Can Gravity Separation Boost Zircon Recovery?
DASEN Machinery recently completed a zircon sand gravity separation test for a client in South Africa, marking another important step in evaluating local zircon beneficiation potential.
The laboratory testing was conducted using a shaking table system designed for fine‑grain mineral recovery.
Gravity Separation Experiment Overview
During the test, raw ore samples were processed on a small‑scale shaking table, and three types of products were collected — concentrate, middling, and tailings — along with the raw feed sample.
The purpose was to determine the degree of zircon enrichment achievable through gravity separation under laboratory conditions.
Testing Data and Results
| Sample Type | Zircon Grade (%) | Silica Grade (%) |
|---|---|---|
| Raw Ore | 0.12 | 80.16 |
| Concentrate Ore | 9.40 | 39.77 |
| Middling Ore | 0.23 | 84.32 |
The zircon content increased from 0.12 % in raw ore to 9.40 % in the concentrate, demonstrating a strong enrichment effect from gravity separation.
However, the separation efficiency has not yet reached the optimal industrial level, mainly due to the small sample quantity and short shaking time during the test.
Technical Assessment and Improvement Potential
The laboratory results verified that zircon and silica can be effectively separated by gravity concentration, but more refinement is possible.
In full‑scale industrial operations, the quartz (SiO₂) content can be reduced to below 2 %, while the zircon grade can typically increase to around 15 % using long‑duration industrial shaking tables.
Subsequent stages combining magnetic separation and electrostatic separation can further upgrade the zircon product and simultaneously recover valuable ilmenite and monazite fractions.
Next Steps and Process Design
Based on these findings, DASEN Machinery’s engineering team is now designing a complete process flow tailored to the ore characteristics of this South Africa project.
The new design will integrate extended gravity separation with multi‑stage magnetic and electrical separation systems to achieve high‑grade zircon concentrate and comprehensive mineral recovery.
Our engineers continue to analyze test data and optimize parameters — and we’ll share further updates on this case as the project progresses.
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