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Manganese Ore BeneficiationSubmitted by Mukesh Ranjan Behera

1Vision 20201.According to National Steel Policy 2008 , Steel production target 180 MT 2.60% is expected through BF route i.e. 110 MT3.10kg of B.F. grade Manganese ore(28-30%Mn) is required for per tonne of iron ore, For 110MT , 1.1MT Manganese is required4.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 2.7MTPA5.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.

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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.

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5 facts about ManganeseThe effectiveness of Manganese in increasing mechanical properties depends on & is proportional to the carbon content of the steel.Manganese helps to increase the steels 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.

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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.

5Formation of manganese ore1.Hydrothermal2.Sedimentary3.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.6

Manganese BearingMineral

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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 countryCommon Mineral Forms of Manganese ore in India

88Manganese Ore characteristics of Indian deposits Siliceous with medium to High phosphorous contentFerruginous with low phosphorus and High alumina contentOccurrences Maharastra, Andhra Pradesh, Madhya pradeshOccurrences Odisha, Goa, Karnataka

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TYPES AND END USE GRADE OF MANGANESE ORE

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End Products

11Size range for Manganese Ore for different Industries

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13World reserve of Manganese Ore, 2012

14World Production of Manganese Ore During 2005 & 2011 in 000 tones

15BHP BillitonASSMANGCONSMINOMH groupTshipi E Ntle ERAMETCVRO(Vale)Minera AutlanPrivat GroupEurasian Natural Rasources Corporation1. Grootw Eylandt mines, Australia2.Mamatwan-Wessels mines, south Africa4. Azul mines, Brazil3. Moanda mines, gabon5. Molango mines, Mexico6. Nonoalco mines, Mexico7. Urucum mines, Brazil8. Nchwaning mines, South Africa9. Gloria mines, South Africa10. Woodie-woodie mines, australiaTop Ten producer of Manganese in the worldTop ten Manganese mines in the world

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1253467891011BIHARORISSA1. BONAIKEONJHAR & SINGHBHUM2. KALAHANDIKORAPUTMADHYA PRADESHMAHARASHTRA3. NAGPUR--BHANDARABALAGHAT4. JHABUAANOHRA PRADESHSRIKAKULAMKARNATAKA6. SANDURBELLARY7. SHIMOGA8. NORTH KANARAGOA9. GOAGUJARAT10. PANCH MAHALRAJASTHAN11. BANSWARA Distribution of Manganese ore deposits in IndiaMANGANESE 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)

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18(As on 1:04:2010)

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FUTURE DEMAND2000-011.45 MT2011-124.25 MT2016-177.39 MT2025-2622.81 MT2029-3036.87 MT

BY ARETHMATIC AVERAGE METHOD

21MININGMining Method Opencast Under ground

Dongri-Buzurg Open Cast Mine, MOIL, Maharashtra

22Processing of manganese ore1. Manganese ore processing practice in India2. Need for processing3. Process rout of beneficiation of manganese ore4. Beneficiation of different type of Indian manganese ore5. Costbenefit analysis of beneficiation concentrate

23Most of the manganese ore mines have been operated by selective mining for maintaining medium to high grade ore at mining cut off 20% Mn .At this cut-off , blast furnace grade and mixed grade ore (+25% Mn) is readily exploited leaving low grade ores (