APTD-1509
NATIONAL INVENTORY
OK soi |{< i:s
AND EMISSIONS:
MANGANESE - 1968
I .S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Water Programs
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
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APTD-1509
NATIONAL INVENTORY
OF
SOURCES AND EMISSIONS:
MANGANESE - 1968
by
W. E. Davis § Associates
9726 Sagamore Road
Leawood, Kansas
Contract No. CPA-70-128
EPA Project Officer: C. V. Spangler
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Water Programs
Office of Air Quality Planning and Standards
Research Triangle Park, N.C. 27711
August 1971
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The APTD (Air Pollution Technical Data) series of reports is issued by
the Office of Air Quality Planning and Standards, Office of Air and
Water Programs, Environmental Protection Agency, to report technical
data of interest to a limited number of readers. Copies of APTD reports
are available free of charge to Federal employees, current contractors
and grantees, and non-profit organizations - as supplies permit - from
the Air Pollution Technical Information Center, Environmental Protection
Agency, Research Triangle Park, North Carolina 27711 or may be obtained,
for a nominal cost, from the National Technical Information Service,
5285 Port Royal Road, Springfield, Virginia 22151.
This report was furnished to the Environmental Protection Agency
in fulfillment of Contract No. CPA-70-128. The contents of this report
are reproduced herein as received from the contractor. The opinions,
findings and conclusions expressed are those of the author and not
necessarily those of the Environmental Protection Agency. The report
contains some information such as estimates of emission factors and
emission inventories which by no means are representative of a high
degree of accuracy. References to this report should acknowledge the
fact that these values are estimates only.
Publication No. APTD-1509
11
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PREFACE
This report was prepared by W. E. Davis & Associates pursu-
ant to Contract No. CPA 70-128 with the Environmental Pro-
tection Agency, Office of Air Programs.
The inventory of atmospheric emissions has been prepared to
provide reliable information regarding the nature, magnitude,
and extent of the emissions of manganese in the United States
for the year 1968.
Background information concerning the basic characteristics
of the manganese industry has been assembled and included.
Process descriptions are given, but they are brief, and are
limited to the areas that are closely related to existing or po-
tential atmospheric losses of the pollutant.
Due to the limitation of time and funds allotted for the study,
the plan was to personally contact about fifteen percent of the
companies in each major emission source group to obtain the
required information. It was known that published data con-
cerning emissions of the pollutant was virtually nonexistent,
and contacts with industry ascertained that atmospheric emis-
sions were not a matter of record.
ill
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The manganese emissions and emission factors presented are
based on the summation of information obtained from manufactur-
ing companies that represent approximately eighty percent of the
total production, and reprocessing companies that handle about
thirty percent of the manganese used in consumer products. Air
pollution control equipment is in use at many of the manganese
reprocessing facilities, but its use at processing plants is limited.
Manganese emissions and emission factors are considered to be
reasonably accurate.
IV
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ACKNOWLEDGEMENTS
This was an industry oriented study and the authors express
their appreciation to the many companies and individuals in
the manganese industry for their contributions.
We wish to express our gratitude for the assistance of the
various societies and associations, and to the many branches
of the Federal and State Governments.
Our express thanks to Mr. C. V. Spangler, Project Officer,
Office of Air Programs, for his helpful guidance.
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CONTENTS
SUMMARY 1
Emissions by Source. 2
Emission Factors 3
SOURCES OF MANGANESE 4
MATERIAL FLOW
Material Flow Chart 6
Mining 7
Imports and Exports 8
Manganese Stocks 8
Processing 9
Reprocessing 10
Carbon Steel 10
Other Steel 11
Cast Iron 11
Welding Rods 12
Nonferrous Alloys 12
Batteries 13
Chemicals 14
EMISSIONS
Mining 15
Processing 17
Manganese Metal 17
Manganese Alloys 20
Reprocessing 26
Carbon Steel 26
Other Steel 35
Cast Iron 37
Welding Rods 38
Nonferrous Alloys , . . . . 40
Batteries 42
Chemicals and Other Uses 44
vn
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Consumptive Uses 48
Coal 48
Oil 51
Incineration and Other Disposal 55
Sewage and Sludge 55
APPENDIX A
Companies Dealing in Manganese and
Manganese Compounds 56
TABLES
Table I
Uses of Manganese Ore 9
Table II
Properties of Particulate Matter from a
Ferromanganese Blast Furnace 22
Table III
Spectrographic Analyses of Particulate Discharge
from an Open-Hearth Furnace 30
Table IV
Particle Size Distribution of Fume from a
Basic Oxygen Furnace 32
Table V
Composition of Fume and Dust from Basic
Oxygen Furnaces 32
Table VI
Electric Arc Steel Furnace Fume
Particle Size / 34
Table VII
Typical Emissions from an Electric
Arc Furnace 36
Table VIII
Typical Analysis of Welding Rod Coatings .... 39
Table IX
Average Manganese Content in Ash of Coal ... 49
Table X
Manganese Content of Domestic Crude Oils ... 52
Vlll
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SUMMARY
The flow of manganese in the United States has been traced and
charted for the year 1968. The consumption was 1, 150,000
tons while domestic production was only 48, 000 tons. Imports
principally from Brazil, Gabon, Republic of South Africa,
Congo, Guyana, India, Angola, and Australia totaled 1, 053, 000
tons.
Emissions to the atmosphere during the year were 18,992 tons.
About 47 percent of the emissions resulted from the production
of ferroalloys and about 37 percent from the production of iron
and steel. The combustion of coal was also a significant source
of manganese emissions.
Emission estimates for mining, production of manganese metal,
and reprocessing operations are based on data obtained by per-
sonal contact with processing and reprocessing companies.
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Source Category
Mining
Processing
EMISSIONS BY SOURCE
1968
Source Group
Reprocessing
Consumptive Uses
Manganese Metal
Manganese Alloys
Carbon Steel
Cast Iron
Welding Rods
Nonferrous Alloys
Batteries
Chemicals
Coal
Oil
Incineration and Other
Disposal
Sewage and Sludge
Short Tons
325
8,946
4,340
2,770
24
60
90
300
1,950
7
9,271
7, 584
1,957
175
175
TOTAL
18,992
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EMISSION FACTORS
Mining
0. 2 Ib/ton of manganese mined
Processing
Manganese Metal
Ferromanganese
Blast Furnace
Electric Furnace
Silicomanganese
Electric Furnace
25. 0 Ib/ton of manganese processed
4. 1 Ib/ton of ferromanganese produced
23. 9 Ib/ton of ferromanganese produced
69.4 Ib/ton of Silicomanganese produced
Reprocessing
Carbon Steel
Blast Furnace
Open-Hearth Furnace
Basic Oxygen Furnace
Electric Furnace
Cast Iron
Welding Rods
Nonferrous Alloys
Batteries
Chemicals
22.5 lb/1,000
51 lb/1,000
44 lb/1,000
78 lb/1,000
330 lb/1,000
16 Ib/ton of
12 Ib/ton of
10 Ib/ton of
10 Ib/ton of
tons of pig iron produced
tons of steel produced
tons of steel produced
tons of steel produced
tons of cast iron
manganese processed
manganese processed
manganese processed
manganese processed
Consumptive Uses
Coal
7. 7 lb/ 1, 000 tons of coal burned
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SOURCES OF MANGANESE
Manganese is a hard and very brittle metal that melts at 1, 260 C.
Its atomic weight is 54.93 and its specific gravity is 7.4. It is a
relatively abundant element present in varying quantities in about
ninety-five percent of the earth's crust. Ore deposits of commer-
cial importance are found throughout the world. The most import-
ant manganese-producing countries are Australia, Brazil, China,
Gabon, Ghana, India, the Republic of South Africa, and the
U.S.S.R..
The most common manganese minerals are pyrolusite, psilomela.ne,
braunite, hausmannite, rhodonite, and rhodochrosite. They range in
color from red to brown and black, containing from forty to seventy
percent manganese.
In the United States ores containing manganese are found in Arizona,
Arkansas, Colorado, Maine, Montana, Minnesota, New Mexico, and
South Dakota. Most of the ore mined in these states is manganiferous
ore (5 to 35 percent Mn content). The United States is largely self-
sufficient with respect to its use of manganiferous ore, but is almost
entirely dependent on other countries for manganese ore (35 percent
or more Mn content).
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Manganese is also commonly found associated with iron ores,
usually in concentrations too low to make its commercial re-
covery economically feasible.
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SOURCES
MANGANESE
MATERIAL FLOW CHART - 1968
Short Tons - Mn Content
USES
48,000
DOMESTIC
PRODUCTION
1,053.000
IMPORTS
15.000
^ EXPORTS
73.000 ^
GOVERNMENT
STOCK
^ Q nnn
INDUSTRY
STOCK
1. 160. 000 ,
850.000
FERRO-
MANGANESE
120,000
SILICO-
MANGANESE
10,000
SPIEGELEISEN
18. POO
BATTERIES
60. 000 >
CHEMICALS
26.000
ELECTROLYTIC
METAL
66. 000 jr
MISCELLANEOUS
149.000
1.001.000 ^
744.000 ^
CARBON STEEL"
150,000
ALL OTHER
STEEL
16.000
CAST IRON r\
WELDING RODS" > ^UNSUMER
10.000
NONFERROUS
ALLOYS
18.000 J
BATTERIES
60. 000 ^i
CHEMICALS '
PROCESS LOSSES
Figure I
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MATERIAL FLOW
MINING
Manganese produced in the United States during 1968 was approxi-
mately 4 percent of the manganese consumed. Manganese ore (35
percent or more Mn) was produced and shipped from Montana and
New Mexico. Manganiferous ore (5 to 35 percent Mn) was produced
and shipped from Colorado, Minnesota, Montana, and New Mexico.
MANGANESE PRODUCTION IN UNITED STATES l_l
1968
Manganese Content
Short Tons
Manganese Ore 6,000
Manganiferous Ore 42, 000
Total 48, 000
]- Personal Communication;. U. S. Department of Interior;
Bureau of Mines: August, 1970.
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IMPORTS AND EXPORTS
During 1968 imports of manganese ore were principally from
Brazil, the Congo, Gabon, Ghana, India, and the Republic of
South Africa. The imports of manganese ore totaled 1,83J,210
short tons (gross weight), silicomanganese imports for consump-
tion were 25, 142 short tons (gross weight), and ferroma.nga.nese
imports were 207,677 short tons (gross weight) /. The man-
ganese content of the imports was 1, 053, 000 short tons /.
Exports of all forms of manganese during 1968 were 15, 000
short tons (Mn content) / including ferromanganese, manga-
nese and manganese alloys, waste and scrap, ore, and concen-
trates containing more than 10 percent manganese.
MANGANESE STOCKS
During 1968 industry stocks of manganese in all. forms in-
creased 9, 000 short, tons (.Mn content), while government.
stocks decreased 73,000 short tons (Mn content.) /.
1- Minerals Yearbook; Bureau of Mines; 1968.
2- Personal communication; U. S. Department of Interior;
Bureau of Mines; August, 1970.
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PROCESSING
The chief use of manganese ore (35 percent or more Mn) in the
United States is in the production of manganese metal, ferro-
manganese, silicomanganese, and spiegeleisen. These prod-
ucts are used principally in the iron and steel industry.
Other important uses of smaller quantities of the ore include its
use in the manufacture of chemicals, batteries, welding rods and
nonferrous alloys.
During 1968, manganese ore was used in the manner shown in
Table I.
TABLE I
USES OF MANGANESE ORE 1J
1968
Short, Tons
Use
Mn Content
Manganese Metal (electrolytic) 26, 000
Ferromanganese 850, 000
Silicomanganese 120,000
Spiegeleisen 10,000
Chemical Manufacture 60, 000
Battery Manufacture 18,000
Miscellaneous 66, 000
1- Personal communication; U. S. Department of Interior;
Bureau of Mines; August, 1970.
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REPROCESSING
In the United States the principal use of manga.nese is in the pro-
duction of carbon and alloy steels. Metallurgical.ly, it is used
chief.ly as ferromanganese and to a lesser extent in the forms of
silicomanganese, spiegeleisen and manganese metal. For battery
manufacture, it is used in the form of manganese dioxide.
In the chemical industry, manganese is used as an oxidizing agent
in the manufacture of hydroquinone and for-the production of
various chemicals including manganous oxide, manganous chloride,
potassium permanganate, and manganese su.lfate.
The consumption of manganese in the United States during 1968
has been reported at 1, 101, 000 short tons V.
CARBON STEEL
Manganese is used in steelmaking, chiefly, to counteract, the
effects of sulfur; however, it also has other advantages. It has
some deoxidizing power and, when added in certain proportions,
it can. act to harden and reduce the plasticity of steel.
Steels that contain too much sulfur tend to crack during rolling
operations; a condition, known as "hot shortness". Excess sulfur
1- Personal communication; U. S. Department of Interior:
Bureau of Mines; October, 1970.
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also tends to create surface imperfections during fabrication.
The use of manganese in steelmaking effectively prevents these
difficulties. Most of the unwanted sulfur combines with the man-
ganese and is carried into the slag.
In the United States the use of manganese in carbon steel during
1968 was 744, 000 short tons _/.
OTHER STEEL
In addition to its functions in the production of carbon steel,
manganese is used as an alloying agent in special steels to
produce harder and tougher metals for special applications. In
plain carbon steel the manganese content is less than one percent,
but in one group of extremely hard and tough alloy stee.ls the man-
ganese content is from 10 to 14 percent.
During 1968, the use of manganese in other steels was 150, 000
short tons /.
CAST IRON
The principal use of manganese-in^the~produclion of cast iron is
1- Personal communication; U. ~S.. Department of Interior;
Bureau of Mines; October, 1970.
2- Personal communication; U. S. Department of .Interior;
Bureau of Mines: August, 1970.
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t;o nullify the effects of sulfur.
During 1968 the use of manganese in cast iron totaled 16, 000
short tons /.
WELDING RODS
Manganese, in the dioxide form, has important uses in the man-
ufacture of welding rods and welding rod coatings. Its principal
use is as an oxidizing agent. The MnC^ content of typical weld-
ing rod coatings is in the order of 1J percent.
During 1968 about 3, 000 short tons of manganese were used in
the manufacture of welding rods /.
NONFERROUS ALLOYS
Manganese is important in many miscellaneous metallurgical
applications. It is used in the production of aluminum and mag-
nesium and it is alloyed with copper to make manganese bronze.
It impa.rts stiffness and ha. rdness to aluminum and magnesium;
manganese also increases the corrosion resistance of magnesium.
The alloy, manganese bronze, is a. complex b:r.ass. It: has hot
1- Personal communication; U. S. Department of Interior;
Bureau of Mines; October, 1970.
2- Personal communication; U. S. Department of Interior;
Bureau of Mines: August, 1970.
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working properties, high strength, and abrasion resistance. It
is used extensively for ship propellers, boat shafting and other
similar applications.
In the United States, the use of manganese in nonferrous alloys
during 1968 was 10, 000 short tons _/.
BATTERIES
Synthetic ore is a term used chiefly to identify manganese di-
oxide that is produced chemically or electrolytically for use in
dry cell batteries. The Bureau of Mines define synthetic ore
as a material that is the equivalent of, or better than, natural.
ore, which can be put to the same uses, a.nd is produced by
means other than ordinary concentrations, calcining, sintering,
or nodulizing.
In batteries, manganese dioxide acts as a depola.rizmg agent.
Hydrogen released from the electrolyte of the cell tends to form
around the carbon electrode and slow down the cell a.ction. Oxy-
gen provided by the manganese dioxide corrects this condition
by its reaction with the hydrogen.
1- Personal communication; U. S. Department of Interior;
Bureau of Mines; October, 19?0.
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During 1968 manganese used in batteries totaled 18,000 short
tons ./.
CHEMICALS
Manganese dioxide ores are important in the manufacture of
manganese chemicals, ma.ny of which are used as oxidizing
agents. Manganese sulfate is used in fertilizers, fertilizer
additives, as a constituent of animaJ and poultry feeds, as a
paint drier, as a coloring a.gent for ceramics and textiles, and
as a ba.se for other chemicals. Manganous chloride is used in
dyeing textiles, and as a ve.hic.le for alloying manganese with
ma.gnesium. Manganous oxide is also used in a.nima] and poul-
try feeds, fertilizers, and welding applications.
Manganese used in the manufacture of chemicals du.rin.g 1968
totaled 60,000 short tons ./.
1- Persona] communication; U. S. Department of Interior;
Bureau of Mines: August, 1970.
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EMISSIONS
MINING
Because of the marked differences in the manner in which man-
ganese deposits occur, a wide variety of mining methods are used.
In the United States, in recent years, high grade manganese ore
has come from underground mines. On the other hand, manganif-
erous ores are usually mined in the same manner as iron ores
from the same district and, in the United States, this has meant
open pit mines.
Before 1950, very few of the world's manganese ore producers had
milling plants other than simple crushing, screening and washing
installations. This wa.s also the situation in the United States, ex-
cept in the State of Montana where concentrating equipment was
used for battery grade ores. Due to the recent high rate of indus-
trial growth more producers have installed various k.inds of con--
ceint,rating equipment, many times including sintering a.nd nodu.hz-
ing equipment to agglomerate fines and remove deleterious
impurities.
While this study was in progress, mining companies were con.i.a.cted
concerning the quantity of ore mined, its manganese content, and
the manganese emissions occuring during mining and concentration.
It was found that records of manganese emissions to the atmosphere
are not maintained. Mosi of those contacted indicated losses >,o the
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atmosphere are slight, occuring principally during ore handling
or crushing and due to wind loss from tailings.
Based on information obtained and observations made during
visits to mining locations, the manganese emissions to the at-
mosphere from sources of mining are estimated at 0. 2 pounds
per ton of manganese mined. Manganese emissions to the atmos-
phere during 1968 were 4.8 tons.
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PROCESSING
In the United States the principal use of manganese ore (35 percent
or more Mn) is in the production of manganese alloys and pure
manga.nese metal.
MANGANESE METAL
The process currently used to produce pure manganese metal is
an electrolytic process consisting of four principal steps: roasting
of the ore, leaching, purification of the leach liquor, and electro-
deposition Of the manganese. During roasting the primary object:
is to convert all manganese to the oxide form and at the same
time leave as much iron as possible as Fe^O.; however, most
ores treated by this process are relatively low in iron and roasting
is at a high temperature to achieve maximum recovery of manga-
nese without regard to iron content. When the iron content is
low it can be controlled by pH adjustment of the lea.ching acid.
After grinding a.nd roa.sting, the ore is leached with anoJyte from
the electrolytic cell. The concentration of the leach is adjusted
by addition of ammonium sulphate to maintain a concentra.tion of
about 140 grams/litre, and sulphuric acid to give a pH of about
2. 5. After solution, the leach liquor is neutralized to pH 6. 5
by adding ammonia, milk of lime, or calcined ore. On neutrali-
zation of the leach liquor, iron and aluminum hydroxides are
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precipitated. Overall ex.trac.t.ion of manganese f:rom the ore is
about 98 percent.
The neutral leach liquor contains small quantities of numerous
elements, such as arsenic, cobalt, copper, iron, lead, molybde-
num, and zinc which must be removed prior to electrolysis. The
removal is accomplished by first treating the liquor with hydrogen
sulphide or ammonium sulphide, then fi.l.?:e.ring to remove the
sulphides. At this point most of the impurities have been removed
except colloidal sulphur a.nd small quantities of arsenic and molyb-
denum. These are removed by the addition of iron in the form of
copperas. The iron is oxidized at room temperature at a pH of
6. 5 to 7. 0 and ferric hydroxide is precipitated; the arsenic,
molybdenum, and colloids are absorbed. At. this stage the solu-
tion has been purified a.nd is ready for feeding to the el.ec.trolyr.ic
cell.
The cell, consists of an anode compartment and a. cathode com-
partment separated by a diaphragm. The purified solution first
enters the cathode compartment, then flows through a. canvas
diaphragm into the a.node compartment and is discharged to a
storage tank for reuse. The manganese is deposited at the
cathode of the cell.
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The principal manganese emissions to the atmosphere that
occur are due to handling, grinding, and roasting of the ore.
The data obtained regarding two electrolytic plants indicate
overall emissions average 25 pounds per ton of manganese pro-
cessed. In the year 1968 the atmospheric emissions of manga-
nese resulting from the production, of manganese metal totaled
.325 tons.
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MANGANESE ALLOYS
About 85 percent of the manganese ore consumed in the United
States during 1968 was used to produce manganese alloys, the
greater part of which was in the form of high, medium and low
carbon ferromanganese. These and other alloys, including
silicomanganese and spiegeleisen, are used principally by the
steel industry.
Air pollution controls have not been satisfactory in the ferroalloy
industry; thus a more intensive effort will be required in order
to provide adequate control of process emissions. There a.re
numerous technical problems that must be solved and the addition
of proper fume collection equipment is not the only requirement
for a satisfactory long-range solution. There a.re many dust and
fume producing operations. The dust (larger than 2 micron size)
that results from raw material handline, as we 1.1. a.s that from
crushing and sizing of the product, can be handled by conventional
techniques; the major pollution problem is associated with, the
ferroalloy furnaces and the collection of fume that is less than
2 microns in size.
About 65 percent of the ferromanganese is made in blast furnaces
and the remaining 35 percent in electric furnaces. The blast
furnaces used in making ferromanganese are the same type as
those used in making pig iron; quite often the same furnace is
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used to produce both products. Ferromanganese is often pro-
duced by operating a pig iron furnace on manganese alloy pro-
duction long enough to obtain a supply of the alloy, after which
the blast furnace is returned to its normal operation of producing
pig iron.
The effluent from a ferromanganese blast furnace is reported to
be a greater air pollution problem than that from an iron blast
furnace _/. It is said to be the most, prolific pollution producer
of any of the metallurgical processes _/. One investigator has
reported that emissions from ferromanganese blast furnaces, if
uncontrolled, are nearly ] 50 tons of dust per 1, 000 tons of metal.
produced _/. Another invest-.i gator has reported the properties
of ferromanganese blast furna.ce fume as shown i.r. Tab.le II.
Electric furnaces used for making manganese ferroalloys are the
same type as those used in making other ferroalloys a.nd, again,
the furnace used is not always devoted, exclusively to making one
particula.r product. Jr. fact, there is often some inter change-
ability in scheduling production of the various ferroalloys.
1- Thring, N. W. and Sarjant, R. J. ; "Dust Problems of the
Iron and Steel Industry"; Iron and Coal Traders Rev. ;
Vol. 174: Mar. 29, 1957.
2- Wurts, T. C. ; "Industrial Sources of Air Pollution -
Metallurgical"; PHS Publ. 654; 1959.
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TABLE II
PROPERTIES OF PART1CULATE MATTER
FROM A FERROMANGANESE BLAST FURNACE J/
Component
Content %
Manganese
Iron
Total alkali (as Na2O and
Silicon dioxide
Aluminum oxide
Calcium oxide (CaO)
Ma.gnesium oxide (MgO)
Total, sulfur (as SO4)
Carbon
Pa.rticle Size (a.verage)
Appa.rent Density
15 to 25
0. 3 to 0.5
8 to 15
9 to 19
3 to 11
8 to 15
4 to 6
5 to 7
.1. to 2
0. 3 micron
]2 J.b/cu. ft.
1- Bishop, C. A. et al; "Cleaning Ferromanganese B.la.st
Furna.ce Gas"; Iron Steel Engine ei; 28; -Aug. 1951.
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When using the conventional submerged arc electric furnace to
produce manganese alloys, large quan.titi.es of carbon monoxide
a.re generated as a result of carbon, redxiction of metallic oxides.
This gas, along with other primary gas due to moisture in the
charge, reducing agent volatile matter, and various products
of thermal decomposition, rises from the top of the furna.ce
carrying furr.e and entrained micron-size particles of the charge.
In an open furnace all of the carbon monoxide burns with induced
air at the top of the charge, resulting in a, large volume of high.
tempera.ture gas. In a closed furnace most of the carbon monox-
ide is removed without combustion with air. Due to the steady
state operation of the submerged arc furnace, gas generation is
continuous.
Additional fume is generated at the furnace ta.ph.oles, principally
the result of air flow induced by heat transfer from the molten
metal or sl.a.g. After the taphole, there are other sources of
fume tha.t occur in. handling the metal. Because most furnaces
are tapped intermittently, these fumes occur o.nly part of the
operating time.
As mentioned above, the fume size is generally below 2 microns;
fume chemical analysis from the typical open-type furnace pro-
ducing ferromanganese shows the manganese oxide content to be
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about: 33 percent.
In addition to the numerous intermittent and continuous gas
flows described, other factors also contribute to the problem
of air pollution control. Manganese ores contain volatile mat-
ter and moisture that disturb the smooth operation of the fur-
nace. Sudden release of gas results in substantial charge
ejection from the furnace.
Normal gas flow from the typical closed furnace producing
ferromanganese is approximately 160 to 170 scfm per mega-
watt and peak flows may be 40 percent higher. From an open
furnace with, a low hood the gas flow rate may be in the order
of 3,.000 to 5, 000 scfm per megawatt.
Atmospheric emissions resulting from the production of ferro-
manganese in blast furnaces a.verage 4. 1 pounds of manganese
per ton based on 95 percent control, 20 percent manganese in
the particulate (Table II), and 410 pounds of particulate per ton
of ferromanganese (uncontrolled) _/. During 1968 the manga-
nese emissions totaled 1, 113 tons.
Emissions to the atmosphere from electric furnaces producing
1- Office of Air Programs; Emissions report in progress;
1971.
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ferromanganese a.verage 23. 9 pounds of manganese per ton of
ferromanganese produced including a 10 pound per- ton loss dur-
ing handling, mixing, and other non-melting operations _/. .In
the United States the manganese emissions from electric fur-
na.ces during 1968 totaled 3, 669 tons.
Atmospheric emissions due to the production of silicomanganese
in electric furnaces averaged. 69.4 pounds of manganese per ton
including a 10 pound per ton loss during handling, mixing, and
other non-melting operations ./. During 1968 manganese emis-
sions resulting from the production of silicomanga.n.ese totaled
4, 164 tons.
] Office of Air Programs; Reactive metals report in
progress; J9?l.
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-26-
REPROCESS1NG
More than ninety percent of the manganese used in the United
States during 1968 was consumed by the steel industry in the
production of carbon steel, stainless steel, and special steel
alloys, The remainder was used in ma.king cast iron, nonfer-
rous alloys, batteries, chemicals, and numerous other products.
CARBON STEEL
From the standpoint of air pollution, steel mills are very im-
portant sources of manganese emissions. The basic steps in
the production of steel include the partial removal of impurities
when iron ore is reduced to pig iron in the blast furnace. Fur-
ther purification takes place when pig iron and scrap are con-
verted to steel in an open-hearth, a ba.sic oxygen, or an elec-
tiic furnace. Other associated opera.tions include ore crushing,
materials handling, sintering, palletizing a.nd scarfing.
Blast Furnace - Commencing with i;he production of pig iron,
ma.nganese is part of each principal ingredient charged into the
blast furnace. It is in the iron and ma..ngajuferous ore, in the
scrap, and in the slag recycled from the steel converter. More
manganese enters the iron blast furnace through the sma.ll con-
tent of manganese in some iron ores than through the deliberate
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-27-
addition of manganese. The pig iron emerging from the blast
furnace contains about 70 percent of the manganese from the
charge, and the other 30 percent is in the slag and ga.ses that
are byproducts of the reaction.
As the gas leaves the blast furnace, it contains large quantities
of particulates a.veraging about 150 pounds per ton of pig iron /;
however, it is subsequently cleaned and used as fuel. The gas
cleaning is accomplished in two or. three sta.ges and the annual
overall efficiency is a.n estimated 97 percent.
During 1968, 140 million tons of net oies and agglomerates
were consumed in producing 89 million tons of pig iron /. The
estimated manganese content of the particula.te was 0. 5 percent.
Emissions to the atmosphere totaled ], 000 tons, based on. 22.5
pounds of manganese per 1, 000 tons of pig iron.
Open-Hearth Furna.ce - The nex:t step in steelmak.mg is to pro-
duce steel using pig iron, home scrap, and purchased scrap.
Three types of furnaces are commonly used; the open-hearth,
the basic oxygen, and the electric furnace. Rega.rdless of the
1- "Air Pollutant Emission Fa.cr.or s "; Environmental Protection
Agency; Preliminary Document; Apr. 1971.
2- Minerals Yearbook; Bureau, of Mi.ties; 1968.
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-28-
kind of furnace, the primary object of the operation is to reduce
the impurities present in the charge to the limits specified for
the melt.
In the open-hearth furnace, steel is produced from a mixture
of scrap (about 45 percent) and pig iron (about 55 percent) using
oil, coke-oven gas, natural gas, tar, or producer gas to provide
the required heat. The melting begins when the first scrap is
charged and continues as solid material is added. After all the
scrap has melted, molten pig iron is delivered and poured into
the furnace. This step is followed by the ore and lime boil.
Next the working period is employed to: (1) lower the phos-
phorus and sulfur content; (2) eliminate carbon as rapidly as
possible; and, (3) increase the heat for final deoxidation. It
is during this process that the greatest loss of manganese oc-
curs. About 80 to 90 percent emerges in the fume and slag.
It oxidizes readily and tends to pass into the slag, rather than
remaining with the product.
The overall operating cycle of the open-hearth furnace is about
10 hours; fumes are discharged continuously at varying rates.
In spite of the varying actions, average emission factors have
been established for operation both with and without oxygen
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-29-
lancing. With oxygen lancing, the factor for uncontrolled
emissions is 21 pounds of particulate per ton of steel. With-
out lancing, the factor is 8 pounds per ton. The degree of
emission control is estimated at 40 percent, and the average
emission factor (controlled) for all open-hearth furnace opera-
tions is 10. 2 pounds of particulate per ton of steel produced /.
The mean particle size of the dust is generally considered to
be 0. 5 micron _/ and a typical chemical analysis is shown in
Table III.
During 1968 the steel produced in open-hearth furnaces was
65 million short tons _/, and the manganese content of the
particulate matter emitted was about 0. 5 percent. Manganese
emissions to the atmosphere totaled 1, 660 tons based on 51
pounds per 1,000 tons of steel produced.
Basic Oxygen Farnace - The basic oxygen furnace is a re-
fractory-lined, cylindrical vessel that is mounted on trunions
so that it can be rotated and placed in a horizontal or vertical
1- "Emissions, Effluents and Control Practices"; Environ-
mental Protection Agency; Study in progress (unpublished);
1970.
2- Aberlow, E. B. ; "Modification to the Fontana Open-Hearth
Precipitators"; JAPCA; 7_; May, 1957.
3- Minerals Yearbook; Bureau of Mines; 1968.
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-30-
TABLE III
SPECTROGRAPHIC ANALYSIS OF PARTICULATE
DISCHARGE FROM AN OPEN-HEARTH FURNACE 1/
, Approximate Amount
Element ^ _
Percent
Fe
Zn
Na
K
Al
Ca
Cr
Ni
Pb
Si
Sn
Cu
Mn
Mg
Li
Ba
Sr
Ag
Mo
Ti
V
Remaining amount
10 to 15
1 to 2
1 to 2
5
5
2
2
5
5
1
0. 5
0. 5
0. 1
Trace
Trace
Trace
0.05
Trace
Trace
0.05
These data are qualitative only and require supplementary
quantitative analysis for actual amounts.
1- Air Pollution Engineering Manual; Public Health Service
Publication No. 999-AP-40; p. 243; 1968.
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position as required during operation. When charged and in
the vertical position, a stream of oxygen is supplied from
overhead downward into the converter. The oxygen impinges
on the liquid metal surface causing violent agitation and inti-
mate mixing with the pig iron. During the operating cycle of
about one hour, large quantities of gas and particulate are dis-
charged from the furnace.
The emission factor for the basic oxygen furnace has been es-
timated at 46 pounds of particulate per ton of steel _/ and the
degree of emission control at 97 percent. The mean particle
size of the dust is 0. 7 micron (Table IV).
During 1968 the steel produced in basic oxygen furnaces was
48 million short tons _/ and the estimated manganese content
of the particulate emissions was 3.2 percent (Mn,O. 4.4 per-
cent ao shown in Table V). Manganese emissions to the atmos-
phere totaled 1, 060 tons during the yea.r, based on 44 pounds
per 1, 000 tons of steel produced.
1- "Air Pollutant Emission Factors"; Environmental Protection
Agency; Preliminary Document: Apr. 1971.
2- Minerals Yearbook; Bureau of Mines; 1968.
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-32-
TABLE IV
PARTICLE SIZE DISTRIBUTION OF FUME
FROM A BASIC OXYGEN FURNACE ]/
Microns Percent
0-0.5 20.0
0.5 - 1.0 65.0
1.0 - 15.0 15.0
TABLE V
COMPOSITION OF FUME AND DUST FROM
BASIC OXYGEN FURNACES 1 /
Material Percent
Fe2O3 90.0
Mn3O4 4.4
FeO 1. 5
SiO-, 1.3
CaO2 0.4
P205 0. 3
A12O3 0. 2
1- Gaw, R. G. ; "Symposium on Basic Oxygen Furnaces,
Gas Cleaning"; Iron Steel Engr. ; 37; Oct. I960.
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Electric Furnace - Electric arc furnaces are well suited to
the production of alloy steels and are used extensively for
that purpose. They are refractory-lined, cylindrical vessels
with large carbon electrodes passing through the furnace roof.
Emissions generated during steelmaking consist of fume and
dust emitted from the furnace during charging and refining.
While charging the furnace, the top is open to receive the cold
metal and the exposure of the1 cold charge to the high tempera-
ture inside the furnace results in the generation of large quan-
tities of fume. In general, the rate of fume release increases
throughout the operation.
Particulate emissions from electric arc furnaces have been
estimated at 11 pounds per ton of steel with oxygen lancing,
and 7 pounds per ton without _/. The particle size is shown
in Table VI. The degree of control is estimated at 78 per-
cent, and the average emission factor (controlled) at 2. 5
pounds per ton of steel produced.
During 1968 the steel produced in electric arc furnaces was
16 million short tons /. The manganese content of the
1- Air Pollutant Emission Factors; Environmental Protection
Agency; Preliminary Document; Apr. 1971.
2- Minerals Yearbook; Bureau of Mines; 1968.
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-34-
TABLE VI
ELECTRIC ARC STEEL FURNACE
FUME PARTICLE SIZE
..,. Percent
Microns
B
0-5 71. 9 67.9
5-10 8.3 6.8
10 - 20 6.0 9.8
20 and larger 13.8 15.5
A - Los Angeles County Air Pollution Control District,
unpublished data, Los Angeles, California, 1950-51.
B - Erickson, E. O. ; "Dust Control of Electric Foundries
in Los Angeles Area"; Electric Furnace Steel Process;
American Institute of Mining and Metallurgical Engi-
neers; 11; 1953.
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-35-
particulate emissions is estimated at 3. 1 percent (4 percent
MnO as shown in Table VII). Manganese emissions to the
atmosphere totaled 620 tons, based on 78 pounds per 1, 000
tons of steel produced.
OTHER STEEL
Even though there is more manganese in certain alloy steels
than in carbon steel, the production steps are essentially the
same. The principal difference is that more of the alloying
elements are added near the end of the cycle.
Stainless steels are usually produced in an electric arc or
high-frequency induction furnace. The largest tonnages are
processed in an electric arc furnace of the Heroult type. This
furnace is refractory-lined and the steel may be poured by
tilting the entire furnace. After the working period the slag'
is removed and a finishing slag is placed on the bath prior to
the addition of manganese and other alloying elements.
Manganese steels are made by any of the conventional steel-
making processes with the exception that an acid-lined furnace
may not be used. Only a base iron charge is melted in the
acid-lined furnace. The ferromanganese or other manganese
alloy is melted separately in a basic-Lined furnace and added
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-36-
TABLE VII
TYPICAL EMISSIONS FROM AN
ELECTRIC ARC FURNACE l/
Component Weight %
Zinc Oxide (ZnO) 37
Iron Oxides 25
Lime (CaO) 6
Manganese Oxide (MnO) 4
Alumina (A12O ) 3
Sulfur Trioxide (SOJ 3
Silica (SiO2) 2
Magnesium Oxide (MgO) 2
Copper Oxide (CuO) 0. 2
Phosphorus Pentoxide (P^Cv) 0. 2
1- Coulter, R. S. ; "Smoke, Dust, Fumes Closely Controlled
in Electrode Furnaces"; Iron Age; 173; Jan. 14, 1954.
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-37-
to the base iron in the ladle. Hadfield's method consists of
adding molten ferromanganese to carbon-free blown iron. This
is the most widely used method for producing manganese steel
castings.
Manganese emissions resulting from the production of alloy
steels have been included with the emissions estimated for
carbon steel.
CAST IRON
The principal use of manganese in cast iron is to nullify the
effects of sulfur. In spite of recent advancements in the tech-
nology of melting with electric arc and induction furnaces, the
cupola is still the most widely used method for producing cast
iron. The charge into the cupola furnace includes coke, scrap,
and pig iron, each-containing some manganese. As air is in-
troduced, the coke burns and causes the metallic charge in the
furnace to melt. Part of the manganese oxidizes and part com-
bines with sulfur to form manganese sulfide which is discharged
in the slag.
The rate of particulate emissions from gray iron cupolas has
been reported as 4 to 26 pounds per ton of process weight not
including emissions from handling, charging, or other non-
melting operations.
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-38-
Based on information obtained from industry the pa.rticulate
emission factor is estimated at 22 pounds per ton of process
weight, including melting and non-melting operations. The
manganese content of the particulate is 2 percent / and the
degree of emission control approximately 25 percent.
During 1968 the pig iron and scrap used by iron foundries
totaled 16,788,000 short tons _/. Manganese emissions to
the atmosphere due to the production of cast iron were 2, 770
tons.
WELDING RODS
Some welding rods and welding rod coatings contain manganese.
In the coatings there is approximately 10 percent manganese
dioxide as shown in Table VIII, and in aluminum welding rods
there is as much as 1. 5 percent manganese.
During the production of aluminum welding rods the manganese
is added as a general purpose alloy for applications requiring
moderate strength and good workability. An aluminum-rich
alloy ingot containing the manganese is added to a charge of
1- Private communication with industrual source.
2- Minerals Yearbook; Bureau of Mines; 1968.
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-39-
TABLE VIII
TYPICAL ANALYSIS OF WELDING ROD COATINGS
Material
SiO2
TiO2
MnO-,
Fe2°3
MgO
CaO
co2
Moisture, organic
volatile matter
Other
TOTAL
Percent
20.5
41.5
10.9
8.8
5.9
2.5
1.4
6.9
1.6
100. 0
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-40-
virgin aluminum and alloy scrap in a reverberatory furnace
fired to a temperature of about 1,400 F. During the melting
process the metal flows from the main furnace hearth to the
holding hearth through a trough outside the furnace enclosure.
The metal is then tapped and poured into ingots and cooled.
Next, the ingots are heated and rolled in the blooming mill
prior to milling in the rod mill. The product is finished by
forging, swaging, or drawbenching.
Based on information obtained from three industrial sources,
manganese emissions to the atmosphere are estimated at 16
pounds per ton of manganese processed. During 1968 the man-
ganese emissions resulting from the manufacture of welding
rods totaled 24 tons.
NONFERROUS ALLOYS
In aluminum alloy production, manganese is dissolved in the
molten aluminum to provide superior hardness, tensile
strength, and corrosion resistance. Such alloys contain man-
ganese at a level of less than 25 percent; one master alloy
uses 4 or 5 percent.
Magnesium producers use manganese chloride as a flux to im-
part qualities of stiffness, hardness, and corrosion resistance.
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Also, magnesium can be melted and alloyed in steel pots when
manganese is used since it inhibits alloying of the magnesium
with the steel.
When alloyed with copper and zinc, manganese bronze is
formed. These bronzes, containing up to 3. 5 percent manga-
nese, possess good tensile strength and are well known for
their resistance to the corrosive effects of sea water.
Manganese-copper-nickel alloys have a high affinity for carbon
and rapidly'attack acid refractories. Therefore, melting
should be conducted in a basic-lined high-frequency furnace.
The basis of the furnace charge consists of ordinary carbon-
free metallic manganese, ingot copper, nickel pellets, and
returned scrap from previous melts, if available. Satisfac-
tory results have been obtained by melting the copper and
nickel under an oxidizing slag of manganese ore.
Producers of nonferrous alloys contacted during this study
stated their atmospheric emissions average about 12 pounds
per ton of manganese processed. During 1968 manganese
emissions to the atmosphere were 60 tons.
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BATTERIES
An important use of manganese dioxide is as a depolarizing
agent in the ordinary dry cell battery. Hydrogen released
from the electrolyte of the cell tends to form around the car-
bon electrode, slowing the action of the cell. This condition
is corrected as the hydrogen combines with the oxygen that is
provided by manganese dioxide contained in the cell mix.
The main steps in a dry cell battery-making process are dia-
gramed in Figure II.
Emissions to the atmosphere are principally during the early
stages of production. Manganese dioxide, calcined manganese,
and other dry ingredients are emptied from vats and containers
into a dry mixer. These mixed ingredients then travel in buc-
ket elevators to the hopper where they are dumped and enter
the wet mixer.
Information obtained from manufa.cturers of dry cell batteries
shows that their manganese emissions to the atmosphere aver-
age 10 pounds per ton of manganese processed. During 1968
the atmospheric emissions were 90 tons.
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-43-
FLOW DIAGRAM
BATTERY MANUFACTURING
Manganese dioxide, calcined
manganese, graphite carbon
black, ammonium chloride,
and vita film
Zinc chloride and ammonium
chloride solution
Battery cases
Zinc and ammonium chloride
solution
Carbon rod added by machine
Wet Mixer
Pulverizer
Paste
Filling
Machine
Solution
Filling
Machine
Combining
Machine
Figure II
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-44-
CHEMICALS AND OTHER USES
Manganese ore, mainly in dioxide form, is used in the chemical
industry as an oxidizing agent in the manufacture of hydroqui-
none and for the production of various manganese chemicals,
including potassium permanganate, manganese sulfate, manga-
nous chloride, and manganous oxide. It is used in the lea.ching
of uranium and zinc ores, in fertilizers as a trace element, in
animal and poultry feed as a supplement, in pharmaceuticals,
frits, glass, ceramics, and to give a variety of coloring effects
to face brick. For certain of these applications the ore is used
directly; for others, it may be processed into compounds or
salts of manganese prior to use in the final product.
Hydroquinone is important as a photographic developer. Per-
manganates have many uses in a wide variety of applications.
They are used in the chemical industry in air pollution control
for sulfides and mercaptans, in water treatment, as bacteri-
cides and pesticides, and for odor control in barnyards. Potas-
sium permanganate is a powerful oxidant.
Manganese sulfate is used in a multitude of commercial prod-
ucts; one of the largest areas is as a fertilizer or fertilizer
additive. It is also important as a constituent of animal and
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poultry feeds, fungicides, paint driers, coloring agents for the
textile and ceramic industries, and is bften used as a base for
the production of other manganese chemicals. Approximately
10, 000 tons of manganese are used annually in the production
of fertilizers.
Manganous oxide is also found in fertilizers and in animal and
poultry feeds. In addition it is used in certain welding applica-
tions. In dyeing textiles, making welding rod fluxes, and in
alloying manganese with magnesium, manufacturers use man-
ganous chloride.
Another area of interest is the molybdenum-manganese process of
joining ceramics to metal, better known as the moly-manganese
process. It is one of the most widely employed methods in elec-
tronic applications. A thin coating (0. 005 to 0. 002 inch) of a
fine suspension of molybdenum and manganese is fired on the
ceramic in a reducing atmosphere at temperatures approaching
3, 000 F. Then a coating of nickel and copper is electroplated
over the molybdenum and manganese, and is wetted by a brazing
alloy. The resulting metal-ceramic bonds ha.ve a better high-
temperature strength than those formed by any other method.
Tensile strength of 20, 000 pounds per square inch has been re-
ported.
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Fuel additives of organic manganese compounds have been
patented and tested. The most successful antiknock compound
is methylcyclopentadienyl manganese tricarbonyl, which is
mixed with tetraethyl lead to increase the octane rating of gas-
oline. A typical mixture is composed of the following ingredi-
ents: 57.5 percent tetraethy] lead; 7.0 percent methylcyclo-
pentadienyl manganese tricarbonyl; 16. 7 percent ethylene di-
bromide; 17.6 percent ethylene dichloride; and 1.2 percent
other additives such as dye and inert materials.
Various methods of using manganese to remove air pollutants
ha.ve been suggested. Manganese nodules from the ocean floor
can be loosely packed in a column through which a gas passes,
causing a reaction with the sulfur dioxide in the gas to produce
manganese sulfate. One-third of the manga.nese can be re-
covered from the sulfated nodules by ]eaching with weak su.l-
furic acid.
There is no reliable information regarding the average manga-
nese emissions that occur during the production, of compounds
and the subsequent manufacture of products that contain man-
ganese. However, a few rough estimates of atmospheric emis-
sions have been obtained from people in industry. In this report
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-47-
manganese emissions to the atmosphere are 10 pounds per ton
of manganese processed.
During 1968 the manganese in chemicals and other miscellaneous
uses was 60, 000 tons, and atmospheric emissions were an esti-
mated 300 tons.
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CONSUMFTIVE USES
The largest manganese emissions to the atmosphere during
consumptive use are those due to the combustion of coal and
oil. Others that occur are usually of such a nature that atmos-
pheric emissions are negligible.
COAL
The manganese content of various samples of coal has been re-
ported as shown in Table IX, and the average concentration in
domestic coal is about 26.4 ppm. Coal consumed in the United
States during 1968 was 508,990, 000 tons (bituminous and anthra-
cite) /; therefore, the manganese in coal was about 1.3,400
tons. Since fly ash is about 65 percent of total ash and approxi-
mately 75 percent of fly ash is collected, the manganese emis-
sions to the atmosphere should be 16 percent of the manganese
contained in the coal, or 2, 150 tons.
A study has been made regarding emissions from coal fired
power plants and the emissions of manganese have been recorded.
Six power boilers were tested, each a different type, and each
value reported was the average of at least two tests. Two of
1- Minerals Yearbook; Bureau of Mines; 1968.
-------
TABLE IX
AVERAGE MANGANESE CONTENT IN ASH QF COAL
Region Frequency of Mn Content Ash Content
Detection - % of Ash - % of Coal - %
Eastern Province 100 0. 026 9. 3
Interior Province 100 0.0325 10.5
Western States 100 0.0212 9.8
Average Manganese Content of Coal
Mn Content
of Coal -%
0. 0024
0. 0034
0.0021
0. 00264
NOTE - The above table based on "Spectrochemical Analyses of Coal Ash for Trace
Elements" Table 1; Bureau of Mines RI7281; July, 1969.
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-50-
the boilers were fired with Illinois coal; two burned Pennsyl-
vania coal; one used some coal from Ohio and some from West
Virginia; one burned part Kentucky and part West Virginia coal.
Manganese concentrations in the fly ash samples taken before fly
A
ash collection ranged from 4. 2 to 17. 0 grains per scf x 10 .
A
The average was 8.47 grains per scf x 10' . In the samples
taken after fly ash collection, the manganese concentration
ranged from 0. 26 to 1. 6 grains per scf x 10 and the average
was 0. 92 grains per scf x 10"4 _/. Based on 508, 990, 000 tons
of coal consumed in the United States during 1968, 90 percent
application of control, 160 scf of flue gas per pound of coal and
the average concentration in fly ash stated above, the manganese
emissions for 1968 due to the combustion of coal are calculated
at 1, 950 tons.
In this report the figure of 1,950 tons is used as manganese emis
sions to the atmosphere due to the combustion of coal.
1- Cuffe, Stanley T. and Gerstle, Richard W. ; "Emissions from
Coal Fired Power Plants"; Public Health Service Publication
No. 999-AP-35; 1967.
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OIL
In order to estimate manganese emissions to the atmosphere
resulting from the combustion of fuel oil, it was necessary to
determine the manganese content as well as the quantity of oil
received from numerous foreign and domestic sources. Analy-
ses of more than 400 samples of crude and residual oils were
obtained from the major oil companies and the utilities along
the east coast of the United States.
The data show that nearly all crude oil contains some manga-
nese; the concentrations ranging from nearly zero to more
than 2,000 ppm. It also shows that residual oil contains a
higher percentage of manganese than the crude. When oil is
refined the manganese and other trace metals tend to concen-
trate in the heavy fractions; the residual oil, the road oil, and
the asphalt. According to the information obtained from oil
companies, the residua] fuel oils may be expected to contain
4 to 6 times as much manganese as the crude oils.
Unfortunately, most of the analyses available weve of crude
oil. They show oil from California, Colorado, and Utah con-
tains more manganese than that from Kansas, Oklahoma, and
Texas (Table X). Residual fuel oil from the United States con-
tains about 158 ppb manganese, while that from the Middle East
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TABLE X
MANGANESE CONTENT OF DOMESTIC CRUDE Oi:LS
Source
Arkansas
California
Colorado
Kansas
Montana
New Mexico
Oklahoma
Texas
Utah
Wyoming
Manganese
Content - ppb
120
138
208
13
5
21
30
29
1,445
44
NOTE - The above table is based on private communication
with industrial sources.
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-53-
averages about 120 ppb. Analyses of eight residual fuel oils
from South America show that manganese is below the limit
of detection.
During 1968 the demand for residual fuel oil in the United States
was 668, 239, 000 barrels. Imports were 409, 928, 000 barrels,
and the remainder were principally from domestic production V.
Imports were about 92 percent from South America and the West
Indies; 8 percent from the Middle East, Canada, and other
countries /.
MANGANESE IN RESIDUAL OIL,
CONSUMED IN THE UNITED STATES - 1968
g Quantity Mn Content Mn Content
Barrels ppb Tons
United States
South America
Middle East and Other
TOTAL
258, 311,
376,000,
33,928,
668,239,
000 158
000
000 120
000
7
-
1
8
1- "Crude Petroleum, Petroleum Products, and Natural-Gas-
Liquids: 1968"; Petroleum Statement, Annual; Mineral
Industry Surveys; Bureau of Mines; Washington, D. C.
2- Based on import data from the Office of Air Programs;
Durham, N. C.
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-54-
In the past power boilers designed to burn fuel oil were not us-
usually equipped with air pollution control apparatus. It was only
the coal fired or the combination coal-oil units that included
mechanical collectors and/or electrostatic precipitators. When
these combination units burn oil, only a small part of the particu-
late matter becomes an atmospheric emission.
The records show that 669 million barrels of residual oil were
consumed in the United States during 1968. The electric utili-
ties used 28 percent of the total, or 185 million barrels, and
were the only users with any significant degree of air pollution
control. A survey was conducted and it was determined that
the electric utility percent of control when burning fuel oil was
about 32 percent.
Based on 10 percent overall control, the manganese emissions
to the atmosphere during 1968 due to the combustion of fuel oil
totaled 7 tons.
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INCINERATION AND OTHER DISPOSAL
Information concerning sewage and sludge was the only data
available during this study regarding atmospheric emissions
of manganese that result from incineration or disposal.
SEWAGE AND SLUDGE
A recent report concerning the burning of sewage and sludge
indicates the present burning rate in the United States is about
Z, 000 tons per day /. Based on a manganese content of 240
ppm (dry weight) / the atmospheric emissions currently
total 175 tons of manganese per year.
1.- Private communication from the Federal Water Pollution
Control Authority.
2- Clark, L. J. and Hill, W. L. ; "Occurrence of Manganese,
Copper, Zinc, Molybdenum, and Cobalt in Phosphate
Fertilizers and Sewa.ge Sludge"; J. Assoc. Official Agr.
Chemists; 4]; pp. 63.1-637; 195*T
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APPENDIX A
COMPANIES DEALING IN MANGANESE
AND MANGANESE COMPOUNDS
ALABAMA
Woodward Company
LOCATION
Woodward
CALIFORNIA
American Potash and Chemical Corp.
Capco Alloy Steel Company
Electronic Space Products, Inc.
Metal Organics, Inc.
Wilson and George Meyer ;& Company
Mountain Copper Company, Ltd.
Los AngeJ.es
Los Angeles
Los Angeles
San Carlos
So. San Francisco
Martinez
CONNECTICUT
Anaconda American Brass Company Waterbury
Michael Schiavone & Sons, Inc. New Haven
D. C.
Hercules, Inc.
Wa shington
GEORGIA
Frank Smith
Tennessee Corporation
Carre rsville
Atlanta
ILLINOIS
Amsco Division of Abex Corp.
Atlantic Chemicals and Metals Co.
Carus Chemical Company
Ben J. Harris and Company
Hickma.n, Williams and Company
Kraft Chemical Company
Chicago Heights
Chicago
LaSalle
Chicago Heights
Chicago
Chicago
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R. Lavin and Sons, Inc.
Miller and Company
Stresen-Reuter International
Wilson Labs
Chicago
Chicago
Bensonville
Chicago
IOWA
Bonewitz Laboratories, Inc.
Burlington
MARYLAND
Ansam Metals Corporation Baltimore
Chemetals Division, Diamond Shamrock
Chemical Company Baltimore
Glidden Metals Group Baltimore
Manganese Chemical Corporation Baltimore
MICHIGAN
Frankel Company, Inc.
Haviland Products Company
Detroit
Grand Rapids
MINNESOTA
Manganese Chemical Corporation
Minneapolis
MISSOURI
Mallinckrodt Chemical Works
St. Louis
NEW JERSEY
Advance Division, Carlisle'Chemical
Works, Inc.
A and S Corporation
J. T. Baker Chemical Compa.ny
Leonard J. Buck, Inc.
Eastern Chemical Corporation
New Brunswick
Verona
Phillips burg
Jersey City
Pequannock
-------
-58-
General Metallic Oxides Company
Hummel Chemical Company, Inc.
Import Chemical Company
Metallurgical International Inc.
Nitine, Inc.
Octagon Process, Inc..
Shieldalloy Corporation
Taylor-Wharton Company
Tenneco Chemicals, Inc.
Troy Chemical Corporation
Var-Lac-Oid Chemical Company
Max Zuckerman and Sons, Inc.
Jersey City
Newark
Jersey City
New Shrewsbury
Whippany
Edgewater
Newfield
High Bridge
Piscataway
Newark
Elizabeth
Owings Mills
NEW YORK
Airco Alloys and Carbide Division
Air Reduction Company, Inc.
Allied Chemical Corporation
Alloys Unlimited, Inc.
American Smelting and Refining Co,
Anchor Metal Company, Inc.
Anglo-American Metal & Fe.rro Alloy
Corporation
Associated Metals and Minerals Corp.
Atomergic Chemetals Company
H. J. Baker Brothers, Inc.
Be]mont Smelting & Refining Works, Inc.
Berkshire Chemicals, Inc.
Charles B. Chrystal Company, Inc.
City Chemical Corporation
Cometals, Inc.
Continental Ore Corporation
Debevoise-Anderson Company, In.c.
Faesy and Besthoff, Inc.
Fallek Products Company, Inc.
Galla rd-Schlesinger Chemi ca.l
Manufacturing Corporation.
M. Golodetz and Company
W. R. Grace and Company
Herzog Metal Corporation
Hooker Chemical Corporation
Industrial Chemical and Dye Corp.
A. Johnson and Company, Inc.
Kingston Chemical Company, Inc.
Niagara Falls
New York
New York
Melville
New York
Brooklyn
New York
New York
Carle Place, L.I.
New York
Brooklyn
New York
New York
New York
New York
New York
New York
New York
New York
Carle Place,
New York
New York
New York
Niagara Falls
New York
New York
New York
L.I.
-------
-59-
Kolon Trading Company, Inc.
Mackenzie Chemical Works
McKesson Chemical Company
Messina, Inc.
Metallurg Alloy Corporation
Milwaukee Tool and Equipment Co.
Wm. H. Muller and Company, Inc.
Naftone, Inc.
The New Jersey Zinc Company
Ore and Ferro Corporation
Pancoast International Corporation
Charles Pfizer and Company, Inc.
Philipp Brothers
Primary Industries Corporation
Progressive Alloys Corporation
The Selney Company, Inc.
Semi Alloys, Inc.
E. M. Sergeant Pulp and Chemical
Company, Inc.
Smith Chemical and Color Co. , Inc.
Sterwin Chemicals, Inc.
C. Tennant Sons and Company
The Titan Industrial Corporation
Union Carbide Corporation, Ferro-
alloys Division
Union Carbide Corporation, Mining
and Metals Division
United Mineral and Chemical Corp.
Winth.rop Laboratories
Witco Chemical Corporation
New York
Central Islip
New York
Bedford Hills
New York
New York
New York
New York
New York
New York
New York
New York
New York
New York
Brooklyn
New York
Mount Vernon
New York
Brooklyn
New York
New York
New York
New York
New York
New Yor k
New York
New York
NORTH CAROLINA
Mineral Research and Development Corp. Concord
OHIO
Barium and Chemicals, Inc. Steubenville
Chemetron Corporation Cleveland
Chemical. Division Ferro Corporation Bedford
Glidden-Du.r.kee Division Cleveland
Globe Metallurgical Division,
Interlake Steel Corporation Cleveland
-------
-60-
Haley Smelting, Inc.
Hall Chemical Company
Harshaw Chemical Company
McGean Chemical Company
Mooney Chemicals, Inc,
Oglebay-Norton Company
Ohio Ferro-Alloy Corporation
Pickards Mather and Company
I. Schumann and Company
S. C. M. Corporation
Shepherd Chemical Company
C. L. Zimmerman Company
Parma
Wickliffe
Cleveland
Cleveland
Cleveland
Cleveland
Canton
Cleveland
Bedford
Cleveland
Cincinnati
Cincinnati
PENNSYLVANIA
Bethlehem Steel Corporation
Bram Metallurgical Chemical Co.
Brass and Copper Sales, Inc.
C. E. Minerals
Ceramic Color and Chemical
Manufacturing Company
Chase Chemical Corporation
Chemalloy Company, Inc.
Chromium Mining and Smelting Corp.
Colonial Metals Company
Damascus Steel Casting
Fisher Scientific Company
Foote Mineral Company
Gano Moore Company, Inc.
O. Hommel Company
Lavino Division, International
Minerals and Chemicals Corp.
Mercer Alloys
Metallurgical Products Company
J. Meyer and Sons, Inc.
Prince Manufacturing Company
Reading Alloys, Inc.
Fra.nk Samuel and Company, Inc.
Shenango, Inc.
Taylor Wha.rton Company, Division
of Harsco Corporation
Charles A. Wagner Company, Inc.
Welding Wholesale Company
Bethlehem
Philadelphia
Philadelphia
King of Prussia
New Brighton
Pittsburgh
Bryn Mawr
Pittsburgh
Columbia
New Brighton
Pittsburgh
Exton
Wynnewood
Pittsburgh
Philadelphia
Greenville
Philadelphia.
Philadelphia
Bowmanstown
Robesonia.
King of Prussia
Pittsburgh
Easton
Philadelphia
Philadelphia
-------
-61-
TENNESSEE
Eastman Chemical. Products, Inc. Kingsport
Foote Mineral Company Knoxville
(American Meta] Market, Aug. 10, 1970; Thorny s Register,
Dec. 1968 Ed. )
-------
BIBLIOGRAPHIC DATA
SHEET
1. lU-port No.
APTD-1509
3. Recipient's Accession No.
4. Title and Subtitle
National Inventory of Sources and Emissions: Manganese - 1968
5- Report Date
August 1971
6.
7. Author(s)
8- Performing Organization Kept.
No.
9. Performing Organization Name and Address
W. E. Davis & Associates
9726 Sagamore Road
Leawood, Kansas
10. Project/Task/Work Unit No.
11. Contract/Grant No.
CPA 70-128
12. Sponsoring Organization Name and Address
ENVIRONMENTAL PROTECTION AGENCY
Office of Air Programs
Durham, North Carolina
13. Type of Report & Period
Covered
14.
15. Supplementary Notes
16. Abstracts
The inventory of atmospheric emissions has been prepared to determine the nature,
magnitude, and extent of the emissions of manganese in the United States for the year
1968. The flow of manganese in the U. S. for that .year has been traced and charted.
The consumption was 1,150,000 tons while domestic production was only 48,000 tons.
Imports principally from Brazil, Gabon, Republic of South Africa, Congo, Guyana, India
Angola, and Australia totaled 1,053,000 tons. Emissions to the atmosphere during the
year were 18,992 tons. About 47% of the emissions resulted from the production of
ferroalloys and about 37% from the production of iron and steel. The combustion of
coal was also a significant source of manganese emissions.
17. Key Words and Document Analysis. 17a. Descriptors
Air pollution
Emission
Inventories
Sources
Manganese
Consumption
Production
International trade
Industries
Reprocessing
17b. Identificrs/Open-Ended Terms
Year 1968
United States
Utilization
Metallurgical furnaces
17c. COSATI Field/Group
13B
18. Availability Statement
FORM NTIS-35 (REV. 3-721
Unlimited
19..Security Class (Tliis
Report)
UNCLASSIFIED
20. Security Class (This
Page
UNC1.ASS1FIFD
21. No. of Pages
68
22. Price
USCOMM-DC I4Q52-P72
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INSTRUCTIONS FOR COMPLETING FORM NTIS-35 (10-70) (Bibliographic Data Sheet based on COSATI
Guidelines co Format Standards for Scientific and Technical Reports Prepared by or for the Federal Government,
PB-180 600).
1. Report Number. Each individually bound report shall carry a unique alphanumeric designation selected by the performing
organization or provided by the sponsoring organization. Use uppercase letters and Arabic numerals only. Examples
FASEB-NS-87 and FAA-RD-68-09.
2. Leave blank.
3. Recipient's Accession Number. Reserved for use by each report recipient.
4. Title and Subtitle. Title should indicate'clearly and briefly the subject coverage of the report, and be displayed promi-
nently. Set subtitle, if used, in smaller type or otherwise subordinate it to main title. When a report is prepared in more
than one volume, repeat the primary title, add volume number and include subtitle for the specific volume.
5- Report Dote. F.ach report shall carry a date indicating at least month and year. Indicate the basis on which it was selected
(e.g., date of issue, date of approval, date of preparation.
6' Performing Organization Code. Leave blank.
7. Authors). Give name(s) in conventional order (e.g., John R. Rot, or J.Robert Doc). List author's affiliation if it differs
from the performing organization.
8. Performing Orgonizotion Report Number. Insert if performing organization wishes to assign this number.
9. Performing Orgoni xofion Name and Address, dive name, street, city, state, and zip code. List no more than two levels of
an organizational hierarchy. Display the name of the organization exactly as it should appear in Government indexes such
as USCRDR-I.
10. Project/Task/Work Unit Number. Use the project, task and wotk unit numbers under which the report was prepared.
11. Controct/Gront Number. Insert contract or £rant number under which report was prepared.
12- Sponsoring Agency Nome and Address. Include zip code.
13. Type of Report and Period Covered. Indicate interim, final, etc., and, if applicable, dates covered.
14. Sponsoring Agency Code. Leave blank.
15. Supplementary Notes. Enter information not included elsewhere but useful, such as: Prepared in cooperation with . . .
Translation of ... Presented at conference of ... To be published in ... Supersedes . . . Supplements . . .
16. Abstract. Include a brief (200 words or less) factual summary of the most significant information contained in the report.
If the report contains a significant bibliography or literature survey, mention it here.
17. Key Words and Document Analysis, (a). Descriptors. Select from the Thesaurus of Engineering and Scientific Terms the
proper authorized terms that identify the major concept of the research and are sufficiently specific and precise to he used
as index entries for cataloging.
(b). Identifiers ond Open-Ended Terms. Use identifiers for project names, code names, equipment designators, etc. Use
open-ended terms written in descriptor form for those subjects for which no descriptor exists.
(c). COSATI Field/Group. Field and Group assignments are to be taken from the 1965 COSATI Subject Category List.
Since the majority of documents are mult id isc iplinary in nature, the primary Field/Group assignments) will be the specific
discipline, area of human endeavor, or type of physical object. The application(s) will be cross-referenced with secondary
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FORM NTIS-3S IREV. 3-721 . USCOMM-OC 14
t G. P. O. 1973 746-77O / 4182
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