Reducing Losses in Fine Heavy Minerals: 150TPH Beach Sand Plant Case Study

The extraction of heavy minerals from beach sand is a critical process in the mining industry, particularly for valuable resources such as zircon sand, ilmenite, rutile, and leucoxene. Given the low concentration (just 1% total heavy minerals) and fine grain size (0.03-0.3mm), maximizing recovery without complex sorting presents a unique challenge. Our 150 TPH beach sand gravity separation production line in Senegal is designed to efficiently concentrate heavy minerals while keeping the process simple—delivering a mixed heavy mineral product with minimal screening stages.

This article explores the key parameters, process design, and challenges in developing a cost-effective yet high-recovery system that meets the customer’s requirements: a final concentrate with at least 53% heavy minerals, including 43% ilmenite and 11% zircon sand.

 

Understanding the Senegal Beach Sand Gravity Separation Project

 

Project Overview

Location: Senegal

Processing Capacity: 150 tons per hour (TPH)

Ore Characteristics: 
Beach sand containing:

1. Heavy minerals (1% total):

• Ilmenite (68%)
• Zircon sand (15%)
• Rutile (2.5%)
• Leucoxene (1.5%)
• Other heavy minerals (13%)

2. Grain size of heavy minerals:03–0.3mm (fine to medium-grained)

Beneficiation Requirements:

• No individual mineral sorting—only screening the last three stages of the spiral chute to obtain a mixed heavy mineral concentrate.
• Minimum heavy mineral content in concentrate:53% (with ≥43% ilmenite and ≥11% zircon sand).

 

Key Challenges

• Low Heavy Mineral Content (1%): Pre-concentration is critical to reduce processing volume and energy waste.
• Fine Particle Size (0.03-0.3mm): Requires optimized gravity separation to avoid losses in tailings.
• Customer Preference for Simplified Sorting: Avoiding complex flotation or magnetic separation means higher reliance on gravity methods for efficiency.

 

 

150TPH Heavy Minerals Spiral Separation Plant Flowchart Designed by JXSC

To achieve high recovery with minimal complexity, we design the optimized gravity separation flow as

 

 

Process flowchart explained

1. The dredge pump will send the slimy to the trommel screen hopper. The slurry density should be about 25-30%, and the slurry pressure (flowing speed) should not be too high.
2. The trommel screen with a 2mm mesh screen, will remove the +2mm waste sand discharging directly to nearby, 0-2mm slurry will first go to an agitation tank(2000*1500mm) because the slurry flow capacity is big from the trommel screen, it is necessary to agitate the slurry before sending to 1st stage spiral group, so the solid material in the slurry can be distributed evenly to spirals.
3. The slurry from the mixing tank will be sent to 1st stage spiral chute group by Two slurry pumps (8/6E-AH), 1st stage spiral total of 48 sets, divided into two groups, each group of 24 sets spirals, so one pump for one spiral group, each spiral group has one big distribution tank (1800*2000mm).
4. The middling slurry discharged from the 1st stage spiral will go to two slurry tanks. Then use two slurry pumps (413C-AH) to send the middling slurry to the 2nd stage spiral chute(total of 16 sets), only ONE spiral group, with one big distribution tank( 1500*1500mm).
5. The Concentrate ore discharged from the 1st stage spiral chute will go to two slurry tanks. Then use two slurry pumps (312C-AH) to send the concentrate ore discharge to the 3rd stage spiral for final concentration.
6. The tailing discharged from the 1st stage spiral chute will go to two tailing tanks, and then use two slurry pumps (6/4D-AH) to send the tailing dump, which is about 100 meters far away.
7. The Concentrate ore discharged from the 2nd stage spiral chute will go to ONE slurry tank, then use ONE slurry pump (3/2C-AH) to send concentrate ore to the big distribution tank (1000*1200mm) of the 3 m stage spiral with 6 sets of spiral chutes.
8. The tailing discharged from the 2nd stage spiral chute will go to ONE slurry tank.  Then use ONE Slurry pump (6/4D-AH) to send the tailing dump, which is 100 meters far away.
9. The final heavy minerals concentrate product that discharges from the 3rd stage spiral chute will go to one slurry tank, then use ONE slurry pump (1.5/1C-HH) sent to the concentrate heap on the ground, which is 150-200 meters far away.
10. Considering there is a peat Layer in the mine place, which is dark, clay organic matter, an extra Submerged slurry pump (model 80-65-160) is necessary to provide extra water to the trommel screen when such material goes through the trommel and spray high-pressure water on the material, so the clay can go through trommel more easy and avoid-stuck sieve.

 

Q&A Of This WCP Plant

Maintenance and Upkeep

Clients: Describe the frequency and specific procedure for trommel maintenance.
JXSC: Normal maintenance, keep lubrication.

Clients: Explain the procedure if the trommel is clogged or blocked by materials larger than 2 mm.
JXSC: The trommel screen will add a flushing pipe to effectively prevent clogging.

Clients: Evaluate the durability of the 2 mm manganese steel woven mesh screen in an environment where the water is ferrous and salty, and specify its lifespan.
JXSC: It can`t determine the life of manganese steel screens in iron and saltwater environments, but our trommel screens are high-quality stainless steel screens, which are more resistant to corrosion, lifetime can last at least 6-8 months.

 

Clients: Confirm if the Tank distributors are suitable for sticky and clayey materials, particularly for particles smaller than 2 mm.
JXSC: Yes, suitable for material that contains a bit of clay, but your material does not contain much clay.

 

Dimensions

Clients: Provide explanations regarding the height of 3.25 m between the platform and the spirals, which seems excessive.
JXSC: The number of spiral chutes is large, and this height is to better allow the slurry to flow into the slurry tank, especially for each stage of concentrate ore from the spiral, the Heavy mineral concentrate ore flows slowly, so it needs enough height.

 

Assembly and Logistics

Clients: Indicate the rental duration, number, and minimum capacity of the cranes needed.
JXSC: The heaviest equipment trommel screen is about 8~9 tons, so the crane needs to be able to handle a minimum of 10 tons, which is relatively safe.

 

Clients: Is it necessary to have a basin filled with water during the assembly of the WCP?
JXSC: Depending on the site conditions and the balance of the floating platform in the field, this can be confirmed by the engineers of both sides in the field before installing the WCP.

 

Clients: Indicate the number of cranes needed, their capacity, and the expected operating duration.
JXSC: 1 set of cranes, The heaviest equipment trommel screen is about 8~9 tons, so the crane needs to be able to handle a minimum of 10 tons, which is relatively safe.

 

 

Conclusion

This 150 TPH beach sand gravity separation line demonstrates an efficient, cost-conscious design that maximizes recovery while simplifying operations. By focusing on high-capacity spiral concentration and strategic tailings recycling, we ensure the customer receives a high-grade heavy mineral mix (53 %+) with minimal processing stages.

For customized solutions based on specific or other conditions, contact our team for a tailored proposal!