XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1211
the characterization results indicate the samples contain
comparable THM at 7.45% (ore-1) and 6.25% (ore-2).
However, the proportion of very heavy minerals with SG
greater than 4.05 is vastly different. Close to 90% of the
THM in ore-1 has an SG greater than 4.05, whilst just
about 51% of the THM in ore-2 has an SG greater than
4.05.
Mineral Composition
The mineral composition of the THM fraction for ore-1.
was determined using QEMSCAN The mineral composi-
tion of ore-2 was estimated by XRD and validated by XRF
assays. The results of the analysis are shown in Table 3
and indicate the THM fraction derived from each sample
contains major titania minerals, minor REE minerals and
moderate zircon, aluminosilicates, and other minerals.
BENEFICIATION PROCESS CIRCUIT
DEVELOPMENT
General Discussion
Beneficiation plants for mineral sand ores generally include
the following three principal processing circuits.
Feed Preparation Plant
Run of mine ore is scrubbed and de-slimed to liberate min-
eral particles from clay and prepare feed with sizing suitable
for beneficiation. Trash, rocks and barren oversize are also
removed as part of the feed preparation.
Primary Concentrator Plant
The objective of the primary concentrator plant (PCP) is
to remove unwanted minerals (gangue) from the prepared
ore and to produce a raw or intermediate concentrate. The
process often requires a combination of (wet) classification,
gravity and magnetic separation to concentrate the valuable
minerals contained in the ore. Elevated throughput capac-
ity of primary stages of separation are typically required for
processing low grade ores.
The PCP typically focusses on maximizing recovery of valu-
able minerals to concentrate. In other words, the process
aims at maximizing the rejection of gangue minerals to
tailings.
Mineral Separation Plant
The PCP concentrate is processed to separate valuable com-
ponent minerals and upgrade them to the level of purity
required to produce commercial products. The circuits
often utilize a combination of wet and dry separation pro-
cesses. Wet processes include wet high intensity magnetic
separators, gravity spirals separators or wet shaking tables as
well as froth flotation. Dry processes include dry magnetic
separators (Rare Earth Drum, Rare Earth Roll, Induced
Roll Magnetic Separators) and electrostatic separators.
Methodology and Test Work Procedure Description
The results of the characterization tests were used to con-
ceptualize a series of more detailed physical separation
evaluation tests for the purpose of delineating a process
flowsheet for each ore type.
Each of the samples discussed are quite distinct in
terms of their particle size distribution and specific density
profiles. There are however key similarities that are intrinsic
to the nature of the type of resource. The specific gravity of
the valuable REE-minerals is known to occur in the range
4.0 gm/cm3 and it is known to display low to moder-
ate magnetic susceptibility and low electrical conductiv-
ity (Baker 1962). The identified major gangue minerals,
quartz, display significant lower specific gravity.
These physical properties were exploited using com-
mercially proven feed preparation and gravimetric sepa-
ration techniques to produce intermediate mixed heavy
mineral concentrates from each of these distinctly different
ore types.
The heavy mineral concentrate was then used to sepa-
rate valuable component minerals and upgrade them to the
level of purity required to produce commercial products.
Table 3. Mineral composition of the THM fraction derived from each sample
Description
REE-
Minerals Zircon
Ti-Minerals Al-
Silicates Others High Fe High Ti High Si
Unit %%%%%%ppm
Detection limit 0.01 0.01 0.01 0.01 0.01 0.001 10
Ore-1 1.79 7.20 74.1 6.10 n/a 4.40 6.41
Ore-2 2.35 18.0 31.6 12.3 15.4 10.1 10.2
the characterization results indicate the samples contain
comparable THM at 7.45% (ore-1) and 6.25% (ore-2).
However, the proportion of very heavy minerals with SG
greater than 4.05 is vastly different. Close to 90% of the
THM in ore-1 has an SG greater than 4.05, whilst just
about 51% of the THM in ore-2 has an SG greater than
4.05.
Mineral Composition
The mineral composition of the THM fraction for ore-1.
was determined using QEMSCAN The mineral composi-
tion of ore-2 was estimated by XRD and validated by XRF
assays. The results of the analysis are shown in Table 3
and indicate the THM fraction derived from each sample
contains major titania minerals, minor REE minerals and
moderate zircon, aluminosilicates, and other minerals.
BENEFICIATION PROCESS CIRCUIT
DEVELOPMENT
General Discussion
Beneficiation plants for mineral sand ores generally include
the following three principal processing circuits.
Feed Preparation Plant
Run of mine ore is scrubbed and de-slimed to liberate min-
eral particles from clay and prepare feed with sizing suitable
for beneficiation. Trash, rocks and barren oversize are also
removed as part of the feed preparation.
Primary Concentrator Plant
The objective of the primary concentrator plant (PCP) is
to remove unwanted minerals (gangue) from the prepared
ore and to produce a raw or intermediate concentrate. The
process often requires a combination of (wet) classification,
gravity and magnetic separation to concentrate the valuable
minerals contained in the ore. Elevated throughput capac-
ity of primary stages of separation are typically required for
processing low grade ores.
The PCP typically focusses on maximizing recovery of valu-
able minerals to concentrate. In other words, the process
aims at maximizing the rejection of gangue minerals to
tailings.
Mineral Separation Plant
The PCP concentrate is processed to separate valuable com-
ponent minerals and upgrade them to the level of purity
required to produce commercial products. The circuits
often utilize a combination of wet and dry separation pro-
cesses. Wet processes include wet high intensity magnetic
separators, gravity spirals separators or wet shaking tables as
well as froth flotation. Dry processes include dry magnetic
separators (Rare Earth Drum, Rare Earth Roll, Induced
Roll Magnetic Separators) and electrostatic separators.
Methodology and Test Work Procedure Description
The results of the characterization tests were used to con-
ceptualize a series of more detailed physical separation
evaluation tests for the purpose of delineating a process
flowsheet for each ore type.
Each of the samples discussed are quite distinct in
terms of their particle size distribution and specific density
profiles. There are however key similarities that are intrinsic
to the nature of the type of resource. The specific gravity of
the valuable REE-minerals is known to occur in the range
4.0 gm/cm3 and it is known to display low to moder-
ate magnetic susceptibility and low electrical conductiv-
ity (Baker 1962). The identified major gangue minerals,
quartz, display significant lower specific gravity.
These physical properties were exploited using com-
mercially proven feed preparation and gravimetric sepa-
ration techniques to produce intermediate mixed heavy
mineral concentrates from each of these distinctly different
ore types.
The heavy mineral concentrate was then used to sepa-
rate valuable component minerals and upgrade them to the
level of purity required to produce commercial products.
Table 3. Mineral composition of the THM fraction derived from each sample
Description
REE-
Minerals Zircon
Ti-Minerals Al-
Silicates Others High Fe High Ti High Si
Unit %%%%%%ppm
Detection limit 0.01 0.01 0.01 0.01 0.01 0.001 10
Ore-1 1.79 7.20 74.1 6.10 n/a 4.40 6.41
Ore-2 2.35 18.0 31.6 12.3 15.4 10.1 10.2