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The 7 Most Useful Manganese Ore Beneficiation Methods

Author : Jordan | Last Updated :

What are usages of manganese ore?

In modern industry, manganese and its compounds are used in various fields of the national economy. Among them, the steel industry is the most important field, accounting for 90%-95% of manganese, mainly used as a deoxidizer and desulfurizer in iron-making and steel-making, and used to make alloys.

The remaining 10%-5% of manganese is used in other industrial fields, such as the chemical industry (manufacturing various manganese-containing salts), light industry (for batteries, matches, printing, soap, etc.), building materials industry (colorants and decolorants of glass and ceramics), the national defense industry, the electronics industry, etc.

In short, manganese has a very important strategic position in the national economy.

Natural manganese ore

Natural manganese ore

How is the prospect of manganese ore?

Manganese ore products include metallurgical manganese ore, manganese carbonate ore powder, manganese dioxide ore powder for the chemical industry and manganese dioxide ore powder for batteries.

The metallurgical department, the light industry department and the chemical department using manganese ore products have different quality requirements for manganese ore products according to different uses.

The distribution of terrestrial manganese deposits in the world is extremely uneven, mainly in South Africa, Gabon, Brazil, Australia and India. With the rapid development of the economy, the demand for mineral resources has increased dramatically.

The manganese ore in many countries and regions is mostly poor ore and must be treated through beneficiation. From this point of view, the development prospects of manganese ore and its compounds are broad.

Manganese ore dressing on site

Manganese ore dressing on site

What are the methods of manganese ore beneficiation?

Since most manganese ore is a fine-grained or fine-grained inlay, and there are a considerable number of high-phosphorus ore, high-iron ore and symbiotic beneficial metals, it is very difficult to sort.

At present, commonly used manganese ore beneficiation methods include physical beneficiation (washing and screening, gravity separation, strong magnetic separation, flotation separation, joint beneficiation), chemical beneficiation (leaching method) and fire enrichment, etc.

The following will focus on various manganese ore beneficiation methods.

1. Washing and screening

Washing is the use of hydraulic washing or additional mechanical scrubbing to separate the ore from the mud. Commonly used equipment includes washing sieves, cylinder washing machines and trough ore-washing machine.

The washing operation is often accompanied by screening, such as direct flushing on the vibrating screen or sifting the ore (clean ore) obtained by the washing machine to the vibrating screen. Screening is used as an independent operation to separate products of different sizes and grades for various purposes.

2. Gravity separation

At present, the gravity separation is only used to select manganese ore with simple structure and coarse grain size, and is especially suitable for manganese oxide ore with high density. Common methods include heavy media separation, jigging and tabling dressing.

At present, the process of manganese oxide ore dressing in China is generally to crush the ore to 6~0 mm or 10~0 mm, and then the coarse-grade for jigging, and fine-level for tabling dressing.

3. Strong magnetic separation

Manganese ore is a weak magnetic mineral [Specific magnetization coefficient X=10×10^-6~600×10^-6cm3/g], under the magnetic separator with magnetic field intensity Ho=800~1600 kA/m (10000~20000oe), it can be recycled, generally increasing the manganese grade by 4% to 10%.

Because of the simple operation, easy control and strong adaptability of magnetic separation which can be used for the selection of various manganese ore, it has dominated the manganese ore dressing in recent years.

Strong magnetic separation of manganese ore

Strong magnetic separation of manganese ore

Various new types of coarse, medium and fine grain magnetic machines have been successfully developed. At present, the most common in China is the medium-grain strong magnetic separator. The coarse-grained and fine-grained magnetic separators are gradually being applied.

4. Gravity-magnetic separation

Gravity-magnetic separation plant of manganese ore mainly deals with leaching manganese oxide ore, using the jig to treat 30~3 mm of cleaned ore, which can obtain high-quality manganese-containing more than 40% of manganese. And then can be used as manganese powder of battery raw material.

The jigging tailings and less than 3 mm washed ore are ground to less than 1mm, and then selected by strong magnetic separator. The manganese concentrate grade should be increased by 24% to 25%, reaching 36% to 40%.

5. Strong magnetic - flotation separation

The strong magnetic-flotation separation has better adaptability, and it not only effectively removes the slime, but also improves the selected grade of flotation.

The use of strong magnetic-flotation desulfurization can directly obtain the integrated manganese concentrate product; the use of petroleum sodium sulfonate instead of oxidized paraffin soap as a collector can make the pulp be sorted at neutral and normal temperature, saving drug consumption and energy consumption.

6. Fire enrichment

The enrichment of manganese ore by fire is a sorting method for high-phosphorus and high-iron manganese ore which is difficult to select. It is generally called the manganese-rich slag method.

The essence is a high-temperature sorting method for selectively separating manganese, phosphorus and iron by controlling the temperature of them in a blast furnace or an electric furnace.

The fire enrichment process is simple and stable, and the iron and phosphorus in the ore can be effectively separated to obtain manganese-rich slag with low-iron and low-phosphorus.

The manganese-rich slag generally contains 35% to 45% Mn, Mn/Fe 12-38, P/Mn<0.002, which is a high-quality raw material of manganese-based alloy, and it is also an artificial rich ore that is difficult to achieve the above three indexes at the same time. Therefore, fire enrichment is a promising method for mineral processing for low-manganese with high-phosphorus and high-iron.

7. Chemical manganese separation

There are many chemical beneficiations for manganese, and the more promising ones are the dithionate method, the black manganese ore method and the bacterial immersion.

In actual production, most of the manganese carbonate ore beneficiation methods are strong magnetic separation, heavy medium ore dressing and flotation separation.

The manganese oxide ore is mainly based on the gravity separation, and the washing-gravity separation process or the washing-reduction roasting magnetic separation-the gravity separation process is often used.

Of course, for refractory manganese ore, it is often necessary to combine two or more kinds of dressing methods.

Industrial processing requirements for manganese ore

In the metallurgical industry, the manganese ore is mostly used for manganese-forming ferroalloys and manganese metal. The former is used as deoxidizers or alloying element additives for steelmaking, and the latter is used to smelt certain special alloy steels and non-ferrous metal alloys. Manganese ore can also be used directly as an ingredient in steel-making and iron-making.

When smelting manganese-based iron alloys, the useful elements in manganese ore are manganese and iron. The level of manganese is the main indicator for measuring the quality of manganese ore. The iron content is required to have a certain ratio with the amount of manganese.

Phosphorus is the most harmful element in manganese ore. The phosphorus in steel reduces the impact of toughness. Although sulfur is also a harmful element, it has a better desulfurization effect during smelting, and sulfur is volatilized into sulfur dioxide or enters the slag in the form of calcium sulfide or manganese sulfide.

The main equipment of manganese ore processing

There is much equipment used for manganese ore processing. The main crushing equipment include jaw crusher, impact crusher, HD impact crusher, cone crusher and other products. The more advanced manganese ore processing equipment is the hydraulic cone crusher and the German version of the impact crusher(HD).

The main crushing equipment

The main crushing equipment

The main grinding equipment in the manganese ore beneficiation production line is ball mill. It can grind manganese ore to a relatively fine and uniform particle size, which lays a foundation for further magnetic separation of manganese ore.

The main grinding equipment-ball mill

The main grinding equipment-ball mill

The spiral classifier is indispensable grading equipment in manganese ore beneficiation plant. The classification of manganese by spiral classifier can achieve better classification effect.

The spiral classifier

The spiral classifier

The magnetic separator is a highly targeted magnetic separation device specially developed for the properties of manganese ore. The device not only has the advantages of small size, lightweight, high automation, simple and reasonable structure, but also has high magnetic separation efficiency and high output.

Also, the price of the equipment is extremely low, which is suitable for manganese ore dressing plants.

The magnetic separator

The magnetic separator

Since the minerals separated by magnetic separator contain a certain amount of water, it needs to be dried by a dryer.

The dryer produced by Fote Heavy Machinery has the advantages of easy handling, stable operation, high output, low carbon and environmental protection, etc. with an excellent drying effect.

The dryer produced by Fote Heavy Machinery

The dryer produced by Fote Heavy Machinery

Manganese beneficiation plant manufacturer

For the beneficiation of manganese carbonate ore, manganese oxide ore, mixed manganese ore and polymetallic manganese ore in the presence of coarse, medium and fine particles at home and abroad, Fote Heavy Machinery(FTM) can conduct comprehensive mineral processing experiments.

FTM manufactures various crushing, grinding, grading, strong magnetic separator equipment, such as jaw crusher, high-pressure roll crusher, rod mill, ball mill, spiral classifier, cylinder screen, iron remover, different series of flotation machines, strong magnetic separators, etc. FTM has rich experiences and successful cases in manganese ore dressing.

FTM manganese ore beneficiation plant

FTM manganese ore beneficiation plant

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Author : Jordan Jordan is the writer of the blog with a broad knowledge of this industry. Most importantly, he hopes to help you in your projects sincerely.


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