Boosting manganese ore recovery while limiting the environmental impact, allmineral plants and machines are used for the purpose of ore processing from discharge. At 30 installations across the globe, ores featuring a low metal content are concentrated for use in metal smelting via density sorting procedures. Our manganese ore processing plant in Georgia has helped deliver sustained success for our customer, both economically and ecologically. With a material yield of up to 68% at a manganese quality of over 40 Mn wt.% and a processing volume of 200 tons per hour, plant sustainability is a key priority.

While the ores are processed by alljig® jigs in the majority of applications, the allflux® sorter provides an efficient alternative for enriching pre-concentrates in the fine-grain range. One typical application is the processing of waste material material from existing mining facilities in Georgia: allmineral catered to this need by delivering a complete processing plant for subsequent processing in the smelting industry. Last but not least, the closed-loop slurry treatment system represents a sustainable boon for the Kura River, the local fishing industry and the ecology of the wider region.

Georgian manganese: a vital resource for the regional economy

Georgia is much more than just an interface between Asia and Europe. Formerly part of the Soviet Union, the country is now known above all for its stunning mountain villages in the Caucasus and the breathtaking beauty of the Black Sea. The 12th-century cave monastery of Vardzia is embedded in the landscape of the expansive Kakheti wine region. And the capital Tbilisi never ceases to amaze with the atmospheric cobblestone streets in its labyrinth-like Old Town. Georgia also enjoys access to enormous manganese reserves and is one of the largest producers of this mineral.

A short distance from Tbilisi, the city of Chiatura sits on the banks of the Kura River. Within the space of 18 months, allmineral planned, delivered and commissioned a manganese processing plant for the region. This system solution is capable of processing 200 tons of material per hour and delivers a wide range of benefits, both for the operator that commissioned it and for the region as a whole. It also inspired additional companies to relocate to the area, creating large numbers of jobs and helping establish wide-ranging ecological processes. The project was completed successfully with the connection of the plant to a slurry treatment system in accordance with European standards. This ensures that the water used during processing no longer has a negative impact on the surrounding nature – particularly the Kura River.

A number of additional ecological benefits and recycling processes were also realised within the scope of this system solution.

A complex challenge: replacing the high-polluting former plant

The customer was faced with the complex challenge of ensuring cost-effective manganese ore processing while substantially reducing the negative impact of this on the environment. In addition, the existing processing plant was no longer viable in terms of its performance, availability and quality of generated products. Before the allmineral system plant entered operation, the water used for processing was fed back into the river unfiltered – with far-reaching consequences for the region. This high level of pollution placed the entire local economy under strain, nowhere more so than in the fishing industry. 

As an expert partner for worldwide system processing plants, allmineral was commissioned with developing a profitable, efficient and ecological solution. A key hurdle in this regard was the fact that the waste products, which had largely been left unused up to this point, were now earmarked for recycling.

The solution: a world-first system featuring a closed loop

Less than 18 months after the signing of the contract, this turnkey processing plant was ready for handover. The manganese processing plant from allmineral now provides a throughput of 200 tons per hour, with our system solution enabling a material yield of over 68%. This high level of performance is ensured by sophisticated wet processing and high-gradient magnetic separation: first, two alljig® jigs at the heart of the plant are responsible for separating coarse and fine manganese ore. An allflux® upflow sorter is then used to generate a pre-concentrate in the finest range measuring less than a millimetre, after which an allgauss® high-gradient magnetic separator performs further enrichment of the manganese ore.

The plant is connected to a water processing plant. While previous solutions required a constant supply of fresh water that was subsequently fed back into the river unfiltered, we have successfully replaced this with a water recovery system.

All items of equipment and components were transported by road to Chiatura in line with European standards and the technical state of the art. This processing plant has provided a real boost to the regional economy: not only does it benefit local residents, it has also attracted new branches of industry. The long-established agricultural sector also profits from the plant waste products, which serve as ideal fertiliser for improving the soil quality.<br/>  

Efficient and sustainable success with allmineral

Not only does the plant deliver excellent ecological performance, it is also fantastically productive. With a material yield of up to 68% at a manganese quality of over 40 Mn wt.% and a processing volume of 200 tons per hour, plant sustainability is a key priority. Thanks to a combined recovery system featuring mechanical and electromagnetic operation, it was possible to enhance the quality of the generated products to the extent that they could be fed back into the metallurgic production cycle. The mineral fraction can therefore be deployed in the local construction industry – and the additional water processing plant also helps make this new plant more nature-friendly. 

Water recovery achieves a palpable reduction in environmental pollution of the Kura River. As the slurry treatment system of the plant forms a closed loop, it does not have any negative impact on the surrounding nature. The integrated water recovery system also ensures that less fresh water is required.

Since the entirely mechanical separation procedure means that there are no carbon dioxide emissions, the processing plant generates zero air pollution. And as with all system solutions from allmineral, the plant has been designed to get the very most out of the raw materials: even the waste products are perfect for use as fertiliser in local agriculture and help maintain soil quality in the long term. 


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