Heavy Alluvial Ore Beneficiation Solutions (Gravity + Magnetic Separation)

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Product Details

Heavy Alluvial Ore Beneficiation Solutions (Gravity + Magnetic)

Heavy Mineral Sands (HMS) are complex alluvial deposits containing a highly valuable mix of minerals such as Ilmenite, Rutile, Zircon, and Monazite. Because these minerals are naturally liberated but blended together in varying concentrations, processing them requires a highly adaptable, universal flowsheet.

GravityMineral provides a highly efficient, modular combined process centered on "Washing + Gravity Enrichment + Magnetic Separation." By leveraging the significant density and magnetic differences between these minerals, our turnkey EPC solution realizes the efficient recovery and purification of all valuable heavy sands. This flowsheet significantly reduces capital investment and operational costs (OPEX) while ensuring exceptionally high recovery rates across a variety of deposit types, including seaside sands and river alluvial deposits.

Turnkey EPC heavy alluvial ore mineral sand wash plant

Heavy mineral sand spiral chute concentrator for mixed alluvial ores

The Universal Heavy Sand Extraction Flowsheet

Our modular system is designed to handle high volumes of raw sand, discarding the worthless silica quickly before utilizing magnetic fields to separate the heavy mineral mix.

Stage 1: Washing & Screening System

Thorough desliming is critical to prevent clay from interfering with gravity separation.

Rotary Scrubbing: Raw ore is fed evenly from a silo into a Rotary Scrubber equipped with high-pressure water sprays to effectively break down clay balls and remove fine mud and organic impurities.
Grading: An optional Vibrating Screen classifies the washed material (e.g., +2mm, 2-0.5mm, -0.5mm) to ensure precise sizing for downstream equipment.

Rotary scrubber washing machine for heavy alluvial sand processing

Dry magnetic separator equipment for heavy mineral sand purification

Stage 2: Gravity Enrichment System

This stage exploits the stark density contrast between heavy minerals (e.g., Zircon 4.6 g/cm³, Ilmenite 4.5 g/cm³) and light silica sand (2.6 g/cm³).

Spiral Roughing: The washed fine sand enters Fiberglass Spiral Chutes for roughing and sweeping. Spirals discard the silica, achieving a heavy mineral recovery rate of over 80%.
Table Selection: The rough spiral concentrate is passed over 6-S Shaking Tables to further improve the grade and begin visually separating the different heavy minerals bands.

Stage 3: Magnetic Separation System

Once the silica is removed, the remaining mixed heavy sand is separated based on magnetic susceptibility.

Wet/Dry Magnetic Sorting: The gravity concentrate is processed through Medium-Strength Magnetic Separators. This splits strong magnetic minerals (Ilmenite, Magnetite) from weak/non-magnetic minerals (Monazite, Garnet, Zircon, Rutile).
Drying System (Optional): If dry magnetic separation or subsequent electrostatic sorting is required, an Indirect Rotary Dryer (80-120°C) is configured to safely remove moisture without oxidizing the minerals.

Core Equipment Configuration

Process Link	Main Equipment	Technical Characteristics
Ore Washing	Rotary Scrubber & Tumbler Screen	Wear-resistant rubber lining. High-efficiency clay dissolution. (20-300 t/h)
Gravity Roughing	Fiberglass Spiral Chute	Corrosion-resistant; high volume, powerless sorting efficiency. (10-50 t/h)
Gravity Sweeping	6-S Shaking Table	Fiberglass bed with adjustable stroke for high precision. (0.5-2 t/h)
Magnetic Separation	Dry / Wet Magnetic Separators	Adjustable magnetic field strength (0.8 - 1.5T). (5-30 t/h)
Conditioning (Optional)	Indirect Rotary Dryer	Hot air circulation, energy saving, prevents oxidation. (5-20 t/h)

Final commercial grade heavy mineral sand concentrate output

Separated high grade rutile and ilmenite products

Target Technical Indicators & Advantages

Universal Technical Capabilities

Plant Processing Capacity: 20 to 600 t/d (Fully Modular & Customizable).
Ilmenite Extract: TiO₂ ≥ 48%
Zircon Extract: ZrO₂ ≥ 65%
Rutile Extract: TiO₂ ≥ 90%
Monazite Extract: REO ≥ 55%

System Advantages

Flexible Configuration: The modular design allows you to adjust the equipment combination as the mineral composition of your deposit changes.
Economical Investment: A highly streamlined process with low CAPEX and low operating costs (typically 30-40% lower than full-flotation).
Green Production: 100% physical sorting. Zero chemicals are required, and wash water can be safely recycled to reduce discharge.

Frequently Asked Questions (FAQ) About Heavy Mineral Sands

Q1: Why is this considered a "Universal" wash plant?

A: Unlike highly specialized plants that target only one mineral (e.g., exclusively Zircon), this flowsheet is designed to handle a mixed basket of heavy minerals. By utilizing high-volume Spiral Chutes to drop the silica, and modular Magnetic Separators to sort the heavy sand by magnetic susceptibility, this plant can be quickly tuned to process almost any beach or river heavy mineral deposit profitably.

Q2: Can this plant separate Non-Magnetic minerals?

A: This base configuration will separate the magnetic minerals (Ilmenite, Magnetite, Garnet) from the non-magnetic minerals (Zircon, Rutile), giving you a mixed non-magnetic concentrate. If you need to further separate the Zircon from the Rutile, the plant is fully modular, and we can easily bolt on an Electrostatic Separation circuit to the back end of the flowsheet to complete the separation.

Gravity concentration shaking tables processing heavy mineral sands

Large scale heavy mineral sand gravity and magnetic separation plant

End-to-End Heavy Alluvial EPC Engineering Services

GravityMineral provides highly customized, turnkey EPC solutions for mixed heavy sand ore projects globally. We provide a one-stop-shop experience:

Program Design: Tailoring the process flowsheet and equipment configuration according to the exact nature of your ore sample.
Equipment Supply: Supplying the complete suite of heavy-duty wash equipment, spirals, and magnetic separators.
Installation & Training: Global on-site engineer deployment to guide installation, tune recovery rates, and train your operators.

Contact our engineering team today for a customized heavy sand wash plant layout and equipment quotation.

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