Understanding how ore interacts with flux particles at elevated temperatures to create molten slag
is crucial since it governs the dynamics of a chemical reaction. This study explores the smelting
behaviour of pre-reduced Nchwaning manganese ore when combined with lime, with the objective
of examining the evolving interaction between pre-reduced ore particles and lime over time. The
research sheds light on the interaction between solid and liquid and the phases that emerge during
this process. To achieve this, a sessile drop furnace was employed to rapidly heat the materials
positioned adjacent to each other on an alumina substrate and to observe the smelting process as
it unfolded over time. This method allowed for the direct observation of the melting temperatures and
the flux-ore reaction progression rate, and the potential disruptive events that might occur. By
comparing the molten interfaces of the fluxed materials at various time intervals, this study provides
insights into the relative rate of slag formation from the two materials. The results indicate that the
main slag formation initiated at approximately 1400°C and continued to advance with time, with
complete mixing occurring around 1500°C. The possible phases formed were identified using
Scanning Electron Microscopy and modelled using Fact Sage thermodynamic software. In addition,
the iron particles in the pre-reduced Mn ore were separated and settled from a rich MnO-containing
slag. It was found that the separation of molten iron droplets from the slag depends on the rate of
solid MnO particles dissolution into the adjacent slag phase.