We are thrilled to introduce the groundbreaking HAlMan project, dedicated to revolutionizing alloy production by focusing on a more environmentally friendly approach. Our mission is to explore the feasibility of producing Mn/Mn-alloys (Fe-Mn; Al-Mn; Mn) using innovative, greener route that significantly reduces carbon emissions.
The HAlMan project centers on leveraging hydrogen for pre-reduction, followed by an Aluminothermic reduction process for pre-reduced Mn-ores. Additionally, the project aims to manage the high alumina slag produced during smelting by employing advanced leaching techniques to extract pure Alumina.
At the heart of this initiative is the ambition to drastically diminish the net CO2 emissions associated with Mn-alloy production, contributing to a more sustainable future.
My work specifically focuses on studying the aluminothermic smelting-reduction of the pre-reduced Mn-ores and Mn slags. In recent experiments involving the OFZ slag and Nchwaning pre-reduced ore, our findings have been promising. Varying parameters such as CaO/Al2O3 ratio, temperature and holding time in TF2 furnace (see fig 1) revealed intriguing insights. Notably, temperature variations exhibited a profound effect on metal yield and recovery rates. For instance, at 1300 ֠C, minimal metal was formed, while at 1500 ֠C, we achieved an 80% metal recovery.
Pankaj Kumar
PhD candidate
Supervisor: Jafar Safarian
Furthermore, altering the CaO/Al2O3 ratio from 0.8-1.2 significantly influenced slag composition and phase formation. The desired Calcium aluminate phase, for instance, was predominantly formed with a CaO/Al2O3 ratio close to 1.2.
Currently, we’ve achieved a metal composition of 70.80 % Mn, 28.37% Fe, and 0.78% Si from the aluminothermic reduction of Nchwaning pre-reduced ore. Further experiments are underway to delve deeper into the properties of the OFZ slag, and we anticipate sharing more detailed insights in our upcoming newsletters.
Stay tuned for more exciting developments as we continue to pioneer sustainable approaches in alloy production through HAlMan project.