Industry Overview
Silico-manganese (Si-Mn) is a metallic ferroalloy composed principally of manganese, silicon, and iron. It is produced in different grades and sizes and is consumed primarily in steelmaking as a source of both manganese and silicon, with some use as an alloying agent in iron castings. Manganese acts as a deoxidizer and desulphurizer, improves strength, hardness, and hardenability, while silicon is a powerful deoxidizer that contributes to uniform steel chemistry and mechanical properties.
Si-Mn is particularly important in the production of low-carbon steels because it can provide manganese and silicon with comparatively lower carbon addition. Standard Si-Mn generally contains around 65% to 68% manganese and around 17% silicon, while grades differ according to silicon, carbon, phosphorus, and sulphur content. The alloy is produced through carbothermic reduction of manganese- and silica-bearing raw materials in submerged arc furnaces, using coke or coal as reducing agents and electric power as the primary source of heat.
Production involves charging prepared raw materials into a three-phase AC submerged arc furnace, smelting at high temperature, separating molten alloy and slag, followed by cooling, crushing, sizing, and dispatch. The process is energy intensive because silica must be reduced to silicon. The report also covers beneficiation, furnace equipment, metal recovery, pollution control, market position, Indian ferroalloy production, suppliers, environmental aspects, and future outlook.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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
- 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)
Frequently Asked Questions
Silico-manganese is a ferroalloy containing primarily manganese, silicon, and iron that is used mainly in steelmaking.
It supplies both manganese and silicon during steel production, where these elements perform deoxidizing, desulphurizing, and alloying functions. Manganese helps improve strength, hardness, and hardenability, while silicon is an effective deoxidizer. Some silico-manganese is also used as an alloying agent in the manufacture of iron castings. The alloy is available in different grades and sizes, with composition varying according to the required silicon, carbon, phosphorus, and sulphur limits.
Silico-manganese is manufactured by carbothermic reduction of manganese- and silica-bearing raw materials in a submerged arc furnace.
The charge generally includes manganese ore or manganese-rich slag, quartzite, coke or coal, and suitable fluxes. Electrical power is supplied through carbon electrodes to generate the high temperatures required for reduction and smelting. The molten alloy and slag are separated after smelting. The alloy is subsequently cooled, cast, crushed, and sized for handling and dispatch. The report identifies the process as more energy intensive than ferro-manganese production because silica must be reduced to silicon.
The principal raw materials for silico-manganese production are manganese ore, manganese-rich slag, quartzite, coke or coal, and fluxes.
Manganese ore and high-carbon ferro-manganese slag provide the principal manganese-bearing inputs, while quartzite supplies silica. Coke and coal function as reducing agents, and materials such as dolomite or calcite can be used as fluxes. The suitability of each raw material depends on its chemical composition, physical characteristics, impurity levels, and compatibility with the required alloy grade and furnace operating conditions.
A submerged arc furnace is used because it can supply the high electrical energy and reducing conditions required for ferroalloy smelting.
In this process, the raw material charge is heated by high-current, low-voltage electrical power delivered through carbon electrodes. The electrodes remain submerged in the charge, enabling controlled high-temperature reduction and melting. Furnace systems typically incorporate the furnace shell, electrode system, transformer, feeding and batching equipment, exhaust arrangements, tapping facilities, cooling systems, control equipment, and pollution-control equipment. The report specifically describes a three-phase alternating-current submerged arc furnace for Si-Mn production.
Silico-manganese grades are differentiated principally by their silicon and carbon content.
The report identifies three grades, designated Grade A, Grade B, and Grade C. All three have manganese in the stated range of 65.0-68.0, while their silicon limits vary from higher to lower levels. Maximum carbon content also differs among the grades, while the specified maximum phosphorus and sulphur limits are the same in the table provided. Grade selection therefore depends on the steelmaking requirements and the desired balance of manganese, silicon, and carbon contributed by the ferroalloy.
A silico-manganese plant uses furnace, raw-material preparation, material-handling, recovery, and pollution-control equipment.
The report covers equipment including a submerged arc furnace, vibrating feeder, jaw crusher, vibrating screen, ball mill, magnetic separator, flotation machine, spiral classifier, and belt conveyor. It also discusses furnace transformers, batching and feeding systems, control panels, substations, tapping arrangements, cooling systems, product handling, and pollution-control equipment. Crushing, screening, and metal recovery systems are used after smelting to prepare the finished alloy and recover metallic material from slag and middling streams.
Silico-manganese is important because it provides both manganese and silicon in a single ferroalloy addition during steelmaking.
Manganese contributes to desulphurization, deoxidation, strength, hardness, and hardenability, while silicon provides strong deoxidizing action. Combining these functions can reduce the need for separate ferroalloy additions in suitable steelmaking applications. The report also notes that Si-Mn can add less carbon than a combination of standard ferro-silicon and high-carbon ferro-manganese, making its composition particularly relevant where lower-carbon steel grades are being produced.
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