AbstractThis study investigates the hydrogen reduction of Nchwaning manganese ore at elevated temperatures to enhance understanding of reaction kinetics and optimize industrial applications. Experimental investigations were conducted across temperatures ranging from 600 °C to 900 °C to observe reduction behavior and identify rate determining steps. Thermogravimetric analysis (TGA) was employed to monitor manganese ore weight loss, facilitating precise measurement of reduction rates. Various kinetic models validated experimental outcomes for H2 reduction, revealing an apparent activation energy (Ea) of 65.76 kJ/mol and an apparent pre-exponential factor (k0) of 319.66 min⁻1. The rate constant (k) exhibited a significant temperature-dependent increase, following the Arrhenius equation where rates approximately doubled every 100 °C, rising from 0.037 min⁻1 at 600 °C to 0.377 min⁻1 at 900 °C. Morphological and compositional analyses using scanning electron microscopy (SEM) and X-ray diffraction (XRD) assessed structural changes post-reduction. Results demonstrated that pre-reduction temperature critically influences the physical and microstructural properties of the ore particles, particularly above 700 °C, where a notable reduction in BET (Brunauer–Emmett–Teller) surface area and pore volume indicated sintering within the ore. The rate determining step for this reduction process is most likely the chemical reaction at the gas–solid interface between hydrogen and the manganese ore. These findings highlight advancements in efficient manganese ore reduction processes, with significant implications for metallurgical practices and the hydrogen economy. Graphical Abstract