Beneficiation and agglomeration process to utilize low-grade ferruginous manganese ore fines

Characterisation, beneficiation and agglomeration studies were carried out to develop a utilization strategy for typical Indian low grade manganese ore fines. The major mineral phases found are pyrolusite, hematite, goethite, clay, feldspar and quartz. QEMSCAN and Sink–Float studies suggested that 40% of manganese minerals are in liberated form, whereas 30% are locked with iron minerals. Classification followed by two-stage high intensity magnetic separation (1.7 & 1.1 Tesla) process can recover 35–40% material of ferromanganese grade with 47–49% Mn recovery. The recovered material was briquetted adding molasses (7%), cement (3%) and bentonite (1%) to use in the submerged arc furnace for metallurgical applications. A cost effective process flow sheet has been developed to utilize these fines.