Gaseous Reduction of Manganese Ores: A Review and Theoretical Insight

Cheraghi, Alireza; Yoozbashizadeh, H.; Safarian, Jafar

doi:10.1080/08827508.2019.1604523

Cited by 36 publications

(17 citation statements)

References 112 publications

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“…With an estimated world production of 17 million tons in 2018, 1) manganese ores have been widely used in many fields, such as the steel industry and in medicine. Most of manganese alloys produced globally is used in the steel industry, [2][3][4][5][6][7] while only about 6% of manganese ore is worldwide used to produce special metallurgical and chemical products. Management of the energy consumption in manganese alloys has become of primary importance to ensure the competitiveness of the industry as well as the minimization of environmental impacts, such as the greenhouse gas emissions.…”

Section: Introductionmentioning

confidence: 99%

“…Hydrogen gas can also be used to reduce higher manganese oxides, according to the following reactions: Various studies conducted on the reduction of manganese ores have demonstrated that CO and H 2 alone are unable to reduce MnO in the solid state under normal working conditions. 2,3,8,[15][16][17][18][19] The total reduction down to Mn metal must hence be performed with solid carbon.…”

Section: Introductionmentioning

confidence: 99%

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Pre-reduction Behaviour of Manganese Ores in H<sub>2</sub> and CO Containing Gases

2020

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Pre-reduction Behaviour of Manganese Ores in H<sub>2</sub> and CO Containing Gases

2020

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“…Concentrates of Mn ores can be future raw materials as many low-grade ores can be dressed to increase Mn content. As Mn oxides are reduced to MnO via the chemical reactions (1) to (3) in the pre-reduction step, the iron oxides in the Mn lump ore or concentrates are simultaneously reduced to metallic iron, these types of ores have always some iron oxides [4]. Any needed additional iron is then added into the smelting-reduction furnace to produce Green FeMn.…”

Section: Production Of Green Femnmentioning

confidence: 99%

“…It was shown previously that using methane instead of solid carbon via a potential technology is accompanied with less energy consumption and less CO 2 emission, while it is also possible to produce valuable by-products [3]. The idea of using methane was based on the fact that the reduction of Mn oxides (MnO 2 , Mn 2 O 3 , Mn 3 O 4 ) to MnO is possible by CO and H 2 gases, while further MnO reduction to metallic Mn is not possible by these gases and carbon supply from methane is needed to reduce MnO [3,4]. It is worth mentioning that in SAF, MnO reduction occurred by C in a coke bed area and the generated CO reduces the higher Mn oxides in the furnace burden to MnO.…”

Section: Introductionmentioning

confidence: 99%

A Sustainable Process to Produce Manganese and Its Alloys through Hydrogen and Aluminothermic Reduction

Safarian

2021

Processes

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Hydrogen and aluminum were used to produce manganese, aluminum–manganese (AlMn) and ferromanganese (FeMn) alloys through experimental work, and mass and energy balances. Oxide pellets were made from Mn oxide and CaO powder, followed by pre-reduction by hydrogen. The reduced MnO pellets were then smelted and reduced at elevated temperatures through CaO flux and Al reductant addition, yielding metallic Mn. Changing the amount of the added Al for the aluminothermic reduction, with or without iron addition led to the production of Mn metal, AlMn alloy and FeMn alloy. Mass and energy balances were carried out for three scenarios to produce these metal products with feasible material flows. An integrated process with three main steps is introduced; a pre-reduction unit to pre-reduce Mn ore, a smelting-aluminothermic reduction unit to produce metals from the pre-reduced ore, and a gas treatment unit to do heat recovery and hydrogen looping from the pre-reduction process gas. It is shown that the process is sustainable regarding the valorization of industrial waste and the energy consumptions for Mn and its alloys production via this process are lower than current commercial processes. Ferromanganese production by this process will prevent the emission of about 1.5 t CO2/t metal.

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“…The commercial thermochemical software FactSage was chosen as a computational tool because its databases provide thermochemical data for all the compounds relevant in pellet systems. A similar approach involving the application of thermochemical software to study reduction processes was reported by Cheraghi et al [16], for example, who studied the gaseous reduction of manganese ores by CO and H 2 .…”

Section: Introductionmentioning

confidence: 97%

Estimation of Iron Ore Pellet Softening in a Blast Furnace with Computational Thermodynamics

Iljana

Heikkinen

Fabritius

2021

Metals

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In blast furnaces it is desirable for the burden to hold a lumpy packed structure at as high a temperature as possible. The computational thermodynamic software FactSage (version 7.2, Thermfact/CRCT, Montreal, Canada and GTT-Technologies, Aachen, Germany) was used here to study the softening behavior of blast furnace pellets. The effects of the main slag-forming components (SiO2, MgO, CaO and Al2O3) on liquid formation were estimated by altering the chemical composition of a commercial acid pellet. The phase equilibria for five-component FeO-SiO2-CaO-MgO-Al2O3 systems with constant contents for three slag-forming components were computed case by case and the results were used to estimate the formation of liquid phases. The main findings of this work suggested several practical means for the postponement of liquid formation at higher temperatures: (1) reducing the SiO2 content; (2) increasing the MgO content; (3) reducing the Al2O3 content; and (4) choosing suitable CaO contents for the pellets. Additionally, the olivine phase (mainly the fayalitic type) and its dissolution into the slag determined the amount of the first-formed slag, which formed quickly after the onset of softening. This had an important effect on the acid pellets, in which the amount of the first-formed slag varied between 10 and 40 wt.%, depending on the pellets’ SiO2 content.

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Gaseous Reduction of Manganese Ores: A Review and Theoretical Insight

Cited by 36 publications

References 112 publications

Pre-reduction Behaviour of Manganese Ores in H<sub>2</sub> and CO Containing Gases

Pre-reduction Behaviour of Manganese Ores in H<sub>2</sub> and CO Containing Gases

A Sustainable Process to Produce Manganese and Its Alloys through Hydrogen and Aluminothermic Reduction

Estimation of Iron Ore Pellet Softening in a Blast Furnace with Computational Thermodynamics

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