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Zircon titanium ore in Mozambique is typically processed using a combination of gravity separation, magnetic separation, and zircon purification techniques.
This article explains the complete EPC (Engineering, Procurement, Construction) process flow for a zircon titanium project, including key equipment and processing stages.
The project is located on the eastern coast of Mozambique and exploits a typical coastal zircon‑titanium placer deposit. The run‑of‑mine ore mainly consists of ilmenite, zircon, and rutile, with a slime content of 15%–25% and good natural mineral liberation.
Xinhai Mining provided the full‑scope EPC (Engineering, Procurement, Construction) turnkey service.
During the design phase, Xinhai defined core objectives: high‑efficiency wet separation, energy‑saving gravity flow, and continuous stable operation. Based on ore characteristics, site topography, and local climate, we adopted proven mineral processing technologies and large‑scale domestic equipment to control investment, shorten the construction period, and achieve rapid commissioning.
Given the high slime content, fine particle size, and distinct density differences of the ore, experts from Xinhai Mining Research & Design Institute conducted extensive test comparisons and finalized a 7‑stage continuous wet separation process with smooth interstage connection and stable field performance.
Feeding, Slurrying & Trash Removal: Uniform ore feeding with screening to remove oversize debris and prevent equipment blockage.
Hydrocyclone Classification & Desliming: Pre‑removal of fine slime to reduce interference in separation and improve process efficiency.
Spiral Chute Roughing: “One roughing, one cleaning, one scavenging” circuit for rapid separation of heavy minerals from gangue.
Low‑Intensity Magnetic Separation (LIMS) for Iron Removal: Removal of magnetic iron minerals to improve the purity of downstream products.
High‑Intensity Magnetic Separation (HIMS) for Ilmenite Recovery: Production of stable ilmenite rougher concentrate based on magnetic susceptibility differences.
Zircon Cleaning & Upgrading System: A combination of spiral chute roughing/scavenging and table cleaning to upgrade zircon concentrate grade.
Tailings Management & Water Reclamation System: Concentrate dewatering and storage, compliant tailings disposal, and closed‑loop water recycling.
The Xinhai design team optimized the process based on site conditions, creating distinct technical and economic advantages.
Gravity‑flow design using elevation difference
Reduced intermediate pumps; one production line cut multiple medium pumps and lowered installed power by approximately 500 kW, delivering outstanding long‑term energy savings.
“Five reductions, one addition” optimization
Eliminated redundant classifying, regrinding, and repetitive separation units; installed slag‑separation protection at key points to improve equipment stability and service life.
Large‑scale, modular layout
Compact structure, reasonable footprint, easy operation and maintenance, ideal for fast construction and commissioning of overseas projects.
High equipment reliability & low failure rate
Actual operating rate reached over 95%, supporting 24/7 continuous mining production.
After installation and commissioning, the plant entered stable production. Continuous operation data shows performance met and exceeded design expectations.
Underqualified TiO₂ grade in feed ore:
Ilmenite rougher concentrate grade: 40%–42% TiO₂, recovery ≥ 71%
Zircon rougher concentrate grade: 31%–35% ZrO₂, recovery ≥ 80%
Daily processing capacity approached the 10,000‑ton design level. Product quality fully met market requirements, generating stable economic returns for the client.
The project also achieved closed‑loop water reuse and standardized tailings disposal, complying with local environmental regulations.
Zircon titanium ore processing in Mozambique requires a multi-stage beneficiation process combining gravity, magnetic, and purification methods.
Choosing the right process flow depends on:
Ore composition
Mineral content
Project scale
A customized EPC solution can significantly improve both recovery rate and operational efficiency.
If you are planning a mineral processing project for zircon‑titanium placer, coastal placer, or heavy mineral sand, contact Xinhai Mining for professional, practical, and fully implementable solutions.
Q1: What is the best method to separate zircon and titanium?
A: Magnetic separation combined with gravity separation is the most effective method.
Q2: What equipment is used in zircon processing?
A: Spiral chutes, shaking tables, and magnetic separators are commonly used.
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