Process simulation was integrated with life cycle assessment to evaluate process efficiency and environmental impact of the production of manganese ferroalloys for various production modes and different ore mineralogies. Utilizing HSC Sim, the model was designed to evaluate the production process with or without a pretreatment step, where results for simulated cases using a four-zone ferromanganese furnace model were exported to openLCA for a complete life cycle assessment. Two main production scenarios were simulated: a closed ferromanganese furnace running on the duplex method and an open furnace running on the discard slag approach. The closed furnace scenario achieved a 17.5% reduction in energy consumption and a 16.2% decrease in direct CO₂ emissions with CO-rich off-gas pretreatment. The open furnace scenario showed an 11.2% reduction in energy consumption with thermal solar energy pretreatment but no change in CO₂ emissions.

The effect of raw materials on the temperature development and prereduction behavior of Comilog and Nchwaning manganese ores (3.33–4.00 mm or 11.20–15.00 mm) were investigated in a CO-CO₂ atmosphere. Experiments were conducted at a heating rate of 6 °C/min from room temperature to 1000 °C where the ore was mixed with inert material (quartz) in various ratios. A similar heating program gave dissimilar temperature development for Comilog and Nchwaning ores due to differences in oxygen levels and reduction rates. The temperature development, and thus reduction rate, decreased with the increasing amount of inert material in the mix for Comilog ore in size 3.33–4.00 mm. The peak reaction rates observed during reduction were 2.4 wt%/min, 1.0 wt%/min, and 0.8 wt%/min for an ore:quartz weight ratio of 1:0, 1:1, and 1:3, respectively. For Comilog ore in size 11.20–15.00 mm, and Nchwaning ore in both sizes, the temperature development and reduction rates were slightly or insignificantly affected. It was suggested that the effect was low for reactions under a diffusion-controlled kinetic regime.