Evaluation of particulate matter emissions from manganese alloy production using life-cycle assessment

•LCA data was used to investigate globally aggregated industry data for PM emissions from the manganese alloy supply chain.•The assessment shows that most PM emissions associated with manganese production occur beyond manganese facilities boundaries.•Fugitive emissions from metal and slag tapping, casting, crushing and screening are the largest source of Mn-bearing PM at ground level.•Enhancements in control of PM and reduction in occupational exposure can be achieved by trapping and recycling fugitive dust.•Other measures include limiting by-passing of primary furnace emissions controls and applying secondary fugitive emissions controls.

Life-cycle assessments (LCAs) provide a wealth of industry data to assist in evaluating the environmental impacts of industrial processes and product supply chains. In this investigation, data from a recent LCA covering global manganese alloy production was used to evaluate sources of particulate matter (PM) emissions associated with the manganese alloy supply chain. The analysis is aimed at providing an empirical, industry-averaged breakdown of the contribution that processes and emissions controls have on total emissions, manganese releases and occupational exposure.The assessment shows that 66% of PM emissions associated with manganese production occur beyond manganese facilities. Direct or on-site emissions represent 34% of total PM and occur predominantly as disperse sources during mineral extraction and hauling, and as primary furnace emissions. The largest contribution of manganese-bearing PM at ground-level is associated with fugitive emissions from metal and slag tapping, casting, crushing and screening.The evaluation provides a high-level ranking of emissions by process area, to assist in identifying priority areas for industry-wide initiatives to reduce emissions and occupational exposure of manganese. The range of PM emission levels in industry indicate that further enhancements in PM emissions can be achieved by sharing of best practices in emissions controls, limiting furnace conditions which lead to by-passing of emissions controls and application of secondary emission controls to capture fugitive emissions during tapping and casting. The LCA approach to evaluating PM emissions underscores the important role that process optimization and resource efficiency have on reducing PM emissions throughout the manganese supply chain.