Table of Contents
Journal of Metallurgy
Volume 2015, Article ID 679306, 10 pages
http://dx.doi.org/10.1155/2015/679306
Research Article

Mathematical Analysis of the Effect of Iron and Silica on the Reduction Performance of Manganese Ores

1Steel and Ferroalloys Department, Central Metallurgical Research and Development Institute (CMRDI), P.O. Box 87, El-Felezzat Street 1, El-Tebbin, Helwan, Cairo 11422, Egypt
2Pyrometallurgy Department, Central Metallurgical Research and Development Institute (CMRDI), P.O. Box 87, El-Felezzat Street 1, El-Tebbin, Helwan, Cairo 11422, Egypt

Received 30 September 2014; Revised 17 December 2014; Accepted 18 December 2014

Academic Editor: Sunghak Lee

Copyright © 2015 S. Ghali and E. A. Mousa. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Abstract

In the current study, a factorial design is used to investigate the effect of total iron and silica on the metallurgical performance of different grades of manganese ores. The derived mathematical formulations are applied to estimate the reduction disintegration index (RDI+6.3, RDI+3.15, and RDI−0.5), reduction index (total reduction index (RIT), manganese reduction index (RIM), and iron reduction index (RIF)), and softening-melting property (start of softening (), end of softening (), start of melting (), and end of melting ()) of manganese ores. The RDI+6.3 and RDI+3.15 are increased with the individual effect of SiO2 and the interaction effect of iron with silica, while they are decreased as the total iron increased. The high-Fe high-SiO2 manganese ore showed the highest RIT and RIF. The RIM was almost identical in all manganese ores. The presence of high content of SiO2 resulted in a narrow softening range (62–83°C), while the high-Fe high-SiO2 manganese ore exhibited a wider softening range (135–140°C). The melting range was very small in high-Fe low-SiO2 (3–16°C) and high-Fe high-SiO2 (6–8°C) manganese ores, while the low-Fe low-SiO2 manganese ore showed wider melting range (72–74°C). The derived mathematical models are in a good agreement with the experimental results. The calculations are carried out using Matlab program.