MANGANESE
A BRIEF PROFILE
At
present, MOIL operates 10 mines – six located in the
MOIL
is also the largest employer in the manganese mining industry with a total work
force of about 6900 employees.
Capital
Structure & Management
The Authorized Capital of MOIL is Rs.30,00,00,000
(Thirty crores) divided into 28,00,000 (Twenty eight lacs) equity shares of Rs.100/- each and 2,00,000 (Two Lacs) cumulative
preference shares of Rs. 100/- each. and the Paid-up Capital is Rs.28.00 crores.
Recently the paid up capital has increased from Rs.
15.33 Crores to Rs.28.00 Crores
consequent to the issue of Bonus Shares in the ratio of almost 1:1.
After the Bonus issue, the shareholding pattern is as shown below:
The
Company is managed by a Board of Directors nominated by the Government of India
and the State Governments of Maharashtra and Madhya Pradesh. Presently there are 8 Directors including the
Chairman-cum-Managing Director, three full time functional Directors, one
Director each nominated by the Shareholders and one non-official part-time Directors
Uses
of
1. Oxidizing agent in steel industry
2. Dry Battery as Depolarizer
3. Used in the manufacture of
·
Ferro
Manganese (70-74% Mn.)
·
Silico Manganese (60-65% Mn.)
·
Chrome
Manganese (20- 25% Mn.)
4. Preparation of Organic and
Inorganic Chemicals.
5. In Paints, Pigments,
Ceramics and Ferrites.
6. As Micro-nutrients in
Fertilizer and animal Feed.
Special
Uses of
·
Electronics
- High purity manganese oxides are designed specifically for component
manufacture, Tantalum capacitors require manganese diloxide
of controlled particle size with very high purity manganese nitrate
solution. Thermistors
contain manganese sesquioxide (Mn2O3)
·
Fuel
Additives - Manganese containing octane improvers prvide refiners a highly efficient alternative to MTBE
(Methyl Tertiary Butyl Ether). They
reduce pollution while stretching the world’s petroleum resources. Anhydrous manganese chloride plays key role
in resolving this long standing problem of petroleum refiners. Fuel additives manufacture using Anhydrous
Manganese Chloride when blended with fuel stocks after refining to cost-effectivelhy boost octane levels,
enhance gasoline performance and overall reduction in emissions.
·
Welding
Fluxes - Manganese Carbonate, Mangnous Oxides and
weld-grade manganese powder contribute unique properties. Manganese powder acts as an alloying agent to
improve the hardness of welds. Manganous oxides used in flux-cored electrodes for
submerged-arc welding fluxus enhance the quality and
integrity of the weld.
Production
The main product of the Company
is manganese ore of different grades.
The Company has also producing valued added products of Electrolytic
Manganese Dioxide (EMD) and Ferro Manganese.
The production achieved by the Company during the last few years is
shown below:
|
Production – Quantity in Tonnes |
||||
|
Year |
High Grade |
Total |
EMD |
Ferro Manganese |
|
1999-00 |
421575 |
651523 |
761 |
9787 |
|
2000-01 |
450991 |
654448 |
781 |
11327 |
|
2001-02 |
505128 |
675704 |
786 |
8763 |
|
2002-03 |
510132 |
713986 |
930 |
5996 |
|
2003-04 |
542798 |
799096 |
975 |
10899 |
|
2004-05 |
589106 |
943169 |
1123 |
10325 |
|
2005-06 |
572359 |
864890 |
1301 |
6170 |
The in-situ reserves of manganese ore at present, in the leasehold
areas of MOIL is around 62.690 million tonnes. The mine-wise details of in-situ and recoverable reserves of different grades of manganese
ore is shown below:
|
Reserves in Million tonnes |
||||||||||
|
Category |
Balaghat |
Beldongri |
Chikla |
Dongri |
Gumgaon |
Kandri |
Munsar |
Tirodi |
Ukwa |
Total |
|
In-situ |
22.832 |
0.679 |
5.540 |
9.902 |
4.380 |
1.468 |
3.963 |
2.977 |
10.949 |
62.690 |
|
Recoverable |
11.416 |
0.578 |
2.543 |
4.978 |
2.409 |
0.809 |
1.981 |
1.489 |
5.474 |
31.677 |
MOIL
is continuously carrying out exploration for location of new / additional
reserves. The main focus area is to
prove depth extensions of the ore zone within the existing operating mines. MOIL has a separate exploration wing with its
own fleet of equipment. On an average
about 2500 meters of diamond drilling is done per year which proves about 1.0
million tonnes of additional reserves.
Marketing
Scenario
Due to steep increase in
the production of Steel, the demand for ferro alloys
and manganese ore had been on the increase since the beginning of last
year. To meet the increased demand, the
Company had to put in extra efforts to increase production and quality so that
the supplies to the domestic ferro alloy products
could be met to the maximum extent possible.
Though there has been a glut of export enquiries for MOIL’s
ore, the Company did not make any shipments as it is committed to fulfill
domestic requirement first. The sales
performance achieved during 2004-05 is the highest ever since the inception of
MOIL. For the first time in the history
of MOIL, the sales turnover has crossed the Rs.300 crore
mark during 2003-04.
Even during the current year i.e. 2004-05, the demand continues to be
quite high and the sales are even better.
The
sales performance achieved for the last few years is shown below:
|
|
Finance
MOIL is one of the few well
managed PSUs in the country. It has been showing excellent performance year
after continuously and earning profits for the last many years. The Company has been paid dividend of 20% to
the Government for the last nine years in succession. The quantum of dividend rose to 27% for the
years 2000-01 to 2002-03 and 30% for the year 2003-04. For the year 2004-05, the Company has
declared highest ever dividend of 60%. A ‘Zero-Debt’ Company having repaid all
its loans to the Government years back.
The Company is funding its working capital requirements and investment
for diversification and expansion plans, through internal generation resources.
The financial results of the Company during the last few years are given below:
|
Financial Performance – (Rs. in Crores) |
||||
|
Year |
Turnover |
Gross Margin |
Pre-tax Profit |
Net Profit |
|
1999-00 |
134.11 |
22.83 |
17.21 |
11.73 |
|
2000-01 |
165.22 |
36.83 |
30.99 |
20.05 |
|
2001-02 |
167.92 |
38.35 |
29.96 |
19.52 |
|
2002-03 |
177.88 |
34.59 |
27.83 |
17.78 |
|
2003-04 |
228.74 |
52.67 |
45.29 |
28.52 |
|
2004-05 |
378.78 |
210.65 |
202.27 |
126.90 |
|
2005-06 |
334.10 |
179.47 |
169.00 |
114.52 |
Electrolytic
Manganese Dioxide Plant
As a first step towards
diversification, an Electrolytic Manganese Dioxide (EMD) Plant with an installed
capacity of 800 TPY was installed at Dongri Buzurg Mine. EMD is
used in the manufacture of dry batteries and MOIL’s
Plant was only the second of its kind in the country, based solely on
indigenous technology. After overcoming
initial hurdles, the Plant made a turnaround in 1995-96. MOIL’s EMD is
widely accepted by the end users and encouraged by this success; the installed
capacity has been expanded to 1000 TPY. With the international standard for
quality of EMD and increase in domestic and global demand, MOIL is poised to
undertake further expansion of EMD capacity to 2000 TPY in the near
future. R&D experiments are being
undertaken to produce EMD for alkaline batteries as it is a future product required
in the dry battery manufacture. The production
and sale of EMD is given below:
|
Production and |
||
|
Year |
Production |
|
|
1999-00 |
761 |
803 |
|
2000-01 |
781 |
642 |
|
2001-02 |
786 |
865 |
|
2002-03 |
930 |
971 |
|
2003-04 |
975 |
669 |
|
2004-05 |
1123 |
1356 |
|
2005-06 |
1301 |
1132 |
The
Plant is running in profit at present despite stiff competition due to import
of cheap EMD from
Ferro
Manganese Plant
As
a part of diversification, the Company has set up a 5 MVA capacity Ferro
Manganese Plant with installed capacity 10000 TPA. The Plant was commissioned on 1.10.1998. The submerged Arc Furnace of 5 MVA capacity
is able to produce about 10000 TPA of Ferro Manganese or 6800 TPA of Silico Manganese or any combination of these two products
depending on the market scenario. The
capital cost of the Plant is about Rs.5.00 crores.
High Carbon Ferro Manganese is a vital constituent
for the production of steel. It is used as
deoxidizer in steel making and also finds strategic importance as alloying
element when additional or specific properties are required in the special
steel such as Stainless Steel, Alloy Steel, etc. High Carbon Ferro Manganese is produced
through smelting of charge burden consisting of manganese ore, coke, steam
coal, dolomite, iron ore, etc., in the furnace. The High Carbon Ferro Manganese produced in
the plant is of the best quality in
The Plant has been awarded with ISO
9001-2000 Quality Certificate during the year 2004-05.
As production of ferro
alloy is power intensive, the Company is considering to set
up a captive power plant of 50 MW capacity to meet its power requirements. The Company is also planning to expanding the capacity of ferro manganese plant and setting up a new 16.5 MVA Silico Manganese Plant to meet the ever increasing demand
of the ferro alloys globally.
The production and capacity utilization
of the plant is given below:
|
Year |
Production - Tonnes |
Sales - Tonnes |
Capacity Utilization
(%) |
|
1999-00 |
9787 |
8883 |
97.87 |
|
2000-01 |
11327 |
11851 |
113.27 |
|
2001-02 |
8763 |
7789 |
87.63 |
|
2002-03 |
5996 |
8100 |
59.96 |
|
2003-04 |
10899 |
10668 |
108.99 |
|
2004-05 |
10325 |
6151 |
103.25 |
|
2005-06 |
6170 |
8320 |
61.70 |
Integrated
Manganese Beneficiation Plant
As a part of mechanization of ore handling
and beneficiation of manganese ore, the Company has set up an integrated
Manganese Ore Beneficiation Plant comprising of crushing, handling, wet
screening, drying and magnetic separation operations in one complex at a capital cost of
Rs.4 crores, in 2001.
The plant is located at Dongri Buzurg Mine of the Company which is operated by mechanized
means by deployment of optimum capacity excavator, dumper, etc. The Development and production of this mine
has grown many times since the inception of this mine resulting in the need for
mechanized ore handling and processing facilities.
The plant is
designed for a capacity to process 4 lakh tonnes of RoM per annum. The plant is utilized for bulk handling of RoM and to improve the productivity of the mine and also
the grade ore ores. This will help in
sustaining production and market requirements in future. The plant is first of its kind in the country
to be set up for manganese ore beneficiation.
Research
& Development
Proved reserves of Manganese ore in
1.
Optimisation
of stope designs.
2.
Development
of process parameters for manufacture of manganese based chemicals.
3.
Studies
for reclamation of waste dumps and investigations for other environmental
protection measures.
4.
Studies
for beneficiation of low grade ores.
5.
Development
of alternative mining methods and support systems for underground mines.
6.
Improvements
in blasting techniques in Opencast and Underground workings.
Corporate
Social Responsibility
1. ENVIRONMENT:
MOIL is fully aware of the
impact of mining on environment and has taken adequate steps to protect the
environment and maintain ecological balance in and around is mining areas. The Company’s strategy towards eco-friendly
mining encompasses the following:
¤ Scientific Mine Planning
¤ Effective Pollution Control Measures
¤ Optimisation of Resources Utilisation
¤ Biological Reclamation
¤ Rehabilitation of Reclaimed Areas
¤ Rural and Community Development
The
Company has embarked upon a programme viz. Integrated
Bio-technical Approach (IBA) in collaboration with National Environmental
Research Institute (NEERI) to rejuvenate the waste dumps through scientific
research. This has yielded excellent
results at some of the Mines. The
Company is also carrying our afforestation activity
and has planted more than 12 lakh trees so far with a
survival rate of over 80%. For the very
good work done in this area, the Company has been awarded Misrilal Jain
Environment Award by Federation of Indian Mineral Industries (FIMI) for
the following mines:
1.
Gumgaon Mine for the year 1993-94
2.
Dongri Buzurg Mine for the year 1998-99
2. HEALTH CARE:
Being a labour
intensive mining organization and the lines having located at remote tribal
areas, the Company lays special emphasis on health and hygiene. The Company is having hospitals at all mines
manned by qualified doctors and para-medical
staff. In addition to providing medical
care, the Company with the help of NGOs conducts period medical camps not only
for its employees but also for the villagers in and around the mining
areas.
3. EDUCATION:
Providing education to the
children / dependents of employees of the Company as well as the children of
the surrounding areas of mines is given priority. Basic educational facilities are available at
all the mines. For secondary school
level education, school buses are provided to take the children to nearby
reputed schools. In fact, at Balaghat Mine, Kendriya Vidyalaya has started the classes in which students from Balaghat town are coming to get education besides MOIL
employees children.
With
a view to impart technical education after schooling, the Company has promoted
one Polytechnic viz. Vivekanand Polytechnic near one
of its mines i.e. Chikla. From a humble beginning, the institution has
grown from strength to strength to an extent that last year one more branch on
the latest subject i.e. Information Technology (IT) has been introduced. The students of this institution have been
selected for jobs even outside MOIL through campus selection.
At MOIL, Training to its employees is a regular on-going
process. Employees at all levels are imparted training both within and outside
the Company in order to have their knowledge and skills updated on a continuous
basis.
Mine
Safety
Mining is one of the most
hazardous professions in the world.
Therefore, safety of men and machine deployed in mining operations are
to be protected from all hazards. MOIL
lays utmost importance towards safety and provides to its employees engaged in
mining operations, the latest safety equipment to protect themselves. The Company is having an Internal Safety
Organization (ISO) headed by a very senior official at corporate level. All accidents are thoroughly analyzed and
immediate corrective action taken to prevent its recurrence. Every one is encouraged to contribute
innovative ideas towards improvement of safety standards. As a result, the Company has established a
very good track record in this area.
MOIL is getting National Safety Awards continuously every year since 1982. In addition the MOIL team participates regional and national level mine rescue competitions and has own laurels.
OUR SAFETY POLICY
* To
plan and design operations and systems to eliminate or materially reduce mining
hazards.
* To
implement statutory rules and regulations to achieve superior standards of
safety.
* To
bring about improvement in working conditions by suitable changes in
techno0logy.
* To
provide all material and monetary resources needed for smooth and efficient
execution of safety plans.
* To
organize appropriate forum with employees’ representation for joint
consultations on safety matters and
secure motivation and commitment in safety management.
Achievements
MOIL is one of the best
managed PSUs in the country and known for its
excellent show of performance from year to year. A strong performer, the Company has received
several awards some of them are listed below:
¤ Economic
of
¤ Prime Minister’s Merit Certificate for Excellence in the
Achievement of MoU Targets for the years 1998-99 to
2003-04
¤ National Safety Awards
¤ Misrilal Jain Environment Award
¤ Indira Gandhi Raj Bhasha
Shield
¤ Chal Vaijayanti Raj Bhasha Shield
¤ Nation Energy conservation
award
Future
Prospects
Dedicated
manpower, great skill and spirit of team work are the major assets of
MOIL. Manganese being the 12th
largest mineral available on Earth has uses in several industries. With the existing resources available in the
leasehold areas of MOIL, the Company has excellent prospects of growing into a multiproduct organization through value addition in the
areas of ferro alloys, manganese alloys, manganese
based chemicals, etc. The Company is
marching towards achieving this goal and is in the process of expanding its
activities even outside
With ambitious
diversification plans on hand, the Company is now poised for a great leap ahead
in the near future.