Zirconium Ore Production Line and Process Solutions

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Primary Zircon Ore Production Line Solution is designed for the complex separation of Zircon (ZrSiO₄) from hard rock deposits.

This solution utilizes a comprehensive "Gravity - Magnetic - Electrostatic" combined process. It effectively separates Zircon from associated minerals like Ilmenite and Rutile, achieving a high-grade concentrate of ZrO₂ ≥ 65%.

What Is Primary Zircon Beneficiation?

Primary Zircon Beneficiation is the process of extracting Zircon crystals from igneous rocks (unlike alluvial sand, which is already loose). It requires Crushing and Grinding to liberate the minerals, followed by Gravity Separation to remove light gangue, and finally Electrostatic Separation to separate non-conductive Zircon from conductive Rutile and Ilmenite.

Zircon Ore Beneficiation Plant

Zircon Beneficiation Process Steps

Step 1: Crushing & Grinding (Liberation)

Goal: Liberate Zircon crystals without damaging them.

Crushing: Jaw Crusher (Coarse) -> Cone Crusher (Fine) reduces ore to 10-15mm.
Grinding: Ball Mill with rubber liners grinds ore to 75-85% passing 200 mesh.

Zircon Grinding and Classification

Step 2: Gravity Separation (Roughing)

Goal: Discard light gangue minerals (Quartz, Feldspar).

Roughing: Spiral Chute utilizes density difference for preliminary enrichment.
Cleaning: Shaking Table further concentrates the heavy minerals (Zircon, Rutile, Ilmenite).

Spiral Chute Gravity Separation

Step 3: Drying & Magnetic Separation

Goal: Remove magnetic minerals before electrostatic separation.

Drying: Rotary Dryer heats concentrate to 80-120℃ (Moisture < 0.5%).
Magnetic Sep: Magnetic Separator removes Ilmenite and Magnetite.

Magnetic Separation Machine

Step 4: Electrostatic Separation (Purification)

Goal: Separate non-conductive Zircon from conductive Rutile.

Equipment: High-Tension Electrostatic Separator.
Mechanism: Using 40-60kV voltage, conductive Rutile is thrown off, while non-conductive Zircon is pinned to the drum.

Electrostatic Separator for Zircon

Separation Techniques for Zircon Ore

Method	Target Minerals	Principle
Gravity Separation	Zircon, Rutile, Ilmenite vs. Silica	Density Difference (Heavy vs. Light).
Magnetic Separation	Ilmenite (Removed) vs. Zircon	Magnetic Susceptibility.
Electrostatic Sep	Rutile (Removed) vs. Zircon	Electrical Conductivity.

Core Equipment Configuration

System	Main Equipment	Performance
Crushing	Jaw Crusher + Cone Crusher	Closed circuit, uniform 10-15mm size.
Grinding	Ball Mill + Hydrocyclone	Rubber lined to protect crystals.
Gravity Sep	Spiral Chute + Shaking Table	Graded recovery of heavy minerals.
Electric Sep	High-Tension Electrostatic Separator	60kV voltage for precise separation.

Zircon Processing Equipment

Frequently Asked Questions (FAQ)

Q1: Why is Electrostatic Separation necessary?

A: Zircon and Rutile are both heavy and non-magnetic, so they cannot be separated by gravity or magnets. However, Rutile is conductive while Zircon is non-conductive, making Electrostatic Separation the only effective method.

Q2: Do I need to dry the ore?

A: Yes. For Electrostatic Separation to work, the material must be completely dry (moisture < 0.5%) and often heated (tempering) to enhance the conductivity difference.

Q3: What is the typical grade of Zircon Concentrate?

A: A well-designed plant produces premium Zircon sand with ZrO₂ ≥ 65% and low impurities (TiO₂ ≤ 0.3%).

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We have extensive experience in rock and sand zircon projects.
Contact us for a customized beneficiation plan and quotation.

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