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<p>Manganese (Mn) impurities in iron ore compromise steel quality, yet conventional removal methods are energy-intensive and non-selective. This study unveils a mechanochemical breakthrough using ceramic (Al<sub>2</sub>O<sub>3</sub>-rich) balls, despite being lighter, outperform steel balls in selectively extracting Mn while minimizing iron (Fe) dissolution, achieving industrial-grade purity (&lt; 4% Mn) in just 5&#xa0;min—three times faster than steel. Through systematic experiments with sulfuric-oxalic acid (1:2 ratio), ceramic balls’ unique composition, confirmed using aluminium oxide and aluminium sulfate, promotes a reducing environment, enhances reaction kinetics, reducing Mn by 74.7% with 35% lower energy consumption (0.8 vs. 1.2 kWh/kg). Power-law models reveal strong size-dependent efficiency for ceramics (Fe% = 58.2D<sup>− 0.34</sup>; Mn% = 7.5e<sup>− 0.41D</sup>), while steel balls show negligible size effects. Al³<sup>+</sup> ions from ceramic balls act as redox mediators, creating a pH-buffered environment that selectively targets Mn. These findings redefine sustainable ore upgrading, offering a faster, greener alternative to traditional leaching.</p>

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How Do Ceramic Balls Beat Steel Balls in Selective Manganese Extraction from Iron Ore?

  • 期刊论文

  • 发表日期：

    2026年7月17日

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  • A. A. El-Midany,
  • Rawya Gamal Mohamed Saad Sayed

摘要

Manganese (Mn) impurities in iron ore compromise steel quality, yet conventional removal methods are energy-intensive and non-selective. This study unveils a mechanochemical breakthrough using ceramic (Al2O3-rich) balls, despite being lighter, outperform steel balls in selectively extracting Mn while minimizing iron (Fe) dissolution, achieving industrial-grade purity (< 4% Mn) in just 5 min—three times faster than steel. Through systematic experiments with sulfuric-oxalic acid (1:2 ratio), ceramic balls’ unique composition, confirmed using aluminium oxide and aluminium sulfate, promotes a reducing environment, enhances reaction kinetics, reducing Mn by 74.7% with 35% lower energy consumption (0.8 vs. 1.2 kWh/kg). Power-law models reveal strong size-dependent efficiency for ceramics (Fe% = 58.2D− 0.34; Mn% = 7.5e− 0.41D), while steel balls show negligible size effects. Al³+ ions from ceramic balls act as redox mediators, creating a pH-buffered environment that selectively targets Mn. These findings redefine sustainable ore upgrading, offering a faster, greener alternative to traditional leaching.