Physical Separation in Science and Engineering,

September–December 2004, Vol. 13, No. 3–4, pp. 119–126

SLON MAGNETIC SEPARATORS APPLIED IN THE

ILMENITE PROCESSING INDUSTRY
XIONG DAHE*
Ganzhou Nonferrous Metallurgy Research Institute, 36 Qingnian Road,
Ganzhou 341000, Jiangxi Province, P.R. China

(Received 10 September 2004; Accepted 18 September 2004)

SLon vertical ring pulsating high gradient magnetic separators possess the advantages of a large beneficial
ratio, high processing efficiency, strong adaptability, high resistance of the magnetic matrix to clogging,
and high equipment availability. In recent years, these separators have been successfully applied to the ben-
eficiation of ilmenite ores at the Panzhihua Ilmenite concentrator, and several other ilmenite processing
plants, promoting the rapid development of the ilmenite industry in China.

Keywords: SLon high-gradient magnetic separator; Ilmenite; Matrix

1. INTRODUCTION

The ilmenite deposit in Panzhihua region, Sichuan Province of China accounts for 35%
of the titanium resource in the world, and for approximately of 92% in China. Efficient
utilization of the ilmenite resources is very important for development of the titanium
industry.
Because a SLon vertical ring pulsating high gradient magnetic separator (SLon VP
HGMS) possesses the advantages of high efficiency, a high beneficiation ratio, a high
resistance of the matrix to clogging and high reliability [1,2,3,4,5,6,7], they have been
widely applied, in recent years, in the ilmenite processing industry in China.

2. MINERALOGICAL FEATURES

The Panzhihua deposit consists of vanadium, titanium and iron minerals and other
gangue minerals. Magnetite is the major iron mineral and vanadium exists in magnetite.
Ilmenite is the major titanium mineral. A typical elemental assay and mineralogical
analysis of ilmenite-containing minerals are shown in Tables I and II, respectively.

*E-mail: [email protected]

ISSN 1478-6478 print: ISSN 1478-6486 online ß 2004 Taylor & Francis Ltd
DOI: 10.1080/14786470412331316081
120 X. DAHE

TABLE I Elemental assay of Panzhihua Ore

Element (%)
TFe FeO Fe2O3 TiO2 V2O5 SiO2 Al2O3 CaO MgO Na2O
27.10 18.51 18.46 6.51 0.27 26.64 9.95 3.90 9.15 0.51
K2O S P MnO Cu Co Ni Cr2O3 Roasting lost
0.28 0.35 0.038 0.32 0.027 0.020 0.024 0.025 4.80

TABLE II Mineralogical analysis of Panzhihua Ore

Mineral Magnetite Hematite Ilmenite Pyrite Olivine Titaniferous augite Plagioclase

Mass (%) 30.6 3.5 6.1 0.7 16.2 13.1 15.8
Hornblende Mica Chlorite Cyphoite Kaolin Spinel Others
2.3 0.2 4.2 3.0 3.6 0.5 0.2

TABLE III Elemental assay of the tails of LIMS

Element (%)
TFe FeO Fe2O3 TiO2 V2O5 SiO2 Al2O3 CaO MgO
13.40 10.56 7.37 9.51 0.072 35.76 11.67 11.22 9.26
Na2O K2O S P Cu Co Ni Cr2O3
0.68 0.85 0.564 0.021 0.015 0.019 0.012 0.008

TABLE IV Typical mineral properties in the tailings of LIMS

Mineral Molecule Mass Grade Specific Magnetic Specific

(%) (TiO2%) density susceptibility Resistance
(g/cm3) (
106cm3/g) (
cm)

Vanadium–titanium (V, Ti, Fe)3O4 2–5 13.4 4.6–4.8 >1000 1.38
106
magnetite
Ilmenite FeTiO3 15.3–17.5 51.89 4.6–4.7 240 1.75
105
Titaniferous Augite Ca(Mg, Fe, Ti)[(Si, Al)2O6] 46–46.5 1.85 3.2–3.3 100 3.13
1013
Pyrite FeS2 2–2.5 4.4–4.9 4100 1.25
104
Plagioclase (100  n)Na[AlSi3O8]  nCa[Al2Si2O8] 31–34 0.097 2.7 14 >1014

All of the mineral processing plants in the Panzhihua region recover magnetite
with low-intensity magnetic separation (LIMS), while the tailings which contain
about 10% TiO2, serve as the feed to various ilmenite processing flowsheet. The typical
elemental assay and mineral properties in the tailings of LIMS are shown in Tables III
and IV.

3. SLON VP HGMS APPLIED TO THE RECOVERY OF FINE ILMENITE

The Panzhihua Ilmenite Processing Plant is the biggest producer of ilmenite concentrate
in China. The iron processing plant recovers magnetite and vanadium before the
ilmenite processing plant. The tailings from the iron processing plant represent the
feed into the ilmenite processing plant.
 SLON MAGNETIC SEPARATORS 121

The previous flowsheet of the ilmenite processing plant was based on classification
into þ0.1 mm (coarse), 0.045 þ 0.1 mm (middle) and 0.045 mm (fine) fractions.
The coarse and middle particle fractions were treated with spirals and electrical separa-
tors. The fine fraction was discarded as the final tailings for the lack of efficient
beneficiation technology. The overall recovery of ilmenite had been only 17–20% of
the feed to the ilmenite processing plant.
In recent years, the mass of the fine fraction has reached about 50% as the iron
processing plant grinding became finer and finer for higher iron concentrate grade.
The TiO2 grade of the fine fraction is almost the same as that of the feed to the ilmenite
plant. The recovery of ilmenite from the fine particle fraction is getting more and more
important in order to increase the overall recovery of the ilmenite plant.
From 1997 to 2004, the Panzhihua Ilmenite Processing Plant built two circuits for
the recovery of 0.045 mm ilmenite using the SLon VP HGMS-Flotation flowsheet.
Twelve SLon-1500 VP HGMS are applied as roughers, followed by flotation for
cleaning as shown in Figs. 1 and 2.

Mass%, TiO 2% Feed(-0.045 mm)

Recovery of TiO2%
100.00, 10.12
100.00
slime(-0.01 mm)
Φ 125 mm cyclone(deslime)
60.78, 11.03 39.22, 8.71
66.24 33.76
SLon-1500 magnetic separator
mags nonmags
24.09, 21.22 36.69, 4.34
50.51 15.73

Flotation to remove pyrite 23.44, 21.46

49.70
0.65, 12.57
0.81 30.26, 21.71
6.82, 22.57
64.91
15.21

Ilmenite floatation (roughing)

pyrite
12.53, 42.87 17.73, 6.76
53.08 11.83

Ilmenite flotation (cleaning) Ilmenite flotation (scavenging)

2.96, 28.35 3.86, 18.13

8.29 6.92
13.87, 3.59
9.57, 47.36 4.91
44.79 89.78, 6.13
54.40

Ilmenite concentrate Tails

FIGURE 1 Twelve SLon-1500 VP HGMS machines are applied to the recovery of 0.045 mm ilmenite in
the Panzhihua Ilmenite Processing Plant.
122 X. DAHE

FIGURE 2 A photograph of SLon-1500 VP HGMS in the Panzhihua Ilmenite Processing Plant.

The SLon VP HGMS operation is very important. It discards most of the gangue and
slimes before flotation. Only a small mass portion containing about 21.22% TiO2 enters
flotation. It creates a very good condition for flotation, which guarantees that the
flotation operation can get good results at low cost. The total results of the flowsheet
are: feed grade 12.12% TiO2, ilmenite concentrate grade 47–48% TiO2, recovery
44.79% TiO2.
Now The Panzhihua Ilmenite Processing Plant produces 150 000 tonnes of
0.045 mm ilmenite concentrate with average 47.5% TiO2 each year. The TiO2 overall
recovery of the plant was increased from 17–20% to about 35%.

4. APPLICATION OF SLON VP HGMS FOR THE RECOVERY

OF ILMENITE FROM THE PANZHIHUA TAILINGS

The Panzhihua Iron and Steel Company treats 10 million tones of iron ore annually.
Approximately 5.7 million tonnes of tailings from the low-intensity magnetic separation
circuit, containing about 9.5% TiO2 serve as the feed to the Panzhihua Ilmenite
Processing Plant as mentioned above. After a portion of ilmenite is recovered into
the magnetic concentrate, the tailings of the plant still contain about 7% TiO2, in
about 5.4 million tonnes that are discharged and pumped to the tailings dump.
In the past few years, a mineral processing plant has been built at the middle of the
pumping pipeline to recover the remaining iron and ilmenite minerals from the
discarded tailings. The flowsheet is shown in Fig. 3. Low intensity magnetic separators
recover the remaining magnetite. Two SLon-1500 VP HGMS are applied as the
roughing stage and one SLon-1500 VP HGMS is used as the cleaning stage to recover
 SLON MAGNETIC SEPARATORS 123

Mass%, Tio 2% Pan Zhi Hua tails

Recovery of TiO2%

LIMS 100.00, 7.68

100.00

To iron processing 2 SLon-1500 roughing

stage 32.62, 14.25 67.38, 4.50
60.52 39.48

1 SLon-1500 cleaning
18.50, 21.55 14.12, 4.69
51.91 8.61

+0.1 mm -0.019 mm
Condensing and classifying

0.019–0.1 mm 81.50, 4.53

11.59, 17.47 0.93, 22.63 48.09
5.98, 29.28
26.36 2.75
22.80
Shaking table Flotation
1.98, 47.30 9.61, 11.34 3.05, 47.89 2.93, 9.85
12.17 14.19 19.02 3.78

13.47, 11.80
20.72
5.03, 47.66 94.97, 5.56
31.19 68.81

Ilmenite concentrate
Tails

FIGURE 3 Three SLon-1500 VP HGMS units are used to recover ilmenite from the tailings.

ilmenite. As the Panzhihua tailings are enormous, the feed into each SLon-1500 at the
roughing stage is about 45 t/h (nominally 20 to 30 t/h), so that as much ilmenite as
possible is recovered. The magnetic fraction of the cleaning SLon-1500 containing
21.55% TiO2 are condensed and classified into þ0.1 mm (coarse), 0.1 þ 0.019 mm
(fine) and 0.019 mm (slime) fractions. The coarse fraction is cleaned further by shak-
ing tables and the fine fraction is cleaned further by flotation. The slime is discharged
directly as the final tailings. The advantages of this flowsheet are that three SLon-1500
separators discharge 81.5% of the mass fraction to the final tailings at very low cost.
Only 18.50% mass fraction enters the further cleaning stages. The results of the total
flowsheet are: feed grade 7.68% TiO2, ilmenite concentrate grade 47.66% TiO2, TiO2
recovery 31.19%. This flowsheet recovers 30 000 tonnes of the ilmenite concentrate
annually, at good quality, and about 50 000 tonnes of the iron concentrate is also recov-
ered each year.

5. APPLICATION OF THE SLON VP HGMS TO THE RECOVERY

OF ILMENITE IN THE TAIHE IRON MINE

The Taihe Iron Mine is located in Xichang of the Si Chuan Province, close to the
Panzhihua Region. Its ore is similar to the Panzhihua ore. A low-intensity magnetic
124 X. DAHE

separation (LIMS) circuit was installed to recover magnetite before 1994. In 1994 to
1995, an ilmenite processing circuit was introduced to produce ilmenite concentrate
from the tailings from the LIMS circuit. At first spirals and shaking tables were used
as roughers and flotation was used as cleaner, however spirals and shaking tables
were not able to recover fine ilmenite particles. Their roughing concentrate contained
only coarse particles, and the flotation cleaning stage was not able to recover coarse
ilmenite particles. Therefore, high losses of TiO2 from the coarse and fine fractions
were incurred. The TiO2 recovery was, therefore, very low, only about 10% TiO2
from the LIMS tailings. The ilmenite concentrate production was only 2000 tonnes
per annum.
In 2000, three SLon-1500 VP HGMS units were installed at the Taihe Iron Mine to
recover ilmenite. Two SLon-1500 separators replaced the previously used spirals
and one SLon-1500 separator replaced the previously used shaking tables. These
three SLon-1500 separators are incorporated, together with the flotation circuit, into
a magnetic-flotation flowsheet as shown in Fig. 4.

Mass%, TiO 2% Feed

Recovery of TiO2% 100.00, 12.06
100.00
116.89, 12.14
117.64
+0.1 mm -0.02 mm
Condensing and classifying
60.04, 12.91 0.02–0.1 mm 19.35, 10.28
64.27 32.50, 11.70 16.49
31.53
SLon-1500 roughing
32.87, 21.00 27.17, 3.12
57.24 7.03

-0.1 mm
Classifying SLon –1500 Roughing
13.53, 22.28 18.97, 4.15
25.00 6.53

46.41, 21.37
82.25

MIMS
42.07, 21.16 4.34, 23.44
73.81 8.44 Ferrous matters
SLon-1500 Cleaning
28.85, 27.21 13.22, 7.96
65.08 8.73

Flotation 88.04, 7.20

11.96, 47.85 16.89, 12.60 52.56
47.44 17.64

Ilmenite concentrate Tails

FIGURE 4 Three SLon-1500 high-gradient magnetic separators are applied at the Taihe ilmenite
processing flowsheet.
 SLON MAGNETIC SEPARATORS 125

In the first stage, the feed (the tailings from LIMS) is thickened and classified into
þ0.1 mm (coarse), 0.02 þ 0.1 mm (fine) and 0.02 mm (slime) fractions. The coarse
and the fine fractions are roughed separately by two SLon-1500 separators. The
coarse magnetics from the SLon machine are milled to 0.1 mm, and mixed with the
fine magnetics from the SLon-1500 unit. A medium-intensity magnetic separator
(MIMS) of the drum type is used to remove the remaining magnetite and other ferrous
materials. The non-magnetics from the MIMS machine are cleaned by a SLon-1500
separator, the magnetics of which are fed into the flotation stage for further cleaning.
The advantages of this flowsheet are as follows:
(1) The coarse and the fine fractions are treated separately by SLon VP HGMS, so that
different magnetic parameters can be chosen for optimal results.
(2) The grade of the feed into the flotation circuit is relatively high, about 27.21%
TiO2, which saves flotation reagents and reduces the production costs.
(3) The flotation tailings containing about 12.60% TiO2 are returned to the feed of the
flowsheet which helps to increase TiO2 recovery.
This flowsheet recovers effectively coarse and fine ilmenite fractions. It guarantees
that the grade of the ilmenite concentrate is greater than 47% TiO2 and the overall
recovery of TiO2 is increased to approximately 47%. Presently the production of the
ilmenite concentrate at the Taihe Mine reaches 40 000 tonnes per annum, compared
to the previous production of 2000 tonnes per annum. In 2003 to 2004, this mine
ordered additional three SLon-1750 VP HGMS machines to scale-up the ilmenite
processing flowsheet. The work is expected to be completed in 2005.

6. CONCLUSION

(1) SLon vertical ring pulsating high-gradient magnetic separators possess the advan-
tages of large beneficiation ratio, high mineral processing efficiency, high resistance
of the matrix to clogging, high throughput, high equipment reliability and availabil-
ity. In recent years, these separators have been successfully applied in eight Chinese
ilmenite processing plants. Three typical examples of ilmenite processing flowsheet
are described in this article.
(2) Twelve SLon-1500 VP HGMS units are applied at Panzhihua Ilmenite Processing
Plant to recover 0.045 mm ilmenite. These separators are used to beneficiate the
feed containing 10.12% TiO2 to 21.22% TiO2, at low cost. The mass of SLon mag-
netic concentrate is only 24.09%, which is very favorable for the following flotation
cleaning stage. The overall results of the magnetic-flotation flowsheet are: feed
grade 10.12% TiO2, ilmenite concentrate grade 47.36% TiO2, recovery 44.79%
TiO2. Each year 150 000 tonnes of the ilmenite concentrates of good quality are
produced by this flowsheet.
(3) Three SLon-1500 VP HGMS machines are applied to recover ilmenite from the
Panzhihua tailings; two of them are used as roughers and the other is used as
a cleaner. These machines enrich the feed, with wide size distribution, from
7.68% TiO2 to 21.55% TiO2, The SLon magnetics are then classified into
þ0.1 mm (coarse), 0.019 þ 0.1 mm (fine), 0.019 mm (slime) fractions. The
coarse fraction is further cleaned by shaking tables and the fine fraction is further
126 X. DAHE

cleaned by flotation. The overall results of this magnetic—gravity–flotation flow-

sheet are: feed grade 7.68% TiO2, ilmenite concentrate grade 47.66% TiO2, recov-
ery 31.19% TiO2. Annually, 30 000 tonnes of good quality ilmenite concentrate
are produced.
(4) Three SLon-1500 VP HGMS units are applied in the Taihe ilmenite processing flow-
sheet. The feature of this flowsheet is that the feed is first classified into þ0.1 mm
(coarse), þ0.02 – 0.1 mm (fine), 0.02 mm (slime) fractions. The coarse and the
fine fractions are then roughed by the SLon-1500 separators separately for optimized
results. The coarse magnetics of a SLon-1500 separator is ground to 0.1 mm, mixed
with the fine magnetics from the other SLon-1500 separator, and then cleaned
by the third SLon-1500 machine, the magnetics of which are further cleaned
by flotation. The overall results of this magnetic – magnetic–flotation flowsheet
are: feed grade 12.06% TiO2, ilmenite concentrate grade 47.85% TiO2, recovery
47.44% TiO2. Annually 40 000 tonnes of the ilmenite concentrates of good quality
are produced.
(5) In all of the ilmenite processing flowsheet mentioned in this article, SLon VP
HGMS machines are used as roughers or first cleaners. The separators successfully
remove most of the gangue at low cost and leave a small mass portion for the final
cleaning stage. SLon VP HGMS machines also discard all of the 10 mm slimes
which otherwise would be harmful to flotation. As the ilmenite flotation reagents
are expensive, SLon VP HGMS units greatly reduce the total cost of the ilmenite
concentrate production.
(6) The applications of SLon VP HGMS separators successfully solved the difficult
problem of beneficiation of the 0.045 mm ilmenite fraction, greatly increased
the ilmenite recovery and greatly reduced the production cost. The successful
applications of SLon VP HGMS separators in the ilmenite processing industry
significantly promoted the rapid development of Chinese titanium industry.

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