Heavy Alluvial Ore Beneficiation Production Line and Process Flow

OreSolution Heavy Mineral Sands Beneficiation Plant. Features Gravity, Magnetic, and Electrostatic Separation. Recovers Ilmenite, Zircon, and Rutile with >90% recovery.

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Product Details

Heavy Alluvial Ore Beneficiation Production Line is designed for the comprehensive recovery of valuable Heavy Mineral Sands (HMS).

This solution adopts a combined process of "Washing - Gravity Separation - Magnetic Separation - Electrostatic Separation". It efficiently separates Ilmenite, Rutile, Zircon, and Monazite from beach sands and alluvial deposits, achieving a comprehensive heavy mineral recovery rate of ≥ 90%.

What Is Heavy Alluvial Ore Beneficiation?

Heavy Alluvial Ore (Mineral Sands) Beneficiation involves separating heavy minerals from light silica sand and then separating the heavy minerals from each other. The process typically utilizes a Wet Mill (Gravity concentration) to remove silica, followed by a Dry Mill (Magnetic/Electrostatic separation) to separate magnetic Ilmenite from non-magnetic Zircon and Rutile.

Heavy Mineral Sands Beneficiation Process Flow

Process Steps: Wet Mill & Dry Mill

Phase 1: Washing & Gravity Separation (Wet Mill)

Goal: Remove trash, slime, and light silica sand.

Washing: Rotary Scrubber or Trommel Screen removes clay and oversize trash (+2mm).
Gravity Enrichment: Spiral Chutes use gravity and centrifugal force to separate heavy minerals. A Roughing + Sweeping setup ensures high recovery.
Cleaning: Shaking Tables further upgrade the concentrate.

Phase 2: Separation & Purification (Dry Mill)

Goal: Separate heavy minerals based on physical properties.

Drying: Rotary Dryer removes moisture to prepare for electrical separation (80-120°C).
Magnetic Separation: Separates magnetic Ilmenite and Monazite from non-magnetic Zircon and Rutile using Dry Magnetic Separators.
Electrostatic Separation: Uses High-Voltage Separators to separate conductive minerals (Rutile) from non-conductive minerals (Zircon).

Process Performance Indicators

Mineral	Separation Method	Target Grade	Recovery Rate
Ilmenite	Magnetic Separation	TiO₂ ≥ 48%	85-92%
Zircon	Electrostatic (Non-Conductive)	ZrO₂ ≥ 65%	80-90%
Rutile	Electrostatic (Conductive)	TiO₂ ≥ 90%	75-85%
Monazite	Weak Magnetic	REO ≥ 55%	70-80%

Core Equipment Configuration

System	Main Equipment	Function
Washing	Rotary Scrubber / Trommel	Desliming and screening.
Gravity Sep	Spiral Chute, Shaking Table	Enrichment of heavy minerals.
Magnetic Sep	Magnetic Separator	Separates Ilmenite/Monazite.
Electrostatic	High-Tension / Arc Plate	Separates Rutile/Zircon.
Drying	Rotary Dryer	Prepares feed for dry separation.

Heavy Mineral Sands Plant Site

Frequently Asked Questions (FAQ)

Q1: How do you separate Zircon from Rutile?

A: Since both are heavy and non-magnetic, we use High-Tension Electrostatic Separation. Rutile is conductive and gets thrown from the rotor, while Zircon is non-conductive and is "pinned" to the rotor.

Q2: What is the processing capacity?

A: Our modular lines can process 20-300 t/h. For larger projects, we run parallel lines. The capacity is scalable based on your deposit size.

Q3: Is the process environmentally friendly?

A: Yes. The process uses physical separation (Gravity, Magnetism, Electricity) and requires no chemicals. We also design water recycling systems to reuse >90% of the process water.

Get Your Custom Mineral Sands Plant

We customize the solution based on your specific mineral assemblage (Ilmenite/Zircon/Rutile).
Contact us for a flow sheet design and quotation.

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