Sensitivity of Pellet Physical and Mechanical Properties to Reducibility Behaviour in Anka Manganese Ore

This study examines the beneficiation and pelletization of manganese ore from Anka Mines, Zamfara State, Nigeria, to improve its suitability for metallurgical applications. The ore was sourced from the mines and communited, followed by characterization, fractional sieve size analysis, and concentration test via froth flotation method. The manganese concentrate was then pelletized using limestone, bentonite, and hydrated lime binders at different dosages and mechanical/physical properties test were carried out. Chemical characterization using energy-dispersive X-ray fluorescence (ED-XRFS) revealed MnO content of 52.11% alongside significant silica (17.02%), alumina (15.30%), and iron oxide (10.94%), indicating the need for beneficiation. Particle size analysis identified the liberation size at the − 125 + 90 μm fraction. Flotation tests under varied operating conditions showed that round 3 achieved optimal performance, producing a concentrate grade of 70.61% MnO, recovery of 69.9%, and enrichment ratio of 1.17. Mechanical property evaluations show that bentonite-produced pellets have superior strength and durability compared to limestone and hydrated lime produced pellets. The study revealed that upgrading Nigeria’s manganese resources is valuable for the steelmaking and ferroalloy industries, while contributing to economic diversification through value-added mineral processing.