The electrolytic manganese metal industry

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The electrolytic manganese metal industry
9 October 2003 Chongqing
The first choice in pure manganese

• Keith Saffy

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MANGANESE FLOWCHART
ElMn EMD
10
5
Mn Ore
85
15
Chemical
Slag
Mn Alloy
Steel Aluminum
90
crude steel
HCFeMn
SiMn
MC/LCFeMn
50 (Mn units)
40 (Mn units)
10 (Mn units)
25
70
85
Integrated
Integrated
Integrated
15
75
30
Mini-mill
Mini-mill
Specialty steel
S/S Steel HSLA Steels
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History

• 1936 US Bureau of Mines - SO2 process
• 1941 Chuo Denki Kogyo (Japan) 3600tpa plant
• 1942 Tosoh (Japan) 12000tpa (Yamagata plant)
• Development of SeO2 process in Russia India
  1950s
• 1957 Shanghai
• 1960 Emcor (South Africa) 2500tpa
• 1962 Kerr Mcgee (USA) 12000tpa
• 1971 Tosoh 6000tpa (Hyuga)
• 1973 Delta (South Africa) 14500tpa (Nelspruit)
• 1973 Tosoh closes Yamagata plant
• 1980s and 1990s many Chinese plants built
• Now we move to the 1990s.

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Typical properties of ElMn

• Mn 99.9
• Se zero
• C 0.002
• S 0.03
• P 0.001
• Pb lt 5ppm
• Thickness 1.5 to 1.8mm

• Mn 99.7
• Se 0.04 to 0.16
• C 0.01
• S 0.03
• P 0.001
• Pb gt 100ppm
• 0.6 to 0.9mm

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Cost drivers

• Electricity
• Cellhouse unit consumption 7.5-10 MWh/t
• Labour
• Productivity 8-400 manhours/t
• Ore
• Mn efficiency 60-80
• Ore utilisation 2.5-8.0 t ore/t Mn metal
• Environmental
• Residue treatment and disposal
• Effluent treatment

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World demand for ElMn by industry (2002)
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Total World Output Growth of China
Growth in SS200 series in China
Substitution into low carbon FeMn
ElMn industry in China decentralised
Chinas 5-year plan encourages growth of export
industries
China CAGR 12
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Demand, Output, Price Capacity
China capacity doubles
Price basis 99.7 ElMn
Chinese plants close
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Capacity changes in China
66
30
70
No. of producers
World capacity in numbers
12
Stainless Steel in China
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Mn unit options in steel

• HCFeMn 78 Mn, gt7 C, lt0.025 S, lt0.10 P
• MCFeMn 80 Mn, lt1.5 C, lt0.025 S, lt0.10 P
• LCFeMn 80 Mn, lt0.5 C, lt0.010 S, lt0.10 P
• ULCFeMn 90 Mn, lt0.10 C, lt0.015 S, lt0.10 P
• ULCSiMn 59 Mn, lt0.10 C, lt0.01 S, lt0.10 P
• Mn metal 99 Mn, lt0.01 C, lt0.03 S, lt0.001 P

Price
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The first choice in pure manganese
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