In the HAlMan process, hydrogen and aluminum are used to produce manganese ferroalloys with low energy consumption and carbon footprint. In this process, hydrogen gas is used to pre-reduce manganese ores, which is further reduced at elevated temperatures by aluminium in a smelting-aluminothermic reduction process. It is shown that the process temperature is a key parameter affecting the extent and rate of the ore reduction and yielding pre-reduced ore with significantly different properties. Mass and energy balances results are presented, and they indicate that ferromanganese production by this process will prevent the emission of about 1.5 t CO2/t metal, with high metal quality. In an Innovation Action HAlMan EU project, the process is implemented in pilot scale and the produced metals are further processed to produce commercial Mn-containing commercial steels and alumium alloys in pilot scale. Moreover, the slag by-product is treated hydrometallurgically in a pilot plant to produce alumina, and extract critical raw materials, including rare earth elements. The production of manganese dioxide for the energy sector is another important material that is studied in this project.