 with a content of lg.01,204-0%
Z-3 with a content of 100%150
manganese content) is produced in
USSR standards:
manganese and 0022 % phosphorus
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a NI a.
manaiid 0020 % phosphorus
a
manganese and 0.18 % phosphorus
Silicospiegel is produced in
1800-24.0 percent manganese, 9.0-13,
phorusi
one grade S Sch-1 containing
0 silica and 0020 percent phos-
MI13 Ite
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In addition to these grades, the ferrous industry is using
also non-standard grades of spiegel, particularly those richer in
manganese but still limited as to their phosphorus content? Silo
icospiegel may be used with a lower content in silica (4 8 percent).
Spiegel is smelted from manganese ores rich in iron, from
which standard ferromanganese cannot be obtained* The best ores are
those containing highest quantities of manganese and iron and low-
est quantities of phosphorus. Various grades of spiegel may be ob-
tained depending on the ratio of manganese to iron in the ores.
Priority is given to ores richer in manganese ores containing more
silica which may be used for the production of silicospiegel.
Considering the composition of various types of Spiegel it
is possible to give a general classification of grades of ferro-
manganese ores suitable 'for this purpose (Table 8)o
TABLE 8
REQUIREMENTS FOR FERROMANGANESE ORES SUITABLE FOR THE
PRODUCTION OF SPIEGEL AND SILICOSPIEGEL
Type Mn+Fe Mn:Fe SiO2
50-60% 105 0.6 up to 15% up to 0009-$0018%
II 40.050 200-008 15s$25 0008000015
III 30-40 25-435 0007-0.12
As the ratio manganese to iron indicates, a wide range of
variations in manganese content may be encountered in ores of this
class. The best raw material is ores of Type I and II with an ave-
rage manganese content not lower than 18-20 percent. The use of
ores of Type III for the production of spiegel, particularly if
they are rich in silica and poor in alkaline earths, should be un-
dertaken only in cases of extreme necessity. This also applies to
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ores in Classes I and 11 poorest in manganese, particularly if they
contain quantities of phosphorus above the specified limits. If
this is the case, such ores as well as ores of Type III may be used
only as a charge for the production of ordinary pigs*
Strict demands are made on ores as to phosphorus content.
The limit content of this harmful element in ores destined for the
melting of spiegel is established at 00009 percent per 1 percent of
manganese contained in ores. (Calculation tables on phosphorus
content are given at the end of the book (see Appendix II)0 This
will explain the wide range of phosphorus variation, shown in Ta-
ble 8, for each type of ore*
In nature, however, are encountered more often manganese ore
deposits poor in iron which are not suitable for the production of
ferromanganese, because their manganese content is not sufficiently
high. Such ores, provided their phosphorus content falls within
the limits, may be used for the production of spiegel and silico-
spiegel only with an appropriate addition of iron ores poor in phos-
phorus and iron and steel shavings. (In the production of steel,
spiegel is to be fed in sizeable portions and therefore it is added
in liquid form in order not to disturb the smelting process. For
this purpose, specia34furnaces for the smelting of pigs are built
in the steel plants called cupola furnaces.) As in all other ca-
ses, the ferromanganese-oms rich in calcium are of particular ins.
46s.vg? ?v?drok"..?*....4"""."...rommeillom".?""41.?"4?.
terest and may often be found in carbonaceous varieties of ores.
With respect to ores suitable for the manufacture of spiegel,
which is less essential to the ferrous metallurgy, the lack of ex-
tensive production experience in using them for this purposes does
not yet permit to formulate special requirements for such ores. In
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general, however, such requirements coincide with those of raw mate-
rials suitable for the production of spiegel except for the silica
content which in this case is not liarmful.
Ores for the Production of Manganese Pigs
For these purposes manganese iron ores are used. They are
not widely found in nature. However, some known deposits contain
rather important reserves of this type of raw material.
Manganese pigs containing 5-10 percent of manganese destined
for the carburization and deoxidation of steel may be smelted from
manganese iron ores for which ordinary requirements are:
a. Iron content should be 40 percent or over;
b. Manganese content -- to lo percent;
C . Phosphorus content not to exceed 0.05 percent in the
ore.
The strict requirements with respect to phosphorus in ores
are due to the fact that in steel production manganese pigs are fed
into the furnace or ladle in important quantities at end of the
smelting process. The phosphorus has no time to flux and is gen-
erally absorbed by the steel.
Ores as Basic Fluxes for Steel Melting in Martin Furnaces
0.1411.......16?WMOM?101.11??????11FIV.1.4?????????010r1?010..NOWAI 0.0.00.*W01,~01810.1
Rich in calcium manganese ores, which are seldom found in
nature, are a very precious raw material for the ferrous metallurs?
gy (particularly ores poor in phosphorus) for :various. puuoses: a.
As tests have indicated, even with a law content of manganese (8.012
percent) they may, as fluxes) replace to a large extent ferromangan-
ese in Martin furnaces; b. Mixed with iron ores or shavings, they
may be utilized in blast furnaces for the production of spiegel, and
-16a.
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they may be obtained from ores rich in silica-silicospiegel. In
addition, their utilization as fluxes will probably make it pos-
sible to obtain ferromanganese from relatively poor silicomangan-
ese ores, and also manganese pigs from iron ores.
The requirements for these types of ores are not yet worked
out, but according to existing experiences rich in calcium ores
with an 8-12 percent manganese content and about 0.005.0.006 per-
cent phosphorus per 1 percent manganese are of definite industrial
importance?
Recently carbonaceous ores poor in calcium (5-10 percent)
and richer in manganese (up to 20 percent) were tested for this
purpose at the Serov plant, It was determined that these ores,
used in steel production in Martin furnaces, have a beneficial ef-
fect on the liquefaction of tough slags and at the same time per-
mit a sharp reduction in the consumption of ferromanganese.
Ores for Charges, in the Smelting of Ordinary Pigs from Iron Ores
in Blast Furnaces
As already mentioned, manganese and ferromanganese ores poor
in manganese or rich in phosphorus are used for this purpose. The
value of these ores is naturally appreciably lower compared with
ores suitable for the production of the above mentioned special pigs.
If an iron ore contains close to 1.3 to 1.7 percent mangan-
ese, it may be used for the manufacture of converter pig without the
?
. V ??
addition of manganese ores. With some modificati:ons, in connectibri
with special processes of steel production) a manganese content in
iron ores of 0.8 to 1.0 percent may be considered sufficient for
the production of ferromanganese converter pigs with 0,6-0.8-1,0
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percent Mn. However, inasmuch as the main operative deposits of
iron ores contain a lesser quantity of manganese, it is necessary
to add manganese to the furnace charge in the form of Martin slags
and manganese ores, or only manganese ores and green slags (depend-
ing on the availability of such slags and the acceptable amount of
phosphorus in the melted pigs).
Usually ores with a manganese content of 20-30 percent are
used for this purpose. This content may be lowered to 10-15 per-
cent provided it contains 15 percent or more iron. The general man-
ganese content in the ore charge (including the manganese in the
iron ore itself) should amount to 25-30 kilograms for each ton of
pig.
An iron content in these ores is generally desirable, the
more iron, the better.
The requirements relative to phosphorus are logered compared
with the requirements on ores used for the smelting of special pigs
inasmuch as the manganese added to the charge is fed to the furnace
in loads and in the ore smelting process the phosphorus may be
fluxed. The acceptable phosphorus content in manganese ores for
these purposes is up to 0.3 percent.
A high silica content is not desirable since its scorifica-
tion not only requires additional quantities of limestone) but also
-tdquires an additional expenditure in coke which lowers the produc-
tivity of the blast furnaces ? The desirable silica content in manm
ganese ores added to the charge should not exceed 35 percent but in
case of necessity it may be acceptable at 45-5o percent. Ores with
a high silica content are used in the smelting of foundry pigs.
171
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II. PHYSIGILL REQUIREMENTS FOR ORES
The requirements as to the chemical composition of manganese
ores were laid down above. However, the physical properties also
are of great importance*
The most desirable for the ferrous industry are hard ores,
which do not have to be concentrated and which during processing
give lumps not containing small particles* Such ores can be eas-
ily transported and do not have any large losses during strong blast-
ing in large blast furnaces. The loading weight also depends on the
size of the ore lumps which is of importance to the ore transporta-
tion. Therefore, in surveys it is necessary to establish the char-
acteristics of ores according to the size of the material. If the
ores contain important quantities of small particles (under 5 mil-
limeters) it is desirable to sift the ores in order that the smaller
parts may be compressed into bricks or agglomerated, or used in the
chemical industry*
Large pieces of manganese ore are crushed on the ore yards
near the blast furnaces into morsels of 50 to 70 millimeters in or-
der to create more favorable conditions for the reduction of the
ore mass. In surveying new deposits it is extremely desirable to
indicate the degree of friability of the ores, resistance to press-
ure and other mechanical properties which are important for the or-
ganizatiods planning and designing projects, concentration, and met-
allurgical plants. It is desirable that the resistance of the lumps
to pressure should not be under 60 kilograms per square centimeter*
Ores are subjected to concentration in cases where it is nec-
essary to increase their quality, in particular) to increase the
metal content and eliminate the parts not containing metal or reduce
..19.m
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the content of harmful admixtures. For manganese ores, as is also
the case for all other useful ores, the beneficiation process de-
pends largely on the physical properties and in particular an the
structure and texture of the ores* As is known, the texture and
structure of the ore components determine the necessary degree of
crushing. Therefore, in surveying deposits, special attention should
be given to the formation characteristics of the various types of
ores and an approximate calculation should be made on the quantita-
tive importance of the texture of the ore components. This applies
particularly to ores composed of oolite-like concretions, ores in
their layers, etc.
Inasmuch as the products resulting from the concentration of
manganese ores are chiefly fed into blast furnaces, it is natural
that attempts are made to employ ordinary and comparatively cheap
ore concentration methods such as sifting or washing of the ores,
and in the case of preliminary crushing concentration is done by
jigging machines in order to obtain a maximum number of large size
classes (over 5 millimeters) of preliminary concentrates* However,
if the ore is subjected to a satisfactory preliminary concentration,
an ore deposit with particle size of under 5 millimeters maybe con-
sidered of industrial value, provided there are large reserves of
it which will insure the work of the concentration plant for a def-
inite amortizable period and under favorable economic regional pre-
. 4t
requisites*
Expensive concentration methods of fine milling and grindirg
of the ore and subsequent flotation are used in exceptional cases)
when the deposit is large or the ore cannot be subjected to a suit-
able preliminary concentration by any other method: True) the powm
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der-like concentrate obtained by this method is of high quallik but
it absolutely requires pressing into bricks and agglomeration. It
is desirable to prepare an agglomerate of a self-fluxing composit-
ion and add, in addition to coke, the necessary quantities of cal-
cium-containing materials.
The porosity of the texture components (oolites, concretions,
ore layers, etc) indicates, on the one hand, a positive, and on the
other hand, a negative influence on theproperties of manganese oreso
The importance of the porosity of ore components is such that
it is strongly reflected on the degree of reduction of manganese ox-
ides and, consequently, on the efficiency of the blast furnace, the
time required for the processing of a charges and fuel expenditure.
The water containing pyrolusite-psilomelane ores, namely, the pri-
mary oxides of young precipitation-deposits as well as ores of man-
ganese hats have the greatest porosity (Tchiatoursk, Polounotch and
other regions). The anhydrous hydrometallic and metamorphogenic
deposits have the lowest ore component, porosity (deposits of Sapal$
Central Khazakstan, etc). Therefore, they are much harder to reduce.
On the other hand, the porosity of the ore greatly increases
its capacity to absorb water. The moisture content of such ores
often reaches 12-15 percent and in some types of ores of the Tchia-
tar deposits it reaches 18-25 percent. It-ie seif.bevident that
this is of great importance in the transportation of the ores. A
high degree of moisture content increases appreciably the weight of
the material per cubic meter of ore, consequently, the freight ex-
penses. In addition, the high moisture content of ore deposits lo-
cated in the northern latitudes causes them during the winter to
freeze and stick to the walls of the storage bins. Moisture also
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affects the normal loading of the blast furnace which must work at
a low production rateo
In addition to absorbed water (moisture) the ores may also
contain water, chemically combined with some minerals (manganite,
psilomelanel vermadite and others). This water may be removed by
heating to 110 degrees Centigrade, In the process of heating in
the blast furnaces the loss of such water sharply increases poros-
ity and consequently the specific surface. This increases the re-
duction speed of manganese oxides. From this point of view the an-
hydrous braunite-hausmannite ores, having lower qualities, have to
be crushed in order to increase the specific surface, which results
in agglomeration.
The thermal stability of ores, that is, ability to regain in
lumps at high temperatures, also influences the efficiency of the
blast furnace. More or less compact oxide and hydro-oxide mangan-
ese ores usually withstand high temperatures. Only soft, moist ores
dry out and crumble in the heating process. This causes high los-
ses during strong blasting, not to mention that a large amount of
small particles strongly affects the gas permeability of the charge
by creating at the blasting places passages for the non-productive
stream of gases and by clogging in other places the spaces between
the lumps of the charge. With respect to carbonaceous ores, these
ores are subject to strong cracking-up and,srambITITO'high temper-
4 ? .? ? 4.0 'W. 04.4.
as a result of the dissociation of carbon and large libera-
tion of carbon dioxide. In some cases, where it is necessary to re-
sort to preliminary oxidizing burning, the pure carbonaceous ores
practically lose their lumpiness or the strength of the lumps them-
selves is sharply weakened if admixtures of binding substances are
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not used* Only the opale-carbonaceous manganese ores do not change
appreciably their lumpiness during burning. The cracking of carbo-
naceous manganese ores at high temperatures must not be considered
as an adverse factor of blast furnace efficiency since the dissocia-
tion of carbonates is carried out at high temperatures (700-800 de-
grees Centigrade, judging by the temperature recorders)* On the
contrary, when using manganese limestone and calcium-manganese ores
as basic flux in the Martin furnace, the cracking up and pulveriza-
tion of the carbonaceous substance at places of contact with the mel-
ted metal is an extremely favorable factor contributing to the re-
duction of manganese ore to metal.
The clinkering capacity, i.e., the ability of the mineral
powdered substances to form during burning nodulizing combinations
with manganese ores, represented by hydrous-oxides (psillomelane-
pyrolusite and manganite varieties), is found to vary considerably*
Ores represented by anhydrous minerals (braunite, hausmannite) do
not have these properties at all, Clinkering experiments made at
the Magnitogorsk Plant on ores of the Tchiatur region indicated
that, although the clinkering action is not normal (because of the
lump part), the obtained agglomerate, however, is sufficiently
strong. Thanks to the elimination of appreciable quantities of
coMbined water and parts of oxygen (from the dissociation of pyre-
, ....lusitg)4.thpsoyosity and, consequently, the degree of reduction of
4 ? id ? 4
the agglomerated ore should increase sharpl The preparations of
self-fluxing agglomerates is, of course) the most rational) i.e.)
with admixture of fuel and slag components.
B. Chemical Ores
OIM.044411444a4V14?4404444.4044110461M11.4?1?444?Vaya
In the chemical industry manganese ores are used for various
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purposes in the production of dry electric batteries, in the pre-
paration for the same purpose of articifially activated products
from pyrolusite ores) in the glass industry for the discoloration
of green glass) in the production of chemical preparations used in
medicine) in the preparation of special anti gases for protection
against carbon oxides) catalysts of the hopealite type for the clean-
ing of automobile engines from harmful admixtures in the exhaust
gases, in the production of drying oil, grease, wax, in the procac-
tion of chrome leather) in photography, preparation of paints for
porcelain and glazed pottery) in the production of bromine, iodine,
etc.
For industrial chemical uses, particularly for the produc-
tionof dry electric cells, only those of the numerous manganese
minerals are of importance which contain manganese dioxide in the
largest quantity* Such minerals include: pyrolusite minerals) of
the psilomelane and venanzite groups. The remaining hydrous ox-
ides and oxides of manganese (manganite) braunite) hausmannite and
others) are less important for such purposes*
Among the manganese deposits containing ores rich in 4-va-
lence manganese) suitable for the chemical industry, of most imporp
tance are the comparatively young sedimentary, stratified deposits
(of the Tchiatur deposit type) and the oxidization zones of the de-
posits, regardless of their genetic type. For these industries in
which the superficial energy of the mass is used) the fully oxidized
04
manganese ores are particularly valuable (in particular the so-called
?
? 4
black belts of the Tchiatur deposits)) having an ums iti cov-
ered crystalline porous mass of pyrolusite of low consistency.
Of all the above named chemical uses the production of drywm
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cells assumed the greatest importance in the past 25 years, especi-
ally in connection with the development of radio technology. Tests
carried out in the past years have shown that the content in Mn02 In
the ore used for these purposes is not critically important as the
depolarization depends on the decomposition speed of the manganese
dioxide which,apparently, is related to the degree of dispersion of
the material used.
Pyrolusite ores are used advantageously for these purposes.
The requirements for ores used in the production of dry electric bat-
teries are generally as follows:
10 The content of manganese dioxide is not to be lower than
80 percent, i.e., in terms of metallic manganese content not under
50 percent;
2. Iron content is not to exceed 3 percent;
3. Calcium is acceptable up to 2-3 percent;
40 Soluble combinations of cobalt, nickel and arsenic are
considered as extremely harmful elements and only traces of these
elements are acceptable.
5. Copper content is not to exceed 0.2 percent.
Silica and phosphorus have no substantial importance. Sim-
ilarly, there are no special requirements as to the physical prop-
erties of the ores. For this purpose small grain concentrates, which
.4 are sometimes obtained in important quantities during the concentra-
tion of meiallic.orts, may also be used successfully.
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