Effect of Calcination of Manganese Ore on Reducing Hydrogen and Energy Consumptions in Hydrogen-Based Direct Reduction Process

Manganese is a critical raw material and there is currently a great interest in decarbonization in the metallurgical sector for its production. Hydrogen use in manganese and its alloys’ production is in principle possible for sustainable production; however, this requires a technological shift from traditional carbothermic processes to completely new processes; like the HAlMan process. To design a process, it is crucially important to optimize the process conditions (such as temperature) and minimize the quantity of hydrogen gas and the related energy consumptions. In the present work, energy and mass balances for a hydrogen-based reduction reactor were carried out employing thermodynamics software and analytical approaches from room temperatures to 900 °C. It was found that the quantity of hydrogen gas required for the pre-reduction of manganese ore can be significantly reduced via coupling the reduction reactor with a calciner and the hot charge of the calcined ore into the reduction reactor. Moreover, hot H2-H2O gas mixture from the reduction reactor outlet can be used for preheating the hydrogen feed of the reactor, and the calcination of the ore, while a portion or all its hydrogen can be recovered and looped. The integrated coupled calcination-reduction process was found to be operated with no external energy supply, or insignificant fuel use.