A Novel Circulation Process to Effectively Produce Electrolytic Manganese Metal (EMM) with Low-Grade Manganese Oxide Ores and High-Sulfur Manganese Ores

A novel circulation process of electrolytic manganese metal (EMM) production with low-grade manganese oxide ores (LGMO) and high-sulfur manganese ores (HSMO) was studied and developed. The unit operations mainly include dissolution of LGMO, purification of leach liquor and electrolysis for EMM preparation. Based on the theoretical thermodynamic analysis, a reductive roasting-acid leaching process for utilizing LGMO using HSMO as reductant was investigated. The leaching efficiency of Mn and Fe could get to 97.30% and 17.50% with conditions set as following, which have all been verified through a series of experiments: the material ratio of 1.67:1 (mass ratio of HSMO to LGMO, w/w), roasting temperature of 600 °C for 60 min, L/S ratio of 5:1, stirring speed of 150 rpm, sulfuric acid concentration of 1.0 mol/L and the leaching temperature of 60 °C for 35 min. Meanwhile, the reduction roasting-acid leaching process applies to the Mn extraction for assorted manganese dioxide ores in general. Furthermore, the leach liquor was purified in two steps, and following a scale-up electrolysis process was implemented to prepare EMM from the purified liquors. The uniform and dense α-Mn with bcc crystal structure, meeting the requirement of metallurgical industry standard (YB/T 051-2003), could be stably produced in 9-day incessant ongoing test.