MANGANESE ORE JIGGING PLANT
[EIRI/EDPR/1375] J.C. 148
INTRODUCTION
Manganese is one of the most important strategic minerals, being the one which the greatest tonnages are required, and also the one in which the United States has had a limited production, Manganese is an absolute necessity in the steel industry, as this industry uses about 14 pounds of manganese in every ton of steel produced. Annual statistics show that over 90 percent of the annual amount of manganese consumed in the United States goes into the production of steel. From this it can therefore be seen that the stability and accessibility of a steady supply of manganese ore is a controlling factor in the maintenance of the steel industry. The remaining 10 percent of the manganese consumed yearly in the United States is used in the manufacture of dry batteries, chemicals, glass, tile, and brick.
One of the outstanding characteristics of the utilization of manganese in steel making is that in the process of being used, most of the metal is dissipated into the slag in a form not readily susceptible to subsequent recovery as a secondary metal. In fact, the amounts that are returned to use in this way are so small as to be practically negligible, and the full requirements for each year must be net from new mine production. No other metal in the strategic list has such a low secondary return as manganese. Another prominent fact in connection with manganese is that little of it is produced in the form of a pure metal, as most manganese is converted from the ore into ferro alloys, ferro manganese and spiegeleisen. However, what small amount of manganese is converted into more or less a pure metal, does not go into commercial use in that pure form, but is further used in taking various non-ferrous alloys.
Manganese deposits in the United States have supplied only a small fraction of the domestic requirements for high-grade manganese ores (+35 percent manganese). The remainder of the supply of manganese ore has been imported, chiefly from India, Gold Coast, Brazil, French Morocco, Union of South Africa, Cuba, and Russia. The average yearly domestic production for the last decade was less than 10 percent of our total requirements.
COST ESTIMATION
Plant Capacity 100 MT/Day
Land & Building (20,000 sq.mt.) Rs. 1.04 Cr
Plant & Machinery Rs. 1.46 Cr
Working Capital for 2 Months Rs. 1.87 Cr
Total Capital Investment Rs. 4.46 Cr
Rate of Return 28%
Break Even Point 59%
CONTENTS
INTRODUCTION
MANGANESE MINERALS
IMPURITIES ASSOCIATED WITH MANGANESE ORES
PROPERTIES
CLASSIFICATION OF MANGANESE ORES
USES OF MANGANESE
BLEACH MANUFACTURE
THE STEEL INDUSTRY
OTHER METALLURGICAL USES
THE CHEMICAL INDUSTRY
B.I.S. SPECIFICATION
MARKET POSITION
MANGANESE ORE
PLANT LAYOUT
MANUFACTURING PROCESS FLOW CHART
MANUFACTURING PROCESS - MANGANESE ORE BENEFICATION PROCESSES
CONCENTRATION OF MANGANESE ORES
GRAVITY METHODS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND EQUIPMENTS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
