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REVIEW PAPER
Received: 9 March 2016 / Accepted: 24 May 2016 / Published online: 17 June 2016
Ó The Institution of Engineers (India) 2016
Abstract This review comprises of information about the manganese is above 1,500,000 ton and it is destined to
recovery of manganese through leaching and carbothermic increase [2]. Pyrolusite is an important manganese mineral
reduction routes. In industrial processes, various critical in manganese ores [3]. MnO2 is stable in acidic or alkaline
parameters such as ore size, temperature, pressure, gas oxidizing conditions, this favours the reduction process
atmosphere and ore composition etc. affect the reduction or [4–6]. At present, the main reduction technology is
recovery of Mn from ores. Authors have tried to bring reduction roasting using coal as reductant and fuel in the
those critical parameters in this review which is currently pyrolusite treatment industry [7]. The reason behind the
being considered as important industrial parameters for Mn diminishment of traditional technologies are pollution
ore processing. This paper deals with both pyro-metallur- problems and greenhouse effect [8]. Therefore, production
gical and hydro-metallurgical routes for Mn ore reduction of manganese demands more clean and eco-friendly pro-
and gives brief summary about the critical parameters. cesses than the traditional processes.
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148 J. Inst. Eng. India Ser. D (January–June 2017) 98(1):147–154
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J. Inst. Eng. India Ser. D (January–June 2017) 98(1):147–154 149
Fig. 1 Non-isothermal
carbothermal reduction of
Wessels ore in hydrogen. Ramp
rate 5 °C/min [17]
phase. Kononov et al. [17] have worked on carbothermal smaller particle size was due to an increase in surface area
reduction of manganese ore in hydrogen, results are illus- for the reaction with CO.
trated through Fig. 1. Very few works have been done on
hydrogen atmosphere. Effect of Carbon Content
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150 J. Inst. Eng. India Ser. D (January–June 2017) 98(1):147–154
Bio leaching, electro leaching and acid leaching are some Electro-Reductive Leaching
of the leaching techniques used in Mn recovery process.
Bio leaching and electro-leaching involve chemical Mn can be dissolved through electro reductive process as
reduction as a primary step. MnO2 is a semiconductor and can be used as an electrode.
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Effect of Temperature
Fig. 5 Effect of liquid/solid ratio upon the leaching recovery of
manganese; oxalic acid concentration 0.31 mol/L, H2SO4 concentra-
It can be seen that increasing the temperature from 25 to tion 2 mol/L, time 90 min, temperature 70 °C [42]
90 °C increases the recovery of manganese from 67.3 to
98.1 % and for iron from 10 to 35.6 %. It concluded that in
the presence of H2O2 and at 25 °C, a recovery of 82.5 % and for iron from 12 to 21 %. It was found that at the
was obtained for manganese and that elevated temperatures conditions studied a complete recovery of manganese was
did not affect the manganese recovery (opposite to the case achieved at the liquid/solid ratio of 30/1.
of oxalic acid); however, the iron recovery increased from
9.5 % (at 25 °C) to 21.8 % (at 85 °C). Similarly, it has Effect of Sulfuric Acid Concentration
been found that manganese recovery in the presence of
H2O2 decreased at elevated temperatures (more than Ismail et al. [6] have studied about the effect of sulfuric acid
55 °C). Hydrogen peroxide decomposes to hydrogen and concentration on Mn recovery at different sulfuric acid con-
water during an exothermic reaction. centrations ranging from 10 to 40 % in both sawdust treatment
method and lactose-treatment method, while keeping the stoi-
Effect of Time chiometric amount of acid to MnO2 constant at 2, consequently
the solid/liquid ratio was varied from 14.29 to 3.57 in sawdust
Ismail et al. [6] have studied the time factor on Mn case and from 12.5 to 3.13 in lactose case. They revealed that
reduction in the period range from 15 to 180 min. They the conversion extent of manganese was increased by
found that the dissolution of manganese from low grade increasing sulfuric acid concentration in both sawdust and
manganese oxide ore by either sawdust or lactose may lactose cases, where by increasing acid concentration from 10
involve at least four steps in series, hydrolysis to to 40 %, the manganese recoveries were increased from 61.75
monosaccharaides, diffusion of the reductant from the main to 91.6 % and from 59.19 to 88.50 % in sawdust and lactose
bulk of the liquid through the boundary layer to active respectively. Although, in lactose case, manganese recovery
sites, i.e. to manganese mineral grains, the nucleation of increased from 82.85 to 86 % by increasing acid concentration
products at the active sites, and hydration of the products from 20 to 25 %, the 20 % acid concentration was favourable
and diffusion into the solution. because the iron recovery was lower than that in 25 % acid
Therefore, the reaction is a time dependent reaction. concentration, where iron recovery increased from 36.75 to
They observed optimum reaction time of pyrolusite ore is 47.35 % by increasing acid concentration from 20 to 25 %. The
90 min in sawdust case and 120 min in lactose case. optimum sulfuric acid concentration required for leaching of
pyrolusite ore is 30 % in sawdust case and 20 % in lactose case.
Effect of Liquid/Solid Ratio At these concentrations, the manganese recoveries were 89.25
and 82.85 % for sawdust.
Ghafarizadeh et al. [42] has investigated about the effect of Ghafarizadeh et al. [42] have also investigated the effect
liquid/solid ratio, exhibited through Fig. 5. They found of H2SO4 concentration on the simultaneous leaching of
increasing the liquid to solid ratio from 5 to 30, the manganese and iron in the absence of any reducing agent,
leaching recovery of manganese increased from 64 to 99 % graphical representation is shown in Fig. 6. They found
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154 J. Inst. Eng. India Ser. D (January–June 2017) 98(1):147–154
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