Manganese-rich slag is a raw material for smelting silicon–manganese alloys using an electric furnace. The blast furnace method is the main method for smelting manganese-rich slag. This method has the problems of a long process, large coke consumption, and easy volatilization of metals such as lead and zinc, which affects smelting safety. A new technology for smelting manganese-rich slag with low-manganese high-iron ore by smelting reduction optimization was proposed. This technology has the advantages of a short process, low energy consumption, low carbon emissions, and comprehensive recycling of lead, zinc, and other metals. According to the chemical composition, X-ray diffraction analysis, and particle size analysis of Cote d’Ivoire low-manganese ore, an experiment was carried out on manganese-rich slag by reduction–smelting separation. Combined with the design scheme of the Box–Behnken principle, three experimental factors (temperature, basicity, and carbon content) were selected as the influences to study. The influence that each factor has on the recovery rate of manganese was studied by response surface methodology, and the experimental factors were optimized. The results show that under the conditions of a reduction-smelting temperature of 1402 °C, basicity of R = 0.10, and carbon content of 10 mass%, the recovery rate of manganese is 97%. A verification experiment was carried out under the optimal conditions, and the error was only 1.24%; this proves that the response surface method prediction model is reliable and accurate. This is of great significance for the comprehensive utilization of lean-manganese ore resources.

富锰渣是用电炉冶炼硅锰合金的原料。高炉法是冶炼富锰渣的主要方法。该方法存在工艺流程长、焦炭消耗量大、铅、锌等金属易挥发，影响冶炼安全等问题。提出了一种冶炼还原优化的低锰高铁矿冶炼富锰渣新工艺。该技术具有工艺流程短、能耗低、碳排放低、可对铅、锌等金属进行综合回收利用等优点。根据科特迪瓦低锰矿的化学成分、X射线衍射分析和粒度分析，对富锰渣进行还原-熔炼分离试验。结合Box-Behnken原理的设计方案，选择三个实验因素（温度、碱度和碳含量）作为影响因素进行研究。采用响应面法研究了各因素对锰回收率的影响，并对实验因素进行了优化。结果表明，在还原熔炼温度为 1402 ℃的条件下，碱度为R  =0.10，含碳量为10质量%，锰的回收率为97%。在最优条件下进行了验证实验，误差仅为1.24%；这证明了响应面法预测模型的可靠性和准确性。这对贫锰矿资源的综合利用具有重要意义。