Detailed Project Report on Manganese Ore Jigging Plant

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)