Zirconium Ore Beneficiation Solution (Gravity + Magnetic + Electrostatic Separation)

Native Zircon Ore Beneficiation Solution, Zircon Ore Gravity - Magnetic Separation - Electrostatic Separation Process

This zircon ore beneficiation solution provides a highly efficient combined process with "crushing - grinding - classification - gravity - magnetic separation - electrostatic separation" as the core, which is based on the mineral characteristics of primary zircon ores (rock ores). Primary zircon ores are usually found in igneous rocks such as anorthosite, chalcocite anorthosite, etc. The main mineral is zircon (ZrSiO₄), which is often coexisted with ilmenite, rutile, apatite, nepheline and other minerals. Through multi-stage crushing, stage grinding, graded gravity separation and magnetic separation + electrostatic separation, the accompanying minerals are effectively separated while ensuring high recovery, and a high-grade zircon concentrate (ZrO₂≥65%) is finally obtained.

I. Process Overview

Zircon is characterized by high density, medium electrical conductivity, non-magnetic, etc., which is suitable for the combined process of "gravity pre-enrichment + magnetic separation/electrostatic purification". This primary zircon ore beneficiation solution realizes high efficient recovery and deep purification of zircon through multi-stage crushing closed circuit, stage grinding and classification, spiral chute and shaking table gravity sorting, as well as magnetic separation and high-pressure electrostatic purification, which is characterized by strong adaptability, high recovery rate and excellent quality of concentrate.

Second, the process flow

1. Crushing System

   • Raw ore is roughly crushed to 50-80mm by jaw crusher, and then finely crushed to 10-15mm by cone crusher;

   • Adopting two sections and one closed-circuit process, the circular vibrating screen controls the product size and improves the crushing efficiency.

2. Grinding and Classifying System

   • The crushed ore enters into ball mill (rubber liner protection), and the grinding products are classified by hydrocyclone;

   • Control grinding fineness-200 mesh accounts for 75-85%, overflow into the re-election, return sand regrinding.

3. Gravity separation system

   • Classification overflow through the spiral chute roughing, preliminary enrichment of zircon;

   • Rough concentrate enters shaking table to concentrate and further improve the grade;

   • The middle ore returns to regrinding, and the tailings enter the tailings system to realize graded recovery.

4. Drying and tempering system

   • Gravity separation concentrate is indirectly heated (80-120℃) by rotary dryer, and the moisture is reduced to below 0.5%;

   • Cooling screen controls the particle size -1mm, creating good conditions for electrowinning.

5. Magnetic separation + electrostatic separation system

   • The dried products first go through dry magnetic separator to remove ilmenite and other magnetic minerals;

   • The non-magnetic products enter the high-voltage electrostatic separator and arc plate electrostatic separator to separate zircon and rutile according to the difference of electrical conductivity;

Third, the core equipment configuration

Main technical and economic indicators

• Processing capacity: 10-100 t/d (expandable)

• Concentrate grade: ZrO₂ ≥ 65%, TiO₂ ≤ 0.3

• Recovery rate: significantly higher than single process

• Payback period: 1-2 years

V. Program Advantages

• ✅ Combined process, high efficiency recovery: gravity beneficiation pre-enrichment combined with magnetic separation and electrostatic separation and purification, high recovery rate and good concentrate quality;

• ✅ High adaptability: it can process primary zircon ores of different grades and mineral compositions;

• ✅ Energy-saving and anti-crushing: multi-stage gravity separation design, rubber liner ball milling, effectively reducing the loss of over-crushing;

• ✅ Advanced technology: "low-temperature drying + tempering electrostatic" to optimize the sorting efficiency, high-pressure electrostatic sorting and precise purification;

• ✅ Modular and flexible configuration: modular design of the equipment is convenient for capacity adjustment and process optimization.

Technical service and support

We provide full process primary zircon ore beneficiation solution technical support, including:

• 🔬 Test and design: ore selectivity test, process flow design and optimization, site planning, drawing design;

• 🛠️ Engineering and equipment: professional equipment selection and configuration, system installation and commissioning guidance;

• 👨‍💻 Training and support: personnel operation training, production optimization and trial production tracking;

• 🔧 After-sales and guarantee: equipment maintenance, spare parts supply, technology upgrade services.

If you have zircon ore beneficiation project needs, welcome to contact our professional team to get customized solutions, equipment quotes and technical support. We are committed to providing customers with stable, efficient, economic and reliable solutions for the whole line of primary zircon ore beneficiation.