Integrated Beneficiation Solution for Titanium-Zirconium Placer Ore (Gravity-Magnetic-Electrostatic)

Stage 1: Pre-Treatment & Wet Gravity Enrichment

This stage rapidly discards light silica sand and cleans the valuable heavy minerals.

• Screening & Desliming: Raw ore is fed via a silo to a Trommel Screen (3-6mm aperture) to reject coarse gravel and organic debris. High-pressure water monitors thoroughly rinse the sand to remove surface clay pollutants.
• Gravity Roughing: The clean sand is pumped to Spiral Chutes (feed concentration 30-35%). The spirals perform the initial high-volume enrichment, capturing the heavy black sand.
• Gravity Sweeping: The heavy concentrate from the spirals is passed over Shaking Tables to further reject fine silica and create a perfectly concentrated mixed heavy sand for dry sorting.

Stage 2: Advanced Magnetic Separation

Before entering the magnetic circuit, the wet heavy sand is processed through a Rotary Dryer (80-120°C) to completely remove moisture without altering the minerals' surface properties.

• Medium-Intensity Magnetic Separation: The dry sand passes over Permanent Magnetic Cylinder Separators, which selectively pull out the strongly magnetic Ilmenite.
• High-Intensity Magnetic Separation: The remaining sand passes through High-Intensity Magnetic Separators to extract neutral/weakly magnetic minerals like Monazite and Garnet.
• Output: What remains is a purely non-magnetic mixture consisting almost entirely of Zircon and Rutile.

Stage 3: Dry Electrostatic Purification

The final challenge is splitting the non-magnetic Zircon and Rutile. Because they weigh the same, gravity is ineffective here.

• Electrostatic Sorting: The non-magnetic mixture is fed into High-Voltage Electrostatic Separators. Because Rutile is highly electrically conductive and Zircon is non-conductive, the electrical field cleanly forces them into separate discharge bins.
• Deep Purification: The products are then passed through multi-stage Arc Plate Electrostatic Separators for extreme precision, ensuring trace impurities are removed and final commercial grades are met.

• Plant Processing Capacity: 20 to 300 t/h (Fully Modular & Expandable).
• Ilmenite Concentrate Grade: TiO₂ ≥ 48% (Recovery Rate ≥ 85%).
• Zircon Sand Grade: ZrO₂ ≥ 65% (Recovery Rate ≥ 80%).
• Comprehensive Heavy Mineral Recovery: ≥ 90%.
• Energy Efficiency: Physical separation eliminates grinding costs, reducing comprehensive energy consumption by 30%.
• Return on Investment (ROI): Typically recovered within 1 to 2 years.

Q1: Why is drying the heavy sand so important before the final stages?

A: The final purification stages rely on High-Voltage Electrostatic Separators to split the Rutile from the Zircon. Electrostatic separation works by applying a high-voltage electrical charge to the minerals. If the sand contains any moisture, the water acts as a conductive bridge across all the particles, completely destroying the separation process. Our integrated Rotary Dryers ensure the sand is bone-dry for flawless sorting.

Q2: What is the sequence for the dry separation circuit?

A: The sequence is critical: Magnetic First, Electrostatic Second. We must first run the dry sand through Magnetic Separators to extract the magnetic Ilmenite and Monazite. If we tried to run the raw heavy sand directly into an electrostatic separator, the highly conductive iron content would disrupt the electrical arc fields. Removing the magnetics first leaves only non-magnetic Rutile and Zircon, which are then easily split by the electrostatic fields.

Full-Cycle Turnkey EPC Placer Engineering Services

GravityMineral provides end-to-end technical support for Titanium-Zirconium placer projects globally. Because our flowsheets utilize 100% physical separation (no chemicals, zero wastewater discharge), environmental permitting is drastically simplified.

• Process Design: Customized flowsheet configurations based on your specific mineral ratios and production scale.
• Manufacturing & Supply: We build and supply the complete suite of heavy-duty wash equipment, magnetic separators, and high-tension electrostatic arrays.
• Installation & Training: Global on-site engineer deployment to guide installation, tune recovery rates, and train your operators.

Maximize the value of your Ti-Zr resources. Contact our engineering team today for a customized plant layout and equipment quotation.