Electrolytic manganese dioxide can be prepared from manganese carbonate ore by crushing, milling and leaching the ore in sulphuric acid. Manganese sulphate is crystallised from the solution, redissolved and electrolysed to give the manganese dioxide. (a) After crushing, the ore is milled from a maximum size of 5.0 mm to 1.0 mm using an energy input of 70kW/tonne. Using Bond’s relationship, calculate the work index. If the milling equipment were allowed to mill to 0.075 mm what will be the energy input? (b) If the crystallisation were performed in a 30m3 tank and the concentration of the solution entering the tank were 160 grams per litre and left the tank at 40 grams per litre, how much MnSO4.5H2O would be produced

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Hazard is the intrinsic property of a material or process which harms the people, buildings, or environment. Health, safety, hazard, risk assessment, loss prevention, and environmental consideration play an important role while designing a chemical processing plant. Hazard is often confused with risk. Risk measures the magnitude of loss and injury of likelihood incidents or the consequence and frequency of incidents.