Manganese Ore

Beneficiation
Submitted by Mukesh Ranjan Behera
1

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

Vision 2020

4.Where as, around 15kg of

Manganese based alloy (grade 6572%) 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.

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.

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 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.

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.

Formation of manganese ore

Sedimentary
Sedimentary deposits
deposits are
are
formed
by
the
deposition
formed by the deposition of
of
material
at
the
Earth's
surface
material at the Earth's surface
and
and within
within bodies
bodies of
of water.
water.
Sedimentation
Sedimentation is
is the
the collective
collective
name
name for
for processes
processes that
that cause
cause
mineral
and/or
organic
particles
mineral and/or organic particles
to
to settle
settle and
and accumulate
accumulate or
or
minerals
minerals to
to precipitate
precipitate from
from aa
solution
solution..

1.Hydrothermal

2.Sedimentary

3.Surficial
Sedimentary
deposits
are the most
abundant
types
6

Manganese
Bearing
Mineral

Common Mineral
Forms of Manganese ore
in India
Psilomelane
(Hydrous oxide of Mn)

Braunite
(Anhydrous sesquioxide of Mn)

Indian Manganese Ore deposit

Psilomelane + Braunite = 90% of Total
Reserve of manganese in country

Pyrulosite
(Peroxide of Mn or Black Mn)

Cryptomelane
(Psilomelane containing some potash or soda)

Manganese Ore characteristics of

Indian deposits

Siliceous with medium to

High phosphorous
content

Occurrences
Maharastra, Andhra
Pradesh, Madhya
pradesh

Ferruginous with low

phosphorus and High
alumina content

Occurrences
Odisha, Goa,
Karnataka

TYPES AND END USE

GRADE OF
MANGANESE ORE

10

EndProducts
Products
End

11

Size range for Manganese Ore for different

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

200mesh (75micron)

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

Steel
making
Grade

Blast
furnace
grade

Battery
Grade

Chemical
Grade
200mesh (75micron)

12

World reserve of Manganese Ore, 2012

Australia; 15%
Brazil; 17%
India; 8%

China; 7%
Gabon; 4%
Ukrain; 22%

Kazakhstan; 1%
Maxico; 1%
Other countries; 1%
South Africa; 24%

14

World Production of Manganese Ore During 2005 & 2011

in 000 tones
14000

14000

12000

10000
8652

8000

2005

7500
6961

2011

6000
4612

4000

3829
3200
3100

2000

3562
2753

2387
1828
1720

1906

2930
2208

2000

1590

2290
1172

15

Top Ten producer of

Manganese in the world

Top ten Manganese mines in the world

1. Grootw Eylandt mines, Australia
2.Mamatwan-Wessels mines, south Africa

1. BHP Billiton
2. ASSMANG
3. CONSMIN
4. OMH group
5. Tshipi E Ntle
6. ERAMET
7. CVRO(Vale)
8. Minera Autlan
9. Privat Group
10. Eurasian
Natural
Rasources
Corporation

3. Moanda mines, gabon

4. Azul mines, Brazil
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

16

Distribution of Manganese ore deposits in India

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)

MANGANESE ORE DEPOSITES---11

10

9 8

6
7

BIHARORISSA
1. BONAIKEONJHAR & SINGHBHUM
2. KALAHANDIKORAPUT
MADHYA PRADESHMAHARASHTRA
3. NAGPUR--BHANDARABALAGHAT
4. JHABUA
ANOHRA PRADESH
SRIKAKULAM
KARNATAKA
6. SANDURBELLARY
7. SHIMOGA
8. NORTH KANARA
GOA
9. GOA
GUJARAT
10. PANCH MAHAL
RAJASTHAN
11. BANSWARA

17

Industrial Consumption of Manganese ore in India

Iron & Steel; 6%

Battery; 0% Lead and Zinc Metallurgy; 0% Chemicals; 0% Others; 0%

Ferro Alloys; 29%

Ferro Alloys
Silicomanganese
Iron & Steel
Battery
Lead and Zinc Metallurgy
Chemicals
Others

Silicomanganese; 64%

18

States wise resources of Manganese ore in India

Maharastra; 8%
Madhya Pradesh; 13%
Andhra Pradesh; 4%
Jharkhand; 3%

Karnataka; 22%

Goa; 3%
Rajasthan; 1%
Gujurat; 1%
odisha; 44%

West Bengal; 0%

(As on 1:04:2010)

State wise production of manganese ore

1999-2000 & 2011-12
648 650

Thousand tonnes

650
600
550
500
450
400 322
350
300
250
200
150 88
100
142
50
0

566
523

329

353

271
136

518
00

7
0

State

20

FUTURE DEMAND
2000-01
1.45 MT

2025-26
22.81 MT

2011-12
4.25 MT

2029-30
36.87 MT

2016-17
7.39 MT

BY AR
E
AVER THMATIC
AG
METH E
OD

21

MINING
Mining Method

Opencast

Under ground

Dongri-Buzurg Open Cast Mine, MOIL, Maharashtra

22

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. Costbenefit analysis of beneficiation concentrate

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.
24

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

Metallic
Fe, Pb,
Cu, Zn,
Ag & As

Slag-Gaunge
Si02, Al2O3,
CaO, MgO,
Ba0

Non-metallic
Sulphur &
Phosphorous

Volatiles
H20, CO2
& organic
matter

25

Ore

gangues
Quartz
Quartz

Siliceous
Siliceous
ore
ore
types
types

Apatite
Apatite
Quartz
Quartz

Garnet,
Garnet,
Quartz
Quartz

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

Electrostatic
Electrostatic separation
separation or
or
sometimes
sometimes flotation.
flotation.

26

Ore
type

Ferruginous

Complex
ore

ore
gangue

Process
Of
upgradation

Hematite, Goethite,
Limonite

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

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

Required three or even

more
Steps for the elimination
of the gangue &
production of high grade
concentrates.
Combination of GravityMagnetic, ESS & Flotation

27

Size classification of beneficiation equipment for Manganese ore

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

28

ROM Feed
(-75mm)

1. Beneficiation of Siliceous manganese ore

1. Beneficiation of Siliceous manganese ore

-75+25mm

Hand
Sorting

-25+6mm

O/F
-0.2mm

-6mm

Reject

Conc.
(-25+6mm)

U/F
-6+0.2mm

Conc.
-6mm

Reject
-6mm

Conc.

Reject
(-25+6mm)

29

Sample:- Bharveli mines, balaghat.

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

FEED:FEED:41.9% Mn
41.9% Mn
19.0% SiO
19.0% SiO
3.3% Fe
3.3% Fe
1.6% AlO
1.6% AlO
3.7% BaSO
3.7% BaSO

Conc.:Conc.:50.8%Mn
50.8%Mn
9.2% SiO
9.2% SiO
Weight yield of 61.6%
Weight yield of 61.6%
Processing of
Processing
of
manganese
manganese

Reject:Reject:27.9% Mn
27.9% Mn
50.28% SiO
50.28% SiO
Weight yeild of 38.4%
Weight yeild of 38.4%

30

2. Beneficiation of high phosphorus ore

2. Beneficiation of high phosphorus ore
ROM

O/F

FEED

Option
Option 11
Apatite
Float

U/F
70% -200mesh

Conditioning

Water
addition

Manganese
Non float

Water
spray

Option
Option 22

Lower PH
to 6.5

Manganese Mineral
Float (Conc.)
Manganese
Mag (Conc.)

Apatite & silica

Non-mag(Tailing)

Silica
Non Float(tailing)

31

Option:-1
Option:-1
Sample :- Chikla mines;
Sample
:- Chikla mines;
Braunite was the main manganese bearing mineral followed by Jacobsite & Hausmanite
Braunite was the main manganese bearing mineral followed by Jacobsite & Hausmanite
are in minor amout.
are in minor amout.
Quartz was the main gaunge mineral followed by hematite in minor amount.
Quartz was the main gaunge mineral followed by hematite in minor amount.
Apatite was observed to be the only phosphorous bearing mineral intimately associated
Apatite was observed to be the only phosphorous bearing mineral intimately associated
with manganese minerals.
with manganese minerals.

Cleaner
Cleaner
Stage
Stage

FEED:FEED:38.2% Mn
38.2% Mn
0.31% P
0.31% P
22.84% SiO
22.84% SiO
8.32% Fe
8.32% Fe

Processing of
Processing
of ore
Manganese
Manganese ore

1st Stage
1 Stage
st

Conc.- (cleaner stage)

Conc.- (cleaner stage)
45.5% Mn
45.5% Mn
0.1% P
0.1% P
Weight yield of 60.1%
Weight yield of 60.1%
Conc.-(phosphorus
Conc.-(phosphorus
Float)
Float)
31.8% Mn
31.8% Mn
1.65% P
1.65% P
Weight yield of 8.8%
Weight yield of 8.8%
Reject:Reject:27.3% Mn
27.3% Mn
0.58% P
0.58% P
Weight yield of 39.9%
32
Weight yield of 39.9%

Option :-2
Option :-2
Sample:- South Tirodi mines;
Sample:South Tirodi mines;
Braunite was the principle manganese bearing mineral followed by Jacobsite in minor

Braunite was the principle manganese bearing mineral followed by Jacobsite in minor
amount.
amount.
Quartz was the main gaunge mineral.
Quartz was the main gaunge mineral.
Apatite was observed to be the only phosphorous bearing mineral intimately associated.
Apatite was observed to be the only phosphorous bearing mineral intimately associated.

FEED:FEED:43.5% Mn
43.5% Mn
9.4% Fe
9.4% Fe
0.31% P
0.31% P

Processing of
Processing
of ore
Manganese
Manganese ore

Conc.(Mag):Conc.(Mag):46.27% Mn
46.27% Mn
0.41% P
0.41% P
9.35% Fe
9.35% Fe
Weight yield of 79.4%
Weight yield of 79.4%
Reject(Non-mag):Reject(Non-mag):32.25% Mn
32.25% Mn
1.05% P
1.05% P
7.47% Fe
7.47% Fe
Weight yield of 20.6%
Weight yield of 20.6%

33

3. Beneficiation of Ferruginous manganese ore

3. Beneficiation of Ferruginous manganese ore

34

Sample:Sample:- Sandur
Sandur area
area ,, Karnataka;
Karnataka;

Psilomelane
Psilomelane &
& Pyrolusite
Pyrolusite were
were the
the manganese
manganese bearing
bearing minerals.
minerals.
Hematite
Hematite &
& Goethite
Goethite were
were the
the iron
iron minerals
minerals present
present in
in the
the sample.
sample.

FEED:FEED:34.1%
34.1% Mn
Mn
17.7%
17.7% Fe
Fe
6.9%
6.9% Al
AlO
O
8.5%
8.5% SiO
SiO
0.5%
0.5% BaSO
BaSO

Conc.(Non-mag):Conc.(Non-mag):49.5%
49.5% Mn
Mn
9.1%
9.1% Fe
Fe
9.2%
9.2% SiO
SiO
Weight
Weight yield
yield of
of 40%
40%
Processing
Processing of
of
Manganese
Manganese ore
ore

Reject(Mag)
Reject(Mag) ::24.4%
24.4% Mn
Mn
24.2%
24.2% Fe
Fe
7.8%
7.8% SiO
SiO
Weight
Weight yield
yield of
of 60%
60%

35

Cost benefit Analysis of Beneficiated concentrate

1. Siliceous and high Phosphorous
1. Siliceous and high Phosphorous

36

2. Ferruginous ore
2. Ferruginous ore

37

Price of Manganese ore

5 Year Manganese Prices and Price Charts

Historical Manganese Prices and Price Chart

1 Year Manganese Prices and Price Charts

6 Month Manganese Prices and Price Charts

38

Average Sale Price for August 2014

India
Manganese Ore

Rs./t

MnO2

22127

Up to 25% Mn
25 - 35% Mn
35 - 46% Mn
Above 46% Mn

1724
4571
10175
12953
Karnataka
Manganese Ore
Up to 25% Mn
25 - 35% Mn
35 - 46% Mn
Above 46% Mn

Maharastra
Manganese Ore
MnO2
Up to 25% Mn
25 - 35% Mn
35 - 46% Mn
Above 46% Mn

Rs./t
52318
2468
5153
10382
12722

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

Rs./t
1872
4365
3600
NA

Jharkhand
Manganese Ore
MnO2
Up to 25% Mn
25 - 35% Mn
35 - 46% Mn
Above 46% Mn

Rs./t
15000
NA
4500
NA
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
Odisha
Manganese Ore
MnO2
Up to 25% Mn
25 - 35% Mn
35 - 46% Mn
Above 46% Mn

(Source - MINERALS & METALS REVIEW, September 2014)

Rs./t
22348
5305
8263
14524
16724

39

MANGANESE ORE INDIA LTD

Balaghat Mines
PO- Bharweli
Dist- Balaghat
Madhya pradesh
Pin- 481102

Integrated Manganese Ore Beneficiation Plant MOIL

Balaghat, Madhya Pradesh
40

Flow
Flow sheet
sheet of
of IMB
IMB plant,
plant, Bharveli
Bharveli mines,
mines, MOIL
MOIL

Plant capacity 5lakh TPA

41

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

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

42

43