Unpredictable changes in demand and prices varying from very attractive to depressing levels have thrown all Manganese ore mines out of normal operating gear. The supply has to be in time-bound fashion, of dependable quality and continuous. With setting-up of numerous small units and with existing ferro-alloy units, ore supply has become extremely sensitive issue. Due to unpredictable swing in price of Mn ore lumps , furnace operators found it economic and convenient to use fines, even at great risks to furnace equipment and operating persons and therefore risks & damages were conveniently & comfortably ignored. Beneficiation Cost(Operating) approx. - (ferruginous ore) - Roast reduction followed by magnetic separation route-particulars - Water 20/-, Power 490/-,Coal fines-675/-,OH-250/-totaling to Rs.1435/T.( Figures are based on actual data from investigations on Orissa & Karnataka sector ores).Feed Grade Mn- 28 to 32 %, Fe - 14 to 25 %, Concentrate (Beneficiated ore fines)- - Mn- 45 to 48 %, Fe - 6 to 8 %.,Recovery - 35 % , Price of 28-30 % Mn ore fines = Rs. 2400 /T, Cost of Concentrated fines (45/ 48% Mn grade) = Rs. 8300 /T, Price of 47-48 % Mn Lumpy ore = Rs.11,000 /T. Sintering Cost (Operating) - Approx-Rs.1195=00 / T Sinter. Therefore cost of Sinter produced from beneficiated concentrate is 9130+1195 = Rs. 10325. The difference in cost of 48%Mn ore Lumps & 48%Mn sintered concentrate = 11000-10325 = Rs.675/T. The main purpose of this paper is to show that establishment of beneficiation unit & Sintering unit is economically feasible. There are many misconcepts, still prevailing, about use of Mn ore sinters. Few of the main misconcepts are-l)Sinters bring no benefit - technical or economical.2) Sinters are very friable and disintegrate easily into high fines during handling/transportation. 3) Fines below 100 mesh cannot be sintered. 4) Silica increases to high level during sintering, resulting in to high slag volume thereby higher power consumption. All are false. Sinters have already been proved to bring enormous technical benefits in smelting operation. However small mine owners find it practically impossible to set up a small beneficiation and/or sintering unit at mine site. Recent advances in dry or pneumatic separation which depends on density difference between valuable mineral and gangue/waste rock, are proving to be advantageous & effective because of its small capacity. Capacity is 5 T/hr or 10 T/hr. When applied to low grade high silica Iron ores Iron content has been found to be enhanced by 8 to 10 % from 48% to 58 % , with overall wt. recovery of 60 to 70 %. Recently this technique was applied to low grade siliceous Mn ore with very encouraging results. Mn content has been found to be enhanced from 25 +/- 2 % to 37 +/- 2 % and with 50 to 65% wt. recovery. Size of feed is restricted to (i) 6 to 25 mm and (ii) 2 to 6 mm. Due to Modular design it is possible to put up units from 50 TPD to 800 TPD capacity.
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