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J. Inst. Eng. India Ser.

D (January–June 2017) 98(1):147–154


DOI 10.1007/s40033-016-0119-7

REVIEW PAPER

An Overview of Manganese Recovery by Hydro


and Pyro-Metallurgical Routes
Deepak Dwivedi1 . Navneet Singh Randhawa2 . Sanjay Saroj3 . Ranjeet Kumar Jana2

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.

Keywords Mn recovery  Mn ore  Hydrometallurgy 


Pyrometallurgy  Leaching Manganese Sources

Most common source of Mn is pyrolusite (MnO2) and most


Introduction of the Mn sources belong to sedimentary deposits which
contained iron rich [9] layers on it. Another competent
Manganese is an important metallic element which is now source of Mn is sea nodules which contain approximately
treated as an industrial major element used for iron and 30–36 % Mn and mostly found in the Pacific ocean along
alloy-steel production. The sector which demands the use with the Atlantic ocean. Earlier, research was focused on the
of manganese are steel production, carbon–zinc batteries recovery of Co and Ni from the sea nodule but now it has
production, fertilizers, as well as colorants for bricks, dyes shifted for the Mn recovery as well. Other sources of Mn
and medicines [1]. The world’s annual consumption of could be the waste batteries, electrodes, industrial wastes,
slag and sludge etc. But the ores or sources containing
[40 % Mn are only considered as metallurgical Mn source.
& Deepak Dwivedi Mn containing minerals has been list out in Table 1 [10].
deepakdwivedi007@yahoo.com
1
Curtin Corrosion Engineering Research Centre,
Perth 6152, Australia Experimental Requirements
2
CSIR National Metallurgical Laboratory, Jamshedpur
831 007, Jharkhand, India The first requirement of the investigation is finding of
3 chemical composition of ore. The chemical composition of
Department of Chemical Engineering, Indian Institute of
Technology Gandhinagar, Gandhinagar 382 424, Gujarat, ore can be determined through the XRF. The preferable ore
India size fraction should be 45–150 lm.

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Table 1 List of Mn minerals along with Mn % [10] Effect of Variables


Mineral Composition % Mn composition
Effects of temperature, ore composition, porosity and size
Bementite Mn5Si6O15(OH)10 43.2 are the prime factor in manganese ore reduction [1, 3, 4, 6,
Braunite Mn2Mn6SiO12 66.6 7, 11–16]. The effect of gas atmosphere on the carbothermal
Cryptomelane KMn5O16 59.8 reduction of manganese ore has been treated as less impor-
Franklinite (Fe, Zn, Mn)O (Fe, Mn)2O2 10–20 tant factor. Not much publications are available in this field.
Haussmannite Mn3O4 72.0 Work on the effect of partial pressure of CO on manganese
Manganite Mn2O3H2O 62.5 ore reduction has been reported. It was found that decreasing
Manganian calcite (Ca, Mn)CO3 35.4 the CO partial pressure by about two-thirds is equivalent to a
Romanechite Ba MnMn5O16(OH)4 51.7 temperature increase of 60°–70°. Skjervheim and Olsen [15]
Pyrolusite MnO2 63.2 have found that CO partial pressure plays a vital role over the
Rhodochrosite MnCO3 47.8 rate of reaction as the partial pressure of CO increases with
Rhodonite MnSiO3 41.9 increase in temperature.
Wad Hydrous mixture of oxides Variable Eric and Burucu [16] showed that the argon and carbon
combination gave the greatest rate and extent of reaction,
followed by the other systems that are CO2 and CO. Data
Samples of manganese ore can be analysed by XRD, obtained by earlier researchers [12] for carbothermal MnO
optical and electron microscopy. Normally, X-ray diffrac- reduction in helium showed that MnO is reduced much
tion with a Cu-Ka X-ray source and a nickel monochro- faster in helium than in argon. Similar results were
mator can use for the study. The XRD can perform with a obtained for MnO, manganese ore and ferromanganese slag
step size of 0.02°. The voltage used should be 30 kV, with [13].
a current of 30 mA. The XRD patterns can be analyzed
qualitatively using ‘‘Traces’’ software with JCPDS-PDF2
database. Important Considerations in Pyro-Metallurgical
Samples for optical and electron microscope analysis Treatments in Manganese Ore
demand the preparation of sample by mounting it on an
epoxy resin mould. These moulds can be prepared by Importance of MnO/C Ratio
drilling through an epoxy blank, and filling the holes with
the ore. Resin should then be poured over the top of the Reduction in hydrogen was examined at different
blank and sample, and mixed with the sample to ensure that MnO/carbon molar ratios. MnO/C molar ratio in the range
the particles should be tightly held. The samples will be 1/0.34–1/2 does not affect the reduction reaction
held within a vacuum chamber for around 30 min before (1200 °C). If the MnO/C ratio lies below the 1/1.22, it
being left to harden for around 24 h. The samples will be won’t be treated as the important parameter in the reduc-
then ground using SiC paper, from 120 to 4000 grade; tion reaction. Kononov et al. [17] found that the ratio of
followed by 4, 1 and 0.5 lm diamond paste on a polishing MnO/C plays a vital role over the formation of phases
wheel. The samples will be washed using soap and water in during reduction, which can be identified by XRD.
an ultrasonic bath between the grinding and polishing, They observed that for samples with MnO/C ratio more
before being rinsed under ethanol. Optical photomicro- than 1 the main phase was MnO; only a small amount was
graphs can be obtained using an inverted stage metallur- manganese carbide Mn23C6. When the molar MnO/C ratio
gical microscope with an attached digital camera. Images was in the range of 1–1/2 or smaller, no oxide phase was
will be captured using the software package. detected.
Samples should be coated or placed on carbon tape for
SEM, EDS and EPMA analysis. Scanning electron Importance of Gas Atmosphere
microscopy (SEM) can be carried out using a high reso-
lution (1.5 nm) field emission SEM (FESEM) with a tilting There is no thermodynamic limitation to the reduction in
stage, back-scatter detector and cathodoluminescence the inert atmosphere; however, at such low temperature as
detector. FESEM should be used to observe the mor- 1200 °C, MnO reduction in inert gas is too slow to be
phologies (microstructure) and section profile of samples commercially viable. The challenge is to develop a tech-
obtained at different reaction stages. Energy dispersive nology providing an acceptable rate of manganese ore
X-ray spectroscopy (EDS) can be done by using an energy reduction at low temperature. Also, a technologically
dispersive x-ray analyser. important factor is the concentration of CO in the gas

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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

Effect of Particle Size The effect of carbon content on carbothermal reduction of


manganese ores was studied in hydrogen at 1200 °C by
Effect of the ore particle size on carbothermal reduction of changing graphite content in the mixture with the ore in the
manganese ores at 1200 °C in hydrogen has been reported in range 5–30 mass%. Kononov et al. [17] (depicted through
earlier works [13–15]. No visible effect on the first stage of Fig. 2), has studied about that Carbon content in the range
reduction was observed for the Wessels. The first stage of 20–30 mass% will not affect the reduction rate. Carbon
reduction of GE-PS ore with a particle size in the range content strongly affected the final phase composition of
300–850 mm was slower than the rate of reduction of the ore reduced manganese ore. They found when carbon content
in the size range 45–250 mm; however, within these ranges, in the graphite–ore mixture was 12–16 mass%, manganese
the particle size had no effect. The second stage of reduction oxide was reduced to metallic Mn and ferromanganese
of all ores was strongly affected by the ore particle size. The carbide (Mn,Fe)23C6. In the sample reduced with
reduction rate increased with decreasing ore particle size. 18 mass % carbon, only carbide (Mn,Fe)23C6 is observed.
Researchers have studied about the Thermal analysis When carbon content increased to 20 mass % and above,
and kinetic modeling of manganese oxide ore reduction they observed that (Mn,Fe)7C3 was formed.
using biomass straw as reductant. They studied with
varying size fractions from a geometric average particle
diameter of 50–300 lm while keeping other conditions as: Pyro Hydrometallurgical Routes
the weight ratio of 10:3 (manganese oxide ore/straw), and
the roasting temperature at 500 °C for 80 min. Geometric This process involves the initial pyro-metallurgical treat-
average particle diameter of corresponding size fractions ment of ores which ends up with the hydrometallurgical
was calculated as: treatment. This process is suitable for the low grade ores
dp ¼ f 1  f 2 such as Mn sea nodules etc. and pyrometallurgy treatment
acts as pre-treatment of ores which involves reduction
where, dp is the average particle diameter, f1 and f2 are the roasting, chloridising, sulphatising (roasting with sulphuric
upper and lower particle sizes of the fraction. They found acid or treatment of ores with SO2 gas which act as a
that with the increase in average diameter from 75 to reductant and sulphatising agent) etc. Sulphatising with
275 lm, the recovery rate of manganese decreased from SO2 gas is specially utilized in Zn and Mn recovery from
95.9 to 76.5 %. They stated that the higher recovery for the batteries [18], processing routes are mentioned in flow

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Fig. 2 Reduction of Wessels


ore with different carbon
content (mass%) in the
graphite–ore mixture at 1200 °C
in hydrogen (mass%) in the
graphite–ore mixture at 1200 °C
in hydrogen [17]

Reductive Leaching with SO2 or Sulphite Salts


Mechanical
speparaon This process is suitable for the sources which contain large
amount of Mn oxides. In this process, SO42- and dithionate
(S2O62-) are the by products and dithionate intermediate
products can be utilized to stabilize the Mn(II) and Ca in
sulphuric solution. This could be considered as an advantage of
acid leaching reductive leaching with dithionate. This process was
developed for low grade Mn ores and recovery of Mn was
around 90 %. Another advantage and importance of
(either in
sulphaon presence of dithionate is that it can be used for low grade Mn slimes
sulphuric acid or
roasng ammonium salt) treatment but usually generation of dithionate is avoided as
it increases the residence time of oxidation (dithionate to
sulphate) [20, 21].
Fig. 3 Flow chart for Mn recovery from Zn–C spent batteries
Another method is direct SO2 leaching. This process is
(observed recovery was 93.4 %)
fast and offers good Mn recovery (around 90–95 %). Dif-
fusion of SO2 in the surface (due to low activation energy
diagram (Fig. 3). Pyro-hydrometallurgical routes are for this) [22, 23] of the ores are the important reaction step
favourable for the recovery of Mn, Co and Ni from the sea for this process and always considered as first order
nodules with good efficiency but the only industrial con- reaction.
cern is the energy consumption.
Another common process involves the reduction roast- Reductive Leaching with Organic Agents
ing (700–900 °C) of ores which proceed with the sulphuric
acid leaching. This process gives the low valent oxides Several organic agents are available and currently employed
(MnO) which is easily soluble in sulphuric acid [19]. for reductive leaching. Few are carbohydrates (as carbohy-
drate is cheap), saw dust, oxalic acid etc. Authors tried to
make a list of organic acid that are being utilized for the
Hydrometallurgical Routes process of reductive leaching mentioned in Table 2.

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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J. Inst. Eng. India Ser. D (January–June 2017) 98(1):147–154 151

Table 2 Organic reducing agents for Mn reductive leaching


Reductant Ore Recovery % References

Sawdust (C6H10O5)n Low Mn ore 90–95 % Mn (99.6 % pure) [24]


Sucrose (C12H24O11) Pyrolusite 94–95 % Mn recovery [25]
Lactose (C12H22O11) Low Mn ores 90–92 % Mn recovery [26]
Glucose Mn nodules (%) Cu 100, Ni 90, Co 60 [27]

Acid concentration, reaction temperature and potential Bio Leaching


affect the efficacy of the process (extraction of Mn from
ore). Elsherief [28] observed that Hg or Hg sulphate can be Thiobacillus ferrooxidans are used to covert Fe and S ions
utilized for the reduction of Mn and MnO and is soluble in to its oxidative forms through oxidation. The thermophilic
acid. sulfolobus is another microorganism which is generally
utilized at high temperature process. Microorganisms help
Leaching with Various Agents in the recovery of Mn and Fe from MnO2 and Fe2O3
through aerobic or anaerobic condition [33]. In aerobic
It has been observed that various reagents such as hydrogen condition, MnO2 is used as an electron acceptor for their
para oxide, HCl etc. have been utilized for Mn leaching respiration whereas in anaerobic condition, Fe, S and Mn
process. H2O2 offers advantage if Ag is also present in ore reducing bacteria donate electron with the help of oxidation
because it acts as oxidation agent for Ag and reductive of organic substrate. Reducing compounds are known as
agent for Mn. Jiang et al. [29] observed 98 % Mn recovery the by-product of metabolism [5, 34–39].
with 85 % Ag recovery for the ore which contained 12.2 % Anaerobic bio leaching is an emerging technology as it
Mn. HCl is also being utilized for Mn recovery and HCl is eco-friendly and cheap but has not been commercialized
converts Mn to MnCl2 along with additional Cl2 and yet [40].
addition of Na2CO3 evolved CO2 and causes MnO2 pre-
cipitation (purified—98 % pure with 17–50 % Mn along
with significant SiO2). But this process is industrially Important Considerations in Hydrometallurgical
unacceptable as it consumes lot of acids for maintaining Treatments in Manganese Ore
acidic conduction because Cl acts as reductive agent in
acidic condition [30]. HNO3 is another option for reductive Effect of Grain Size
leaching [31] agents but since it is costly, it has not been
utilized extensively yet. Ismail et al. [6] carried out a comparative study on acid
Reductive leaching can also been done with the help of leaching of low grade manganese ore using some industrial
ferrous containing solution. Flow sheet of the complete wastes as reductants. They have gone through solid
process is mentioned in Fig. 4 [32]. grinding process.

Fig. 4 Flowsheet for the


process of Mn recovery using
pickle liquor to leach ore

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The purpose of solid grinding is to create sufficient


surface area to allow complete digestion in a relatively
short period of time and to reduce the power input to the
reactor agitation. They observed the influence of grain size
on Mn conversion with different grain sizes 100 % passing
through 5, 16, 52, 100, 150, and 200 mesh.
They revealed that the manganese and iron conversions
were increased with decreasing grain sizes which is a
common phenomenon [41], due to the creation of layer
surface area which increase the chance of good contacts
between sulfuric acid and manganese dioxide and ferric
oxide in the fine particles and consequently facilitates the
diffusion of the reactants and the reaction products through
the particles.

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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