This paper brings an innovative processing route of manganese deep-sea nodules, which results in completely new grades of alloys. Deep-sea nodules were processed by aluminothermic method without the extraction of individual elements, producing complexly alloyed manganese-based “natural alloys”. Three levels of the amount of aluminum were used for the aluminothermic reduction, and hence the alloys differ strongly in the amount of aluminum, which has a significant effect on their phase composition. The alloys have very high wear resistance, comparable with tool steel. The disadvantage of low-aluminum alloy is the susceptibility to local thermal cracking during friction, which occurs especially in the case of a dry sliding wear against the static partner with low thermal conductivity.

The possible use of leaching residue from leaching deep-sea nodules in SO2/H2SO4/H2O medium as a low-cost adsorbent of heavy metals (Pb(II), Cd(II), Cu(II), Ni(II), Co(II), As(V)) was studied. The leaching residue was found to be an effective adsorbent for all of the tested elements; however, it was inactive in the solution containing As(V). The chemical activation of adsorbent in 10 vol. % HCl resulted in the greatest improvement of adsorption properties, while the activation in 10 vol. % HNO3 and heat treatment at 250 °C did not significantly affect the sorption characteristics of treated adsorbents compared with the original leaching residue. After HCl activation, the maximal adsorption capacities for lead (12.0 mg/g at pH 5.0 after 1 h), nickel (3.1 mg/g at pH 5.5 after 4 h) and cobalt (2.0 mg/g at pH 5.0 after 2 h) were achieved. Additional mechanical treatment connected with HCl activation provided the highest adsorption capacities for cadmium (11.5 mg/g at pH 4.0) and copper (5.7 mg/g at pH 4.5). Coprecipitation of Fe/Al-based particles on the surface of the leaching residue increased As(V) removal of the adsorbent. Surface coating based on AlIII was extremely effective, causing the increase of the adsorption capacity from 0 with the original leaching residue, to 28.1 mg/g (pH 7.0, 24 min). Kinetics studies showed the rapid progress of adsorption for Pb(II), Cd(II), and As(V) in tens of minutes, while the adsorption of Cu(II), Ni(II) and Co(II) approached a steady state after 2 h.

Processing of polymetallic ores, especially deep-sea nodules, is always considered as extraction of individual metals. This work brings a new approach, i.e. to reduce the ore in a single step without any separation process. Such new metallurgical approach does not only save the costs, but also generates whole new alloys. The properties of these new alloys were tested. The applicability of the aluminothermic process, as well as the composition and possible use of the slag, are discussed. The alloys, containing manganese-based solid solution and intermetallics including the popular inverse Heusler phase Mn2Fe(Si,Al), are characterized by high hardness and wear resistance. Due to relatively low efficiency of the aluminothermic process, the aluminothermic slags contain significant amount of manganese and reasonable portion of nickel, copper and magnesium and therefore it could be still used as the raw material after the alloy was obtained by aluminothermy.

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