Prereduction of Nchwaning Ore in CO/CO2/H2 Gas Mixtures

Abstract

Prereduction of Nchwaning manganese ore was investigated by isothermal reduction between 600 and 800 °C to optimize the conditions for industrial pretreatment of manganese ores. Experiments were conducted in CO/CO2 gas mixtures with and without hydrogen at two different oxygen partial pressures. Ore in the size fraction 9.52–15 mm was reduced in a thermogravimetric furnace, and the O/Mn ratio from the chemical analysis was used to determine the extent of prereduction. The samples were investigated by X-ray diffraction to investigate the evolution of phases under the course of reduction. The X-ray diffraction revealed that bixbyite and braunite (I and II) were reduced to manganosite with no or limited formation of hausmannite. Reduction of iron oxides subsided with wüstite, which is stabilized by manganese in the monoxide phase, and hydrogen was seen to improve the reduction of iron oxides. Modeling revealed that the reduction rate increased 2.8-fold upon increasing the CO content from 30% to 70% in a CO/CO2 gas mixture. The addition of hydrogen improved the reduction rate with factors of 1.3 and 2.6 for the low and the high oxygen partial pressures, respectively. Hence, the optimal conditions for pretreatment can be achieved by keeping the oxygen partial pressure as low as possible while adding hydrogen to the reducing gas and ensuring a high reduction temperature. Successful pretreatment limits the extent of the Boudouard reaction in the submerged arc furnace, reducing the amount of CO produced and, thus, reducing the CO available for pretreatment. Hydrogen is a useful addition to the pretreatment unit since it lowers the oxygen partial pressure and improves the kinetics of prereduction.

Prereduction Behavior of Manganese Ores With Solid Carbon and in CO/CO2 Gas Atmosphere

“…This is mainly because manganese ores used by industry in the production of FeMn alloys have different origins and therefore differ in mineralogy, chemical and physical properties. Typically, metallurgical grade ores contain more than 35 pct Mn and literature [8][9][10][11][12][13][14] covers properties of ores with Comilog, CVRD, Groote Eylandt, Wessels and Mamatwan type ores as examples. Several studies [10,11,[15][16][17][18][19][20][21][22] have been conducted on the prereduction of manganese ores by either CO gas or solid carbon.…”

“…Typically, metallurgical grade ores contain more than 35 pct Mn and literature [8][9][10][11][12][13][14] covers properties of ores with Comilog, CVRD, Groote Eylandt, Wessels and Mamatwan type ores as examples. Several studies [10,11,[15][16][17][18][19][20][21][22] have been conducted on the prereduction of manganese ores by either CO gas or solid carbon.…”

“…Similar oxygen levels have been reported in previous studies. [10,19,20] Fe concentration in manganese ores as measured by XRF was converted to Fe 2 O 3 , assuming that it is present in the ore as Fe(III). On complete prereduction, Fe concentration was converted to FeO, assuming that it is present there as Fe(II).…”

“…The prereduction of ores is affected by CO concentration in the reducing gas atmosphere. Several studies [10,11,19,26,27] have reported an increased reduction rate of manganese ores with increasing CO concentration in CO-CO 2 atmosphere. The concentration of CO in the reducing gas atmosphere is generated from the metal producing reaction (reaction [8]) and/or the oxidation of C by CO 2 .…”

“…The carbonates present in the ores decompose endothermically. Several studies [10,32,33] have shown that the decomposition of carbonates is highly dependent on temperature and CO 2 content in the reducing atmosphere, with increasing temperature and lowering the partial pressure of CO 2 resulting in a greater extent of decomposition. The remaining CO 2 content in the samples analyzed as a function of temperature is shown in Figure 3.…”