Manganese Ore Beneficiation

Submitted by Mukesh Ranjan Behera

1

Contents :- Vision 2020 Introduction 5 facts about Manganese Where , How and What Formation of Manganese ore Manganese bearing Minerals Types and grade of Manganese ore End use , size range and applications World deposits Indian deposits and Characteristics Mining Processing of Manganese ore Cost analysis

Vision 2020

1.According to National Steel Policy 2008 , Steel production target 180 MT

2.60% is expected through BF route i.e. 110 MT

3.10kg of B.F. grade Manganese ore(28-30%Mn) is required for per tonne of iron ore, For 110MT , 1.1MT Manganese is required

4.Where as, around 15kg of Manganese based alloy (grade 65-72%) is required for , per tonne of steel production, For 180MTPA by 2020, the requirement of manganese alloys would be around 2.7MTPA

5.From 2.7 MTPA , ferromanganese is 1.1 MTPA and Silicomanganese is 1.6MTPA . To produce that amount of high grade i.e. + 44% , we need an average grade of 25-30% Mn of ROM 4.2 MTPA and 3.7 MTPA respectively.

6.So for domestic steel production of 180 MTPA by 2020, we need total of 9 MTPA ROM (for ferromanganese 4.2 MTPA, for silicomanganese 3.7 MTPA and B.F. iron ore 1.1 MTPA ) of manganese ore by 2020.

3

Introduction:- Manganese ore in the form of ferro and silicomanganese alloys

are the most essential ingredients in the production of steel, both crude and stainless.

Presently, India is the second largest importer of manganese ore in the world after China.

MOIL Ltd, a public sector company is the major producer of manganese ore, contributing about 46% of the total production of the country in the year 2010-11.

The average grade of the domestically produced manganese ore has fell to 33.43% Mn from 38.70% Mn, leading to increased imports of high grade manganese ore.

The best ores (or blends) for manganese alloy production should have manganese to iron ratio of 7.5 to 1, be easily reducible, minimize energy consumption, be low in contaminants, have good physical structure and produce manageable amounts of slag.

4

5 facts about Manganese

The effectiveness of Manganese in increasing mechanical properties depends on & is proportional to the carbon content of the steel.Manganese helps to increase the steel’s hardenability.It is also an active deoxidizer.It improves machinability by combing with sulfur.Manganese improves yield at the steel mill by combing with the sulfur in the steel, minimizing the formation of iron pyrite (iron sulfide) which can cause the steel to crack & tear during high temperature rolling.

5

Where can you find manganese in nature?Manganese is not found as the free metal in nature, however manganese minerals consisting of oxides, silicates, and carbonates are the common.

Most Manganese is obtained from ores in Australia, Brazil, Gabon, India, Russia, and South Africa. Manganese nodules on ocean floors holds

contain about 24% manganese.

How was manganese Discovered?Proposed to be an element by Carl Wilhelm Scheele in 1774, manganese

was discovered by Johan Gottlieb Gahn, a Swedish chemist, by heating the mineral pyrolusite (MnO2) in the presence of charcoal later that year.

What kind of metal is manganese?Manganese is a pinkinsh-gray, chemically active element. It is a hard metal

and is very brittle. It is hard to melt, but easily oxidized. Manganese is reactive when pure, and as a powder it will burn in oxygen, it reacts with

water (it rusts like iron) and dissolves in dilute acids.

6

Formation of manganese ore

1.Hydrothermal

2.Sedimentary

3.SurficialSedimentary deposits are the most abundant types

Sedimentary deposits are formed by the deposition of

material at the Earth's surface and within bodies of water.

Sedimentation is the collective name for processes that cause

mineral and/or organic particles to settle and accumulate or

minerals to precipitate from a solution.

7

Manganese BearingMineral

8

Pyrulosite(Peroxide of Mn or Black Mn)

Psilomelane(Hydrous oxide of Mn)

Cryptomelane(Psilomelane containing some potash or soda)

Braunite(Anhydrous sesquioxide of Mn)

Indian Manganese Ore deposit Psilomelane + Braunite = 90% of Total Reserve of manganese in country

Common Mineral Forms of Manganese ore in India

9

TYPES AND END USE GRADE OF MANGANESE ORE

10

End Products

11

Size range for Manganese Ore for different Industries

• 200mesh (75micron)

• 200mesh (75micron)

• 25 to 40mm;• +85mm;10%max• -10mm;10%max

• 10 to 40mm;• +40mm;10%max• -10mm:10%max

Steel making Grade Blast

furnace grade

Chemical GradeBattery Grade

12

13

South Africa24%

Ukrain22%

Brazil17%

Australia15%

India8%

China7%

Gabon4%

Kaza-khstan

1%

Maxico1%

Other countries

1%

World reserve of Manganese Ore, 2012

14

Australia Brazil China Gabon Ghana India Kazakhstan South Africa

Ukrain Other Countries

0

2000

4000

6000

8000

10000

12000

14000

3829

3200

7500

2753

1720 19062208

4612

2000

1172

6961

3100

14000

3562

1828

23872930

8652

1590

2290

2005

2011

World Production of Manganese Ore During 2005 & 2011 in ‘000 tones

15

1. BHP Billiton2. ASSMANG3. CONSMIN4. OMH group5. Tshipi E Ntle 6. ERAMET7. CVRO(Vale)8. Minera Autlan9. Privat Group10. Eurasian

Natural Rasources Corporation

1. Grootw Eylandt mines, Australia

2.Mamatwan-Wessels mines, south Africa

4. Azul mines, Brazil

3. Moanda mines, gabon

5. Molango mines, Mexico

6. Nonoalco mines, Mexico

7. Urucum mines, Brazil

8. Nchwaning mines, South Africa

9. Gloria mines, South Africa

10. Woodie-woodie mines, australia

Top Ten producer of Manganese in the world

Top ten Manganese mines in the world

16

1

25

34

6

7

89

10

11BIHAR—ORISSA1. BONAI—KEONJHAR & SINGHBHUM2. KALAHANDI—KORAPUTMADHYA PRADESH—MAHARASHTRA3. NAGPUR--BHANDARA—BALAGHAT4. JHABUAANOHRA PRADESHSRIKAKULAMKARNATAKA6. SANDUR—BELLARY7. SHIMOGA8. NORTH KANARAGOA9. GOAGUJARAT10. PANCH MAHALRAJASTHAN11. BANSWARA

Distribution of Manganese ore deposits in India

MANGANESE ORE DEPOSITES----

The total resources of Manganese ore in the country as per UNFC system as on 01.04.2010(NMI) are placed at 430MT. Out of these 142MT are categorized as reserves and balance belongs to resources category. The overall grade of the Manganese ore reserve in the country in the range of 30 – 35% Mn.(NMI 1.4.2010)

17

Ferro Alloys; 28.95%

Silicomanganese; 64.42%

Iron & Steel; 6.17%Battery; 0.35% Lead and Zinc Metallurgy;

0.04%Chemicals; 0.04%

Others; 0.03%

Industrial Consumption of Manganese ore in India

Ferro AlloysSilicomanganeseIron & SteelBatteryLead and Zinc MetallurgyChemicalsOthers

18

odisha; 44.20%

Karnataka; 22.37%

Madhya Pradesh; 12.96%Maharastra; 7.94%

Andhra Pradesh; 4.09%

Jharkhand; 3.19%

Goa; 3.16%Rajasthan; 1.35%

Gujurat; 0.69%

West Bengal; 0.05%

States wise resources of Manganese ore in India

(As on 1:04:2010)

Andhrapradesh Go

a

Gujurat

Jharkhand

Karnataka

M.P.

Maharastra

Odisha

Rajastan

050

100150200250300350400450500550600650

88

14 0 5

271329 353

523

0

322

2 0 18

136

648 650

566

7

State wise production of manganese ore 1999-2000 & 2011-12

1999-20002011-12

State

Tho

usan

d to

nnes

20

FUTURE DEMAND

2000-011.45 MT

2011-124.25 MT

2016-177.39 MT

2025-2622.81 MT 2029-30

36.87 MT

BY ARETHMATIC AVERAGE METHOD

21

Manganese Ore characteristics of Indian deposits

Siliceous with medium to High phosphorous content

Ferruginous with low phosphorus and High alumina content

Occurrences Maharastra, Andhra Pradesh, Madhya pradesh

Occurrences Odisha, Goa, Karnataka

22

MINING

Mining Method

Opencast Under ground

Dongri-Buzurg Open Cast Mine, MOIL, Maharashtra 23

Processing of manganese ore

1. Manganese ore processing practice in India

2. Need for processing

3. Process rout of beneficiation of manganese ore

4. Beneficiation of different type of Indian manganese ore

5. Cost–benefit analysis of beneficiation concentrate

24

1. Most of the manganese ore mines have been operated by selective mining for maintaining medium to high grade ore at mining cut off 20% Mn .

2. At this cut-off , blast furnace grade and mixed grade ore (+25% Mn) is readily exploited leaving low grade ores (<25% Mn) untouched.

3. The present industrial practice causes huge loss of manganese values in process/mine rejects and their stacking has adverse effect on environment causing ecological imbalance.

4. No low grade ores are exploited (below mine cut-off and threshold grade i.e.

-20+10 % Mn.

25

In India , due to some impurities associated with manganese ore above their desired limits which is unsuitable for the further application of manganese ore.

Impurities associated with manganese ore

MetallicFe, Pb, Cu, Zn, Ag & As

Non-metallic Sulphur & Phosphorous

Slag-GaungeSi02, Al2O3, CaO, MgO, Ba0

VolatilesH20, CO2 & organic matter

26

Siliceous ore types

Quartz

Garnet,Quartz

ApatiteQuartz

Gravity concentration methods such as Heavy Media Separation, Heavy Media cyclone, jigging, Spiralling, Tabling or high Intensity magnetic Separation. Flotation or Gravity Concentration cum Flotation

Electrostatic separation or sometimes flotation.

Ore gangues Process upgradation

27

Ferruginous ore

Hematite, Goethite, Limonite

A process of magnetising reduction roasting to convert the ferruginous minerals to magnetite followed by low intensity magnetic separation as its liberation size.

Complex ore

Quartz, apatite, Garnet, Clay, Feldspar, Hematite, Hydrated Iron oxide minerals.

Required three or even moreSteps for the elimination of the gangue & production of high grade concentrates. Combination of Gravity- Magnetic, ESS & Flotation

Oretype

gangue

ProcessOf

upgradation

28

Equipment Size rangeHeavy media Separation (HMS) -50+3mmHeavy Media Cyclone (HMC) -6+0.2mmJigging -30+0.5mmSpiral -1+0.03mmTables -1+0.03mmFlotex density separator -1mmCyclone -3mm

Low Intensity Magnetic Separator 1200 gauss

High Intensity Magnetic Separator 7000 to 12000 gauss

Size classification of beneficiation equipment for Manganese ore

29

1. Beneficiation of Siliceous manganese oreROM Feed (-75mm)

-75+25mm Hand Sorting

Conc.Reject

-25+6mm

Reject(-25+6mm)

Conc.(-25+6mm)

-6mm O/F-0.2mm

U/F-6+0.2mm

Conc.-6mm

Reject-6mm 30

Sample:- Bharveli mines, balaghat. Psilomelane & Pyrolusite are the main Manganese bearing minerals;Quartz, mica & feldspar are the main gangue minerals.

FEED:-41.9% Mn19.0% SiO₂3.3% Fe1.6% Al₂O₃3.7% BaSO₄ Reject:-

27.9% Mn50.28% SiO₂Weight yeild of 38.4%

Conc.:-50.8%Mn9.2% SiO₂Weight yield of 61.6%

Processing ofmanganese

31

2. Beneficiation of high phosphorus ore

ApatiteFloat

ManganeseNon float

Conditioning

Lower PH to 6.5Manganese Mineral

Float (Conc.) SilicaNon Float(tailing)

Option 1

Water spray

ManganeseMag (Conc.)

Apatite & silica Non-mag(Tailing)

Option 2

O/F

U/F

FEED

Wateraddition

ROM

70% -200mesh

32

Sample :- Chikla mines;Braunite was the main manganese bearing mineral followed by Jacobsite & Hausmanite are in minor amout. Quartz was the main gaunge mineral followed by hematite in minor amount.Apatite was observed to be the only phosphorous bearing mineral intimately associated with manganese minerals.

Option:-1

FEED:-38.2% Mn0.31% P22.84% SiO₂8.32% Fe

Reject:-27.3% Mn0.58% PWeight yield of 39.9%

Conc.-(phosphorus Float)31.8% Mn1.65% PWeight yield of 8.8%

Processing ofManganese ore 1st Stage

Conc.- (cleaner stage)45.5% Mn0.1% PWeight yield of 60.1%

Cleaner Stage

33

Option :-2

Sample:- South Tirodi mines; Braunite was the principle manganese bearing mineral followed by Jacobsite in minor amount.Quartz was the main gaunge mineral.Apatite was observed to be the only phosphorous bearing mineral intimately associated.

FEED:-43.5% Mn9.4% Fe0.31% P Reject(Non-mag):-

32.25% Mn1.05% P7.47% FeWeight yield of 20.6%

Conc.(Mag):-46.27% Mn0.41% P9.35% FeWeight yield of 79.4%

Processing ofManganese ore

34

3. Beneficiation of Ferruginous manganese ore

35

Sample:- Sandur area , Karnataka;Psilomelane & Pyrolusite were the manganese bearing minerals.Hematite & Goethite were the iron minerals present in the sample.

FEED:-34.1% Mn17.7% Fe6.9% Al₂O₃8.5% SiO₂0.5% BaSO₄ Reject(Mag) :-

24.4% Mn24.2% Fe7.8% SiO₂Weight yield of 60%

Conc.(Non-mag):-49.5% Mn9.1% Fe9.2% SiO₂Weight yield of 40%

Processing ofManganese ore

36

Cost benefit Analysis of Beneficiated concentrate

1. Siliceous and high Phosphorous

37

2. Ferruginous ore

38

Price of Manganese ore

6 Month Manganese Prices and Price Charts

5 Year Manganese Prices and Price Charts

1 Year Manganese Prices and Price Charts

Historical Manganese Prices and Price Chart

39

http://www.infomine.com/investment/metal-prices/manganese/

IndiaManganese Ore Rs./t MnO2 22127 Up to 25% Mn 172425 - 35% Mn 457135 - 46% Mn 10175Above 46% Mn 12953

Andhra PradeshManganese Ore Rs./tMnO2 NAUp to 25% Mn 112025 - 35% Mn 228035 - 46% Mn 2648Above 46% Mn NA

JharkhandManganese Ore Rs./tMnO2 15000Up to 25% Mn NA25 - 35% Mn 450035 - 46% Mn NAAbove 46% Mn NA

KarnatakaManganese Ore Rs./tUp to 25% Mn 187225 - 35% Mn 436535 - 46% Mn 3600Above 46% Mn NA

Madhya PradeshManganese Ore Rs./tMnO2 NAUp to 25% Mn 186625 - 35% Mn 421435 - 46% Mn 9374Above 46% Mn 13044

MaharastraManganese Ore Rs./tMnO2 52318Up to 25% Mn 246825 - 35% Mn 515335 - 46% Mn 10382Above 46% Mn 12722

OdishaManganese Ore Rs./tMnO2 22348Up to 25% Mn 530525 - 35% Mn 826335 - 46% Mn 14524Above 46% Mn 16724

Average Sale Price for August 2014

(Source - MINERALS & METALS REVIEW, September 2014)40

Balaghat MinesPO- BharweliDist- BalaghatMadhya pradeshPin- 481102

MANGANESE ORE INDIA LTD

Integrated Manganese Ore Beneficiation Plant MOIL Balaghat, Madhya Pradesh

41

Flow sheet of IMB plant, Bharveli mines, MOIL

Plant capacity – 5lakh TPA

42

Flow sheet of IMB Plant, Dongri-Buzurg, mine MOIL

Pyrolusite mineral(MnO₂)Gangues- Quartzite, weathered rock, Laterite etc.

43

?

44