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By Sanjay Agarwal

Polymetallic sea nodule is a good source of manganese having 22.3% Mn, 5.4% Fe, 6.14% Si, 1.1% Cu, 1.15% Ni, 0.076% Co & others. These nodules are available in plenty on the sea beds, generated over thousands of years. Nodules mainly consist of manganese dioxide and iron oxide phases and other metals are entrapped in the complex cage of these Mn-Fe oxides phases.World-wide research is going on sea nodules as an alternative future source of many metals, which has led to intensified efforts to develop practical and economical processes for recovery of these metals. Very little attempt has been made world over on manganese extraction from sea nodules. We at CSIR-NML, India have developed a direct reduction smelting process of nodules to recover manganese as Fe-Si-Mn alloy. This alloy is extensively used in the steel industry as deoxidizer and as an alloying element to make different grades of steel. Lab scale experiments were conducted to study the manganese distribution between Fe-Si-Mn alloy and FeO-SiO2-MnO-CaO-Al2O3-MgO slag at different temperatures by varying the basicity of the slag. The direct reduction smelting of nodules is carried out on 1 kg scale in 50 kVA electric arc furnaces to have Cu, Ni and Co alloy and Mn rich slag. This manganese rich slag is further treated in 50 kVA arc furnace to produce Fe-Si-Mn alloy. The composition of Fe-Si-Mn alloy obtained is in the range of Mn: 60-65%, Si: 14-17%, C: 1- 2%, S: 0.03% and the balance iron which is acceptable grade for industrial use. The equilibrium amount of MnO in the final slag is controlled by the temperature of the final melt and the silica, lime, alumina content of the final slag. Increasing the basicity of the slag plays a major role in minimizing the loss of MnO to slag, increasing the amount of SiO2 of the slag, increases the manganese loss in the slag. Increasing the CaO/ Al2O3 ratio of the slag decreases the manganese loss in the slag. Increasing the MgO/CaO ratio of the slag increases the manganese loss in the slag. Thus by adjusting

Sep 1, 2012

By Wilhelm Schwarz

Manganese nodules lay in vast areas of the deep sea floor. Ideal harvesting conditions for a manganese nodule field are dense nodule abundances of nodules between 20 and 60 mm diameter and a metal content as high as possible. With regard to the development of collector technology, the properties of the deep sea soil, in which the nodules are embedded and to which the nodules stick, are of major interest. The forces for loosening the nodules have to be provided by the collector. For this purpose water jets and/or mechanical devices can be employed. For the choice of the best collecting procedure, various criteria, such as collecting rate, energy consumption and the environmental impact on the eco system of the deep sea floor, have to be considered and weighted as to their importance. Nowadays, the concept of a mining system with a flexible transport hose and a self propelled collecting machine is increasingly accepted among the expert community. With regard to the trafficability of the deep sea soil with a self propelled mining machine, the mechanic properties of the soil and the morphology of the deep sea floor are of special importance. The manganese nodule fields, which are interesting with regard to their recoverability, are mostly in the areas of tectonic fracture zones, at which the morphology of the sea floor is formed by vulcanic activities. In these areas, deep sea mountains, pits and other obstacles exist that have to be driven around if not trafficable.

Jan 1, 2003

By William D. Siapno

Approximately a century lapsed between the time nodules were discovered and the beginning of commercial exploration in the early 1960's. A period of rapid development of exploration and mining technology ensued over most of the next two decades. In recent years advancement has been sharply curtailed. This paper discusses the constraints inhibiting nodule mining and some developments that could aid in overcoming certain difficulties. Specifically, the greatest single constraint is economic. With few exceptions mineral markets are badly depressed. Present projections for development of nodules are for the late 1990's or beyond. However, the U.S. awarded exploration licenses in mid-1984 and more recently boundaries of license areas have been released. These conditions promote cooperation among organizations engaged in deep ocean mining. Survey data, and where appropriate some data products, have been exchanged between various consortia. The present hiatus in at-sea activities provides an excellent opportunity to investigate the best means to proceed. This period of quiescence offers a rare moment to distill the meaningful values of an era of hectic activity to permit more efficient development in the future.

Jan 1, 1985

By Carl Zapffe

THE object of the Bradley process is to free manganese oxide from its associated gangue and separate the contained iron oxide by dissolving the manganese and precipitating it from the solution. 'The fundamental features of the process are : making. both 1 a manganese ore and an iron ore; effecting a separation of manganese .and. iron by means of selective roasting; leaching- the manganese from the roasted ore by using ' ammonium sulfate; precipitating the manganese by using the ammonia gas generated during leaching; fixing the precipitate by oxidizing with air; breaking down and reforming the ammonium sulfate, so that daily very little additional ammonium sulfate beyond that originally charged into the system is required; washing the manganese precipitate and the iron-silica residue and evaporating the liquor to conserve the dissolved salts in the moistures of these two products and 'to reduce the sulfur content,; drying the precipitates; magnetic wet-concentration of the iron-silica residue; sinteriny the manganese-and .the' iron-concentrates.

Jan 1, 1929

By Felicia F. Peng

The naturally occurring aged manganese oxide coated on the granular media was found to have a catalytic effect on the removal of low concentration of Mn(II) (-1 ppm) from drinking water. Applying this principle, a manganese removal technique was developed for removal of higher concentration of Mn(II) (-100 ppm) from mine drainage by using various aged filter media and synthesized granular media with manganese oxide coatings. Laboratory-scale continuous granular media column experiments were conducted to assess the feasibility of manganese oxide-coated granular media for Mn(II) removal from synthesized mine drainage. The removals of Mn(II) were evaluated as a function of operation parameters including solution pH, manganese oxide concentration coated on the media, interstitial velocity, and oxidant concentration of influent. Higher solution pH and/or higher manganese oxide concentration promoted the removal of Mn(II) on the oxide-coated granular media under low interstitial velocity. Addition of sodium hypochlorite as an oxidant in the influent resulted in continuously regenerated oxidized surface to serve as the catalyst for Mn(II) oxidation reaction on the surface of oxide-coated media.

Jan 1, 1994

By M D. Urbani

HiTec Energy Ltd has been conducting research since 1996 into novel process routes for the treatment of low-grade and waste manganese sources for the production of high value and high quality electrolytic manganese dioxide (EMD) for the alkaline battery market. HiTecÆs approach is to treat previously unsaleable manganese deposits and mine site tailings using a novel sulfur dioxide leach route, followed by purification and electrowinning to generate the sought-after EMD product by an environmentally superior processing route to those presently practiced throughout the world today.HiTec Energy Ltd expects to be in commercial production with its Stage 1 facility in Kalgoorlie in the last quarter of 2004 for the production of 12 500 tpa EMD. With this production facility being adjacent to a laterite nickel producer with available waste manganese units, the opportunity arose for HiTec to combine its existing technologies with processes (that will be discussed in this paper) to turn two waste by-products into products that are used for high-tech purposes.HiTec Energy Ltd and the Parker Centre have had a collaborative research relationship for a number of years in areas involving EMD and battery related technologies. Meanwhile the solvent extraction (SX) group of the Parker Centre (CSIRO Minerals) has developed SX processes to separate manganese from nickel and cobalt. A project was initiated by HiTec Energy to recover manganese from waste laterite leach solutions using SX technology. Batch tests were conducted to select a suitable organic system for the extraction of manganese in terms of selectivity and extraction and stripping kinetics.A total of eight organic systems were tested by determining pH isotherms of metals using a laterite nickel process waste stream. Two organic systems, the Versatic 10 and Versatic 10/synergist systems, were chosen for further test work with Shellsol D70 chosen as the diluent for both systems.The Versatic 10/synergist system would be advantageous over the pure Versatic 10 system because fewer SX stages are required, resulting in a smaller organic inventory and lower capital costs. The risk of gypsum formation is also significantly lower with the synergistic system.

Jan 1, 2004

By J. W. Jensen

EXTENSIVE research and development was performed on the manganese-copper vibration-damping alloys to determine the relationship between the properties of the alloys and variations in composition, fabrication, Mid heat treatment. Mn-Cu alloys with unusually high specific damping capacity, 20 to 25 percent at a stress of 5,000 psi, have also the following useful properties: Tensile strength, 90,000 to 110,000 psi; yield strong, 60,000 to psi; elongation, 20 to 25 percent; hardness, 90 Rockwell B; and fatigue limit at, 28,000 to 30,000 psi. Both standard and special methods of testing were employed to obtain data on strength, modulus, hardness, resistivity, dilatation, micro-structure, crystal lattice, and damping capacity. The extensive tabular and graphical data on these properties are presented for alloys containing 50 to 85 percent as quenched d solution) and after various aging treatments. Expansion coefficients for all Mn-Cu solid solutions are graphed and a dilatometer study of contraction during aging is reported. Although high damping capacity is associated with aging to precipitate a-Mn from solid solution, with a cubic-tetragonal transformation and with the occurrence of antiferromagnetic ordering in Mn-Cu alloys, a tenable theory of the damping mechanism has not been reached.

Jan 1, 1965

By Frederick M. Becket

SHORTLY after the Armistice there appeared a few references to numerous attempts that had been made to produce steel without the aid of manganese, or at least with manganese in abnormally low percentage. Some years later, during two consecutive days of train travel, I had excellent opportunity to read Sir Robert Hadfield's book, entitled "Metallurgy-Its Influence on Modern Progress," and also his paper, "The Metal Manganese and Its Properties : Also the Production of Ferro-Manganese and Its History," presented at the spring meeting of the Iron and Steel Institute, 1927. Both the book and the paper are most interesting historically to makers of alloy steels and

Jan 1, 1931

By Bruce A. McFarlane

"I WOULD LIKE TO SAY how honoured I am that I have been invited to participate in this panel discussion. I have taken the liberty of narrowing my topic somewhat so that instead of speaking on the Sociology of Professions as a whole I will speak on one aspect of it, that is, on Manpower Problems in the Minerals industry of Canada, with some reference to a new social role for the professionals engaged in this industry. This probably means that I will be encroaching on areas covered or to be covered by other speakers, but I hope that when I do so I will do so from a slightly different vantage point. That is, from a sociological perspective rather than from a historical, industrial, business or professional perspective. I plan to divide my discussion into three areas, namely: (i) problems of ownership and control; (ii) environmental problems; and (iii) manpower and recruitment problems. I do not plan nor am I able to provide clear-cut solutions to the various problems I raise under these three headings. Rather, I hope that my discussion of the problems may form the basis for an extended discussion here and elsewhere. Because of the limitations of time, I will only briefly discuss the first two problem areas noted above – (i) ownership and control and (ii) environmental problems - and I plan to concentrate on the manpower issue."

Jan 1, 1972

By P Thwaites

The mining industry uses many types of mineral and metallurgical plants to produce saleable product from ore mined. Plant design history has left current operations with a mixture of manual operation and various forms of automated process controls. Consequently, we typically see high-variability in the continuous operations together with a shortfall in the attainment of full capacity or higher utilisation of consumables.At a level of best practice, ‘operational performance excellence’ focuses on process control, using automation and control systems to deliver process optimisation. This more sophisticated delivery is a great deal more difficult than the first stage of equipment selection/installation. It includes the appropriate selection of the right instrumentation and control system, key process knowledge, individuals with a solid control engineering background/experience and the essential backing/support of the operations management team together leading to higher-value delivery. Robust solutions can be realised, considerably minimising process variation, thus leading to process optimisation. This approach results in an easier, efficient and safer process while providing considerable returns for the plant owners.How variable are your processes, and do you maintain optimised process performance with dedicated resources, modern instrumentation, ‘best practice’ control systems and performance monitoring tools? In this paper, these questions and their possible answers are discussed.I say we can do much more and be ‘more efficient’ in our efforts to remain competitive. This area remains a major opportunity for improved efficiency, minimising tailings losses and other milling costs.CITATION:Thwaites, P, 2014. Manual control, process automation or operational performance excellence – what is the difference?, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 13–40 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Lewis C. Karrick

Although the Bureau of Mines has thus far made no large-scale experiments with oil shales, and the feasibility of the commercial manufacture of shale-oil products suited to present market requirements has not been demonstrated, there is ample reason to believe that these products will eventually supplement the more commonly used petroleum products and give equally good service. In 1919 the bureau, in cooperation with the Department of Metallurgical Research, University of Utah, began investigating the oil shales of the United States to obtain detailed information on their value. The States of Colorado and Indiana also cooperated through their State universities, in which research laboratories were organized to assist in carrying on the oil-shale studies planned and directed by the bureau. As a result of these studies much information is now available concerning laboratory methods of producing the greatest yields of the best products from oil shale. In order to study the principles that govern the retorting of oil shales and to test the oils produced, it has been necessary to develop and standardize reliable apparatus and methods for distilling shale, and to adapt to the testing of shale oils some of the methods the Bureau of Mines uses for testing petroleum. The methods employed by the Scottish shale-oil manufacturers were also studied, but most of them have been superseded by those described in this bulletin, which give more comprehensive and accurate results and employ more convenient apparatus. This paper is presented, therefore, as a manual of apparatus and methods that the bureau has developed for work on oil shale and found satisfactory for routine tests and for research. Explanation and discussion of the principles underlying the methods of testing are included wherever necessary for a clearer understanding.

Jan 1, 1926

By C. C. Henning

IN any line of human activity logical handling requires an amount of attention to each phase that is in keeping with the importance of that phase. In the complex and rapidly changing field of modern ferrous metallurgy it is difficult to allot the proper degree of attention to the various subjects, and it is not surprising that one or more subjects of major importance should for a time be neglected. Bessemer steel is a good example of a neglected subject. It is largely taken for granted, inferior physical quality is assumed for it, and there is a lack of interest in its technical development and commercial application. Availability of supply is limited. In spite of this technical indifference, limited source and lack of commercial exploitation, bessemer steel constitutes a large volume of tonnage in daily use. There is a fairly prevalent idea even among technical people that bessemer steel survives mostly because of low cost and by reason of a dwindling residue of applications sufficiently common to permit of its use. The difference in cost between bessemer and open-hearth steel is governed largely by the relative cost of manufacture of pig iron and the market price of steel scrap. During the past four years there have been long periods of time during which the price of steel scrap was low enough so that open-hearth steel was considerably lower in manufacturing cost than bessemer. As to application, it may be pointed out that thousands of tons of this material in the form of bessemer screw steel are applied for moving parts in automotive and other equipment, Some forging work and considerable heat treating, particularly carburizing, is performed on this grade. From an economic standpoint the most effective contribution of bessemer steel lies in its free machining qualities. It is by far the freest

Jan 1, 1935

By G. F. Miller

ONLY IN THE Province of Saskatchewan is natural sodium sulphate found in Canada in amounts large enough to make recovery economically sound. Geologists have estimated that the numerous deposits within the Province contain upwards of 200 million tons of Glauber's salt. There are twenty-one deposits in the Province which contain 500,-000 or more tons and about two dozen with lesser amounts. The first recorded production of sodium sulphate in Saskatchewan was in 1918. The company concerned, and others that attempted to develop the industry in its early stages, were unsuccessful. Their failures were caused by two main factors -lack of knowledge of efficient operating methods and the unstable market situation for the finished product. Today, the situation is changed in both respects and the product, commonly referred to as 'saltcake", is a very important chemical requirement of many industries throughout the world. Before proceeding with remarks on manufacturing methods it should be stated that, although this is a general paper on the manufacturing methods and end uses of the saltcake produced in the Province, the writer is, of course, more familiar with the plants operated by Saskatchewan Minerals than with other operations and perhaps may be excused for dealing more particularly with the plants of that Compa11y.

Jan 1, 1958

By Zhouhua Jinag

The attempt has been made to manufacture high nitrogen austenitic stainless steels by pressurized electro-slag remelting furnace with maximum nitrogen pressure of 7MPa. To obtain high nitrogen content in steels, the compound electrodes with different nitrogen sources (FeCrN, Si3N4) were prepared. Using the Si3N4 as the nitrogen alloying source, the silicon contents in ingots were prone to be out of the specification range, and the electric current fluctuated greatly and the surface qualities of the ingots were poor. The surface qualities of the ingots were improved using FeCrN as nitrogen alloying source. The sound and compact macrostructure ingot with the maximum nitrogen above 1.0wt% could be obtained. A series of high nitrogen austenitic stainless steels have been successfully developed by this method. The mechanical and pitting corrosion resistance properties of high nitrogen austenitic stainless steels were investigated. The results show that the steels exhibit excellent mechanical and pitting corrosion resistance properties.

Jan 1, 2009

G. B. WATERHOUSE,* Buffalo, N. -Y. (written discussion?).-One of the most essential features of rail manufacture is the production of rails that will give good service and be free from failures. To this end rails are made to careful specifications and their manufacture is controlled by rigid inspection on the part of both the producing mill and the railroad or its representative, such as the Hunt special inspection referred to in the paper. Captain Hunt refers to the crescent-shape base failures and describes them as ruptures in the rail flanges extending from the outside inward toward the web. This is hardly correct and may be misleading. It has been shown, over and over again, that the base breaks originating in seams invariably start at the center of the rail base; and run longitudi-nally in varying lengths from 3 to 12 in. and sometimes longer. Most of them are from 5 to 8 in. long and then curve outward to the edge of the flange. The split at the center of the base may exist for an indefinite time and not be discovered until the break shows on top of the flange or the piece of flange breaks off. The. stresses that cause the break are explained in two ways: (1) by the eccentric bearing of the rail base, that is taking contact at one side or edge and bringing excessive strain at the center of the base which starts fracture in any seam that may he present at that point; (2) the split may be due to cross strain in the base where this member is thrown into. compression, as happens where a pair of trucks are on opposite sides of the cross tie or rail-base hearing, and the head is put in tension. A careful study of "split base breaks" shows that fully 95 per cent. occur on the tie bearing, which is further evidence that the above de-scribed causes for the initial break are probably correct. These split base breaks are almost invariably progressive, but always start at the center of the rail-base running longitudinally.

Jan 12, 1919

By John B. Hodgeson

AMMONIA is an essential constituent in the production of the ammonium-sulphate and ammonium-phosohate soil fertilizers manufactured by the Consolidated Mining and Smelting Company of Canada, Limited. The fertilizer plant, built in 1930 at Warfield, near Trail, provides a means of utilizing the large amount of sulphuric acid produced from the sulphur dioxide which is removed from the smelter smoke. The plant has an avail-able source of cheap power which makes the production of fertilizer economically possible. The fundamental operations involved in the production of ammonia at the Warfield plant are, first, the manufacture of hydrogen by the electrolytic dissociation of water; next, the recovery of nitrogen by the fractional distillation of liquid air; and finally, the combination of hydrogen and nitrogen in proper proportions and under suitable conditions to form ammonia.

Jan 1, 1938

By A. M. Beebee

IN the present century the coal and manufactured gas industries have been eclipsed in public interest by oil, natural gas, and hydro- electric energy, which have had the benefit of rapid development and novelty. I sometimes wish that our social- order were such that hydro power had been developed first, that the use of gas from coal had never been seriously considered, and that our domestic energy requirements were supplied by other fuels. Sup- pose the manufacture of gas from coal should then come on the scene at the present time with the current plight of the railroads, coal regions, and labor generally, presenting the fact that it could increase the amount of coal mined and shipped by the railroads by some 16,000,000 tons, and increase the coal used at existing u plants five times. Imagine the great public interest that would be manifested; it would supply the cooking and water-heating requirements of a community with a superior character of service at a cost to the customer approximately half that which had obtained previously. Would not such a situation be heralded as the salvation of our country and all help be given it?

Jan 1, 1940

Body Hoists A complete new line of hydraulic dump truck body hoists and bodies featuring many outstanding design improvements has just been announced by St Paul Hydraulic Hoist Fourteen models of this new hoist are available in a selection of capacities from 6 to 25 tons The new body hoist features low standard mounting height, advanced lifting point, new low operating oil pres [ ] sures, a new Uniflex subframe, friction-free roller bearing drive mechanism, including pump and power takeoff, to insure quiet operation and long trouble-free life A stress-eliminating design feature of the new hoists absorbs dumping shocks and permits use of a new principle in hoist design a flexible subframe which ends tendency of rigid hoists to crack or bend when flexed Circle No. 1 Combination Drill A new combination drill offering all three methods rotary, auger, and percussion drilling on the same rig is the revolutionary feature of the latest drill rig designed by Mobile Drilling Inc The B-36 drill is larger, more powerful and versatile than previous models built by this company This new drill has a hydraulic feed of approximately 8000 lb pressure The hydraulic feed cylinder is located directly over the rotary turn table The carriage of the drill is of tubular construction The drill mast, also of tubular construction, nests in the tube members of the drill carriage for cross-country travel with a maximum overall height of 10 ft The drill mast telescopes together with the feed cylinder hydraulically to an operating height of 16 ft The drill can be furnished with an auxiliary cat head, sand reel, and special high pressure water pump The B-36 maximum depth for auger drilling without water is approximately 150 ft, depth for rotary drilling with water is in excess of 300 ft Circle No 2

Jan 1, 1952

Roof Bolts An expansion shell and plug Westinghouse roof bolting assembly made for use with threaded steel rods and large flat washers or steel channel employs a plug larger in diameter than those for trolley wire service. The notched plug helps prevent shell and plug from turning. The unit is shipped complete. Circle No. 1 Fan The Jeffrey Mfg. Co. Aerodyne Midget fan is a self contained blower or exhauster for auxiliary ventilation through tubing. Operating rating with 5 hp motor is 6.5 in. maximum static pressure, and 6200 cfm free delivery volume. Weight is 340 to 475 lb and it may be furnished in open or permissible form. Circle No. 2 Heavy-Density Initial installation in the Mesabi Range country of the Wilmot-Daniels heavy-density concentrating system was a 175 ton per hour plant at the [ ] Skubic Bros. Virginia, Minn., operation. This Wilmot Engineering Co. unit has a separatory vessel providing unidirectional medium flow and as the only moving part uses a standard drag-line conveyor for lifting sink out of the bath. Circle No. 3 Portable pH Meter A low priced battery-operated portable pH meter of utmost simplicity announced by the Photovolt Corp. uses only 3 ordinary radio batteries which give over 2000 hours of service. Accuracy of 0.03 pH is claimed by the manufacturer for the model 125, and AC power line supply is available. Circle No. 4

Jan 1, 1952

Payloader The Frank G. Hough Co. has made available another four-wheel drive tractor-shovel. It has a 1 cu-yd bucket with 60 hp Diesel or 54 hp gasoline power optional. The use of large pneumatic tires, same size all around, and drive on all four wheels gives this new Payloader traction to work effectively in sand, mud and snow, and travel on pavements with- [ ] out injuring the surface. Rear wheel steer with power booster plus short wheel base makes it easy to operate and highly maneuverable. Four speeds in both directions insure fast travel speeds for transport and fast operating speeds on shuttle loading or similar operations. Bulldozer blade, crane hook, fork lift and snow plow attachments are available, quickly interchangeable with the bucket to further increase its multi-purpose usefulness. Circle No. 1

Jan 1, 1952