Manganese ore can be categorized into two main types: manganese oxide ore and manganese carbonate ore. The beneficiation methods for these two types of manganese ores have both similarities and differences. Consequently, the equipment used for manganese mining and processing varies.

Gravity separation is a common method used to sort manganese ore based on the density difference between the rock particles. This process involves placing the mixture of ore particles into a medium flow that moves vertically at variable speeds, allowing for the separation of minerals. The jig, a type of manganese ore dressing equipment, is often used for gravity separation due to its simple structure, low investment, high separation efficiency, high recovery rate, and low operating cost. It can remove approximately 80% of waste rock in siderite under suitable conditions. Gravity beneficiation is particularly effective for manganese oxide ore, as there is a significant difference in specific gravity between manganese minerals and waste rocks.

Magnetic separation is another method commonly used for manganese ore beneficiation. Manganese ore is weakly magnetic, allowing for effective separation using strong magnetic separation equipment with a magnetic field strength exceeding 14,000 gauss. The method involves sorting the ore based on magnetic differences to obtain manganese concentrate. Magnetic separation is predominantly utilized for manganese oxide ore and manganese carbonate ore beneficiation. It is often considered as an auxiliary beneficiation process. However, in areas with water scarcity or without access to water, dry strong magnetic separation can be employed to process manganese ore.

A combination of magnetic and flotation processes is commonly used for manganese carbonate ore beneficiation. This process typically involves using crushers, ball mills, classifiers, mixing drums, flotation machines, and other equipment. It is mainly applied for the beneficiation of manganese carbonate ores or associated polymetallic manganese ores.

To summarize, gravity separation, magnetic separation, and magnetic-flotation processes are employed for the beneficiation of different manganese ore types, depending on their characteristics. Each method has its own advantages and is utilized accordingly in manganese mining and processing operations.

Manganese Ore Processing Plant

1. Rock Manganese Ore Processing

The main equipment for the manganese ore processing plant includes:

• Jaw crusher: For crushing the raw ore into small pieces.
• Cone crusher: Further reduces the size of the ore to obtain fine sizes.
• Vibration screen: Separates the ore, sending the size greater than 20mm back to the cone crusher, while the 0-20mm size goes to the hopper.
• Ball mill: Grinds the 0-20mm materials to a size of 0-1mm.
• Slurry pump: Transports the 0-1mm materials to the spiral chute for separation of heavy minerals.
• Spiral chute: Separates the heavy minerals from the 0-1mm material.
• Double drum magnetic separator: Removes other heavy minerals from the manganese, resulting in a higher grade manganese concentrate.

The manganese ore processing plant setup typically includes various components. Firstly, the raw bin and vibration feeder are utilized to automatically load materials, which can be done by truck, excavator, or other means, into the raw bin. From there, the materials are fed into the jaw crusher, where they are crushed into smaller pieces. The crushed ore then proceeds to the cone crusher, which further reduces it to obtain fine sizes.

Next, the vibration screen is employed to separate the materials. Any particles larger than 20mm are sent back to the cone crusher for further processing, while the 0-20mm fraction is directed to the hopper and electromagnetic feeder. Subsequently, these materials are transferred to the ball mill for grinding. The ball mill reduces the size of the 0-20mm materials to a finer range of 0-1mm.

Once the materials have been ground, a slurry pump is used to transport the 0-1mm particles to the spiral chute. The spiral chute aids in the separation of heavy minerals from the 0-1mm material. Lastly, the double drum magnetic separator comes into play. Its purpose is to effectively separate the manganese from other heavy minerals, resulting in the production of a higher grade manganese concentrate.

The capacity of this washing plant can be customized according to specific requirements, such as 10tph, 50tph, 100tph, or as desired.

2. Alluvial & Rock Manganese Ore Beneficiation Plant

This alluvial and rock manganese ore process plant consists of the following equipment:

1. Trommel scrubber
2. Vibrating screen
3. Impact crusher
4. Belt conveyor

The plant has a capacity for washing of 100 TPH and crushing of 200 TPH.

1. Washing: Raw material is fed into a trommel scrubber for clay scrubbing and washing.
2. Screening: Scrubbed material is screened using a vibrating screen with 4-layer decks for different size separation.
3. Crushing: Raw material around 200mm is fed into an impact crusher for crushing to less than 80mm.
4. Screening (Again): Crushed material is screened again using a vibrating screen, and particles larger than 80mm are sent back to the impact crusher for further crushing.

Please note that the crusher can adjust based on different input stone sizes. The capacity of the process plant can be customized as per specific requirements and mine conditions.