2. 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
3. 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
4. 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. 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
6. 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
7. Formation of manganese ore
1.Hydrothermal
2.Sedimentary
3.Surficial
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
9. 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
16. 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
17. 1
2
5
3
4
6
7
89
10
11
BIHAR—ORISSA
1. BONAI—KEONJHAR & SINGHBHUM
2. KALAHANDI—KORAPUT
MADHYA PRADESH—MAHARASHTRA
3. NAGPUR--BHANDARA—BALAGHAT
4. JHABUA
ANOHRA PRADESH
SRIKAKULAM
KARNATAKA
6. SANDUR—BELLARY
7. SHIMOGA
8. NORTH KANARA
GOA
9. GOA
GUJARAT
10. PANCH MAHAL
RAJASTHAN
11. 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
18. 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 Alloys
Silicomanganese
Iron & Steel
Battery
Lead and Zinc Metallurgy
Chemicals
Others
18
19. 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
19(As on 1:04:2010)
22. 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
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24. 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
25. 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
26. 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
26
28. 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 more
Steps for the elimination of
the gangue & production of
high grade concentrates.
Combination of Gravity-
Magnetic, ESS & Flotation
Ore
type
gangue
Process
Of
upgradation
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29. Equipment Size range
Heavy media Separation (HMS) -50+3mm
Heavy Media Cyclone (HMC) -6+0.2mm
Jigging -30+0.5mm
Spiral -1+0.03mm
Tables -1+0.03mm
Flotex density separator -1mm
Cyclone -3mm
Low Intensity Magnetic Separator 1200 gauss
High Intensity Magnetic Separator 7000 to 12000 gauss
Size classification of beneficiation equipment for Manganese ore
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30. 1. Beneficiation of Siliceous manganese ore
ROM 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
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31. Sample:- Bharveli mines, balaghat.
Psilomelane & Pyrolusite are the main Manganese bearing minerals;
Quartz, mica & feldspar are the main gangue minerals.
FEED:-
41.9% Mn
19.0% SiO₂
3.3% Fe
1.6% Al₂O₃
3.7% BaSO₄ Reject:-
27.9% Mn
50.28% SiO₂
Weight yeild of 38.4%
Conc.:-
50.8%Mn
9.2% SiO₂
Weight yield of 61.6%
Processing of
manganese
31
32. 2. Beneficiation of high phosphorus ore
Apatite
Float
Manganese
Non float
Conditioning
Lower PH
to 6.5Manganese Mineral
Float (Conc.)
Silica
Non Float(tailing)
Option 1
Water
spray
Manganese
Mag (Conc.)
Apatite & silica
Non-mag(Tailing)
Option 2
O/F
U/F
FEED
Water
addition
ROM
70% -200mesh
32
33. 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% Mn
0.31% P
22.84% SiO₂
8.32% Fe
Reject:-
27.3% Mn
0.58% P
Weight yield of 39.9%
Conc.-(phosphorus
Float)
31.8% Mn
1.65% P
Weight yield of 8.8%
Processing of
Manganese ore
1st Stage
Conc.- (cleaner stage)
45.5% Mn
0.1% P
Weight yield of 60.1%
Cleaner
Stage
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34. 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% Mn
9.4% Fe
0.31% P Reject(Non-mag):-
32.25% Mn
1.05% P
7.47% Fe
Weight yield of 20.6%
Conc.(Mag):-
46.27% Mn
0.41% P
9.35% Fe
Weight yield of 79.4%
Processing of
Manganese ore
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36. Sample:- Sandur area , Karnataka;
Psilomelane & Pyrolusite were the manganese bearing minerals.
Hematite & Goethite were the iron minerals present in the sample.
FEED:-
34.1% Mn
17.7% Fe
6.9% Al₂O₃
8.5% SiO₂
0.5% BaSO₄ Reject(Mag) :-
24.4% Mn
24.2% Fe
7.8% SiO₂
Weight yield of 60%
Conc.(Non-mag):-
49.5% Mn
9.1% Fe
9.2% SiO₂
Weight yield of 40%
Processing of
Manganese ore
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37. Cost benefit Analysis of Beneficiated concentrate
1. Siliceous and high Phosphorous
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39. 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
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http://www.infomine.com/investment/metal-prices/manganese/
40. India
Manganese Ore Rs./t
MnO2 22127
Up to 25% Mn 1724
25 - 35% Mn 4571
35 - 46% Mn 10175
Above 46% Mn 12953
Andhra Pradesh
Manganese Ore Rs./t
MnO2 NA
Up to 25% Mn 1120
25 - 35% Mn 2280
35 - 46% Mn 2648
Above 46% Mn NA
Jharkhand
Manganese Ore Rs./t
MnO2 15000
Up to 25% Mn NA
25 - 35% Mn 4500
35 - 46% Mn NA
Above 46% Mn NA
Karnataka
Manganese Ore Rs./t
Up to 25% Mn 1872
25 - 35% Mn 4365
35 - 46% Mn 3600
Above 46% Mn NA
Madhya Pradesh
Manganese Ore Rs./t
MnO2 NA
Up to 25% Mn 1866
25 - 35% Mn 4214
35 - 46% Mn 9374
Above 46% Mn 13044
Maharastra
Manganese Ore Rs./t
MnO2 52318
Up to 25% Mn 2468
25 - 35% Mn 5153
35 - 46% Mn 10382
Above 46% Mn 12722
Odisha
Manganese Ore Rs./t
MnO2 22348
Up to 25% Mn 5305
25 - 35% Mn 8263
35 - 46% Mn 14524
Above 46% Mn 16724
Average Sale Price for August 2014
(Source - MINERALS & METALS REVIEW, September 2014)
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