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Sustainable Utilization of GCP Sludge as a Reductant in the Reduction Roasting of Low-Grade Manganese Ore to Recover Mn and Fe Values

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Abstract

Utilization of low-grade manganese ore adopting the carbothermic reduction roasting process is a proven method to produce high-grade manganese ore. To minimize industrial waste and protect the environment, gas cleaning plant sludge (GCPS), which is a solid waste from steel industries, was employed as a reductant to perform the reduction roasting process. The optimum conditions to carry out reduction roasting of the low-grade manganese ore were found to be: a roasting temperature of 950 °C, a residence time of 2 h, 40% GCPS as reductant, and magnetic separation at 5000 G for a manganese ore size of –10 mm. A low-grade manganese ore comprising Mn grade 31.27% and Fe grade 19.78% having a Mn/Fe ratio of 1.58 containing a high silica content of 26.48% was used for the carbothermic reduction roasting having mineral phases of pyrolusite (MnO2) and hematite (Fe2O3) as found from XRD. The gangue minerals were separated during the magnetic separation, and the upgraded product was obtained, which reached a maximum value of TMn 49.5% with RMn 76.55% and TFe 62.19% with RFe 42.51%. In the study, activated charcoal (AC) was also taken as a reductant for comparative analysis; the experimental results revealed that GPCS performed better than that of the AC, showing potential to be used as a reductant in metallurgical industries. However, the resulted Mn/Fe ratio was very low for the reduced sample; therefore, it can be used for smelting along with high-grade manganese ores as a feed.

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Abbreviations

TMn:

Total manganese grade

RMn:

Manganese recovery

TFe:

Total iron grade

RFe:

Iron recovery

LGMO:

Low-grade manganese ore

GCPS:

Gas cleaning plant sludge

AC:

Activated charcoal

SEM:

Field emission scanning electron microscopy

XRD:

X-ray diffraction

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Acknowledgements

The authors are thankful to GTCR, Bhubaneswar and CSIR-IMMT, Bhubaneswar, India, for the financial resources and experimental facilities to carry out the experiment, respectively. The authors also acknowledge the help of Mr. Ajit Patra (Ex. General Manager (Operations), Essel Mining & Industries Limited, Keonjhar, Aditya Birla group) to obtain the LGMO used in this investigation.

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Authors and Affiliations

  1. CSIR- Institute of Minerals and Materials Technology (CSIR-IMMT), Bhubaneswar, India

    Malaya Kumar Jena, Subhabrata Mishra, Shaswat Kumar Das & Syed Mohammed Mustakim

  2. Grøn Tek Concrete & Research (GTCR), Bhubaneswar, India

    Shaswat Kumar Das

  3. University of Windsor, Windsor, Canada

    Adeyemi Adesina

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  1. Malaya Kumar Jena
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  2. Subhabrata Mishra
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Contributions

M.K Jena– Conceptualization and investigation, S Mishra– Investigation and writing original draft, S.K Das– Investigation, writing original draft, and editing, S.M Mustakim– Supervision, reviewing, and editing, A Adesina– Writing original draft, result analysis, and editing.

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Correspondence to Shaswat Kumar Das.

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Jena, M.K., Mishra, S., Das, S.K. et al. Sustainable Utilization of GCP Sludge as a Reductant in the Reduction Roasting of Low-Grade Manganese Ore to Recover Mn and Fe Values. Mining, Metallurgy & Exploration 38, 1537–1550 (2021). https://doi.org/10.1007/s42461-021-00380-4

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