Welcome to Scribd, the world's digital library. Read, publish, and share books and documents. See more
Standard view
Full view
of .
Save to My Library
Look up keyword
Like this
0 of .
Results for:
No results containing your search query
P. 1




|Views: 489 |Likes:
Published by miningnova
Integrated flow-sheet design and the techno-economics for setting up of a manganese ore beneficiation plant for MOIL at Balaghat mine of Manganese Ore (India) Limited, the principal producer of high-grade manganese ore in the India.
Integrated flow-sheet design and the techno-economics for setting up of a manganese ore beneficiation plant for MOIL at Balaghat mine of Manganese Ore (India) Limited, the principal producer of high-grade manganese ore in the India.

More info:

Categories:Types, Research, Science
Published by: miningnova on Jun 27, 2009
Copyright:Attribution Non-commercial


Read on Scribd mobile: iPhone, iPad and Android.
download as PDF, TXT or read online from Scribd
See more
See less





A. B. Chatterjee*, G. P. Kundargi**
 Manganese ore is important in an industrial economy as manganese in alloy forms is an essential inputin steel making, where it is used both in the ore form as such and as ferro-manganese. Manganese oreimproves strength, toughness, hardness and workability of steel and about 90 to 95% world productionof manganese ore is used in metallurgy of iron and steel. Balaghat mine of Manganese Ore (India) Limited, the principal producer of high-grade manganese orein the country, is situated in Balaghat District of Madhya Pradesh. It remains one of the most important producers of high-grade manganese ore in MOIL as well as in India. In due course the capacity of themine is proposed to be increased to 5.0 lakh tonnes. A 600 TPD Mn ore beneficiation plant already exists at Bharveli Mn ore underground semi-mechanizedmine. Keeping in view the deterioration in ROM ore quality, stringent market requirements and proposedincrease in production capacity of the mine, MOIL has decided to set up a modern, cost effectivebeneficiation plant with state-of-the-art technology. After successful testing of its ROM ore in a pilot plant at IBM, MOIL entrusted CMPDI the assignment of preparation of Techno-Economic Feasibility Report and Tender document for setting up of a modern plant at Balaghat mine based on the Pilot scalebeneficiation studies carried out by IBM. Mineralogy of the as received sample shows that the ore consists of mainly psilomelane, pyrolusite withsubordinate amounts of braunite. The main associated gangue mineral is quartz and minor amounts of mica / manganophyllite. The minerals are free as well as associated / interlocked with silicate gangue. About 75% of the quartz is free. Pilot plant test results proved good amenability of the tested ore for gravity separation methods. An integrated flowsheet comprising crushing, wet screening, classification, hand picking and jigginghas been designed to generate the sized concentrates with specified chemical composition. The plantwill have three main sections, i.e. Ore receiving, screening and crushing section, Beneficiation sectionand Hand-sorting/lumpy ore cleaning floor. The hourly throughput capacity of the plant has beenconsidered as 100 tph considering yearly throughput capacity as 5.0 lakh tonnes. The flowsheet consistsof solid-liquid balance, balance of products and specifications of selected equipment. Estimation of capital cost and plant operating cost has been done at various capacity utilisations. Economic analysisconsisting of cash flow statement, profit and loss statement, pay-back period, break-even point, returnon investment were carried out and the management of MOIL decided to set up the beneficiation plantwhich is going to be the largest Mn-ore beneficiation plant in India with state-of-the-art technology.Construction work is about to start and the plant is expected to be ready within 1-2 years.
*Coal & Mineral Preparation Division, CMPDIL(HQ), Kanke Road, Ranchi – 834 008. E. Mail : a_b_chatterjee@rediffmail.com**Manganese Ore India Ltd. 3, Mount Road Extension, P.O. Box. 34, Nagpur- 1
16-18 January, 2006, Kolkata, India
The Mining Geological and Metallurgical Institute of India (MGMI), Centenary 
368Integrated Flowsheet Design of a Manganese Ore Beneficiation Plan
The total world reserve base of manganese isapproximately 5,000 million tonnes. Total recoverablereserves of manganese ore in India (as on 1.4.1995) areplaced at 167 million tonnes comprising 40 million tonnesin the proved category, 49 million tonnes in the probablecategory and the remaining 78 million tonnes in thepossible category. South Africa, Australia, Gabon & Brazilare the major world producers of high grade ore (Mncontent 37-52%) and India, China and CIS countries arethe major producers of low grade ore (Mn content 25-35%). By considering the statewise reserves, Orissa with52.81 million tonnes accounts for about 31.6% of the totalrecoverable reserves followed by Karnataka 41.05 milliontonnes (24.53%), Madhya Pradesh 23.64 million tonnes(14.13%), Goa 16.86 million tonnes (10%), Maharashtra16.66 million tonnes (9.96 % ), Andhra Pradesh 11.9million tonnes (7.11%) and remaining 3.84 million tonnesfrom Jharkhand and Gujarat. Manganese ore is importantin an industrial economy as manganese in alloy forms isan essential input in steel making where it is used both inthe ore form as such and as ferro-manganese.Manganese ore improves strength, toughness, hardnessand workability of steel and about 90 to 95% worldproduction of manganese ore is used in metallurgy of ironand steel.As the steel production in our country is set to growat a very fast rate, demand for high grade manganese ison the rise. Much of India
s Manganese reserve fall in thelow grade category that makes it all the more necessaryto find out modern cost effective techniques forbeneficiating our modest reserve.Annual production of Manganese ore in India stoodat 1.56 million tonnes during 2000-01. Eleven principalproducers operating 39 mines (out of total 133 reportingmines, 8 are underground and rest are opencast)contributed 86% of the total production. Eighteen publicsector mines jointly accounted for 61% of the totalproduction during 2000-01.Manganese Ore (India) Ltd. (MOIL), Nagpur is theprincipal producer of high grade manganese ore in thecountry. MOIL has 10 working mines in the state ofMaharashtra and Madhya Pradesh. Present level ofproduction is about 1.0 million tonnes per annum ofManganese Ore.Balaghat mine of Manganese Ore (India) Limited issituated in Balaghat District of Madhya Pradesh. Thedeposit was first located in the year 1883 but the regularmining started only in 1903 by M/s C.P.M.O having H.Q.in London, who worked up to 1962. Since then M/s MOILhas taken over the charge. Up to 1920, it was worked byopencast method and later on underground workingstarted. Reserves as on 01/04/2002 are 23.41 milliontonnes upto 25
level and it has 9.361 Million tonnesreserve of Ferro-grade ore with Phosphorus content lessthan 0.10%. Total annual production of the mine in 2002-03 being 236334 tonnes, Balaghat mine remains one ofthe most important producers of high grade manganeseore in MOIL as well as in India. By now, it has achievedthe distinction of being the largest and deepestunderground manganese mine in the whole Asia. In duecourse the capacity of the mine is proposed to beincreased to 5.0 lakh tonnes per annum.The
quality of Manganese ore from Balaghat mine iscritical because ore from this mine is the best of the lotand is used to improve the quality in blending with otherores. The quality of the blended ore, supplied to variousconsumer industries such as, Iron & Steel Industry; FerroAlloys etc, depends mainly on the quality of the ore ofBalaghat mine.In Balaghat mine, change in the backfilling practiceby sand and water mixture (sand-stowing) has resultedin silica sand adhering to the ROM ore and hence in qualitydeterioration of the mined ore. Market pattern of thebeneficiated products have also changed making thequality parameters more stringent. The production fromthe mine is proposed to be increased in the near future.ROM production is projected to rise up to 0.42 milliontonnes in 2006-07 and finally it has to attain full productioncapacity of 0.5 million tonnes.
A 600 TPD Mn ore beneficiation plant already existsat Balaghat Mn ore underground semi-mechanized mineat Bharveli which employ unit operations like crushing,dry screening, hand sorting and jigging to produce two
A. B. Chatterjee and G. P. Kundargi36
concentrates viz. -75 +25 mm lumps assaying 49-50 %Mn and 8.9% SiO
and a Jig concentrate assaying 46%Mn and 14% SiO
. The beneficiation methods adoptedare manual, labour intensive and primitive. Keeping inview the deterioration in ROM ore quality, stringent marketrequirements and proposed increase in productioncapacity of the mine, MOIL has decided to set up a moderncost effective beneficiation plant with the state of the arttechnology.Existing system of upgradation by semi-mechanizedmeans in several Joplin Jigs is quite labour intensive andless efficient and pose problems in maintaining quality.The present backfilling practice by sand and water mixture(sand-stowing) has resulted in silica sand adhering to theROM ore and hence deterioration of the mined ore fromBalaghat mine. The proposed increase in the minecapacity from the present level of 2.4 lakh tonnes to 5.0lakh tonnes per year and deterioration of the mined orehas necessitated setting up of an effective and modernbeneficiation plant at Balaghat mine. Hence, MOILapproached Indian Bureau of Mines (IBM) to carry outcertain test work on the ROM samples. After successfultesting of its ROM ore in a pilot plant at IBM, MOILentrusted CMPDI the assignment of preparation ofTechno-Economic Feasibility Report and Tenderdocument for setting up of a modern plant at Balaghatmine based on the Pilot scale beneficiation studies carriedout by IBM.The desired quality of Balaghat ore for supply to themajor consumer industries is given in table - 1:
Table – 1 : Desired quality of products
Assay %Product size range (mm)
-75 +25 mm-25 + 6 mmMn49.547SiO
8 (max)10 (max)P0.10.1Fe5.05.5
Presently, the run-of mine Manganese Ore is crushedto -75mm and the crushed product is screened to getthree size fractions; namely 75-25mm; 25-6mm and 6-0mm. Quality of 75-25mm ore is upgraded by removal ofthe gangue materials by resorting to manual sorting inthe Ore Cleaning Floor (OCF). 25-6mm fraction isupgraded in a number of semi-mechanised Joplin jigs.The
6mm fraction is stored separately or subjected to jigging by Joplin jigs depending upon customer
srequirement. The entire processing facilities are semi-mechanised and labour intensive.
A low grade manganese ore sample from Bharvelimines of MOIL has been tested in the Ore DressingLaboratory and Pilot Plant of Indian Bureau of Mines (IBM),Nagpur for studying the ore characteristics, its amenabilityto washing in various equipment including Jigs etc. Therelevant extracts from these test results are given asfollows for the purpose of tendering.
Physical :
-The as received sample consisted of lumps up to300 mm size with little fines. The lumps were hardand compact in nature having blackish colour.-The bulk density of the as received sample was foundto be 2.75 T/M
.-The angle of repose of the representative sample(fed to the scrubber) as determined by formation ofa cone was found to be 33
.-The specific gravity of the ore was found to be 3.92.
Chemical :
A representative portion of the as received samplewas subjected to chemical analysis. The result arepresented in following table
2 :
Table - 2 : Chemical analysis of the as-receivedsample

Activity (14)

You've already reviewed this. Edit your review.
1 hundred reads
1 thousand reads
alokism liked this
Raman Kumar Sahu liked this
skgurugsi16349 liked this
ariojudo liked this
ariojudo liked this
sanamsoni liked this
192175 liked this

You're Reading a Free Preview

/*********** DO NOT ALTER ANYTHING BELOW THIS LINE ! ************/ var s_code=s.t();if(s_code)document.write(s_code)//-->