Alternate Approaches to Recover Zircon Mineral Sand from Beach Alluvial Placer Deposits and Badlands

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www.ijm‐me.org International Journal of Material and Mechanical Engineering (IJMME) Volume 2 Issue 4, November 2013

Alternate Approaches to Recover Zircon Mineral Sand from Beach Alluvial Placer Deposits and Badlands Topography for Industrial Applications Sunita Routray1, Tumula Laxmi2and Raghupatruni Bhima Rao3 C V Raman College of Engineering, Bhubaneswar 752 054, India CSIR‐Institute of Minerals and Materials Technology, Bhubaneswar 751 013, India 3Aryan Institute of Engineering and Technology, Bhubaneswar 752 050, India 1 2

sunitaroutray77@gmail.com, 2tumulalaxmi@gmail.com, 3bhimarao@gmail.com

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Abstract At present, recovery of zircon from beach sand and red sediments of badlands topography is a priority due to high demand of zircon for industrial applications. Zircon content in these deposits varies from 0.2% to 2.7% by weight. Results of these studies reveal that heavy mineral content in the beach‐dune sand is 16.7%, in which the zircon is 0.16 %. Red sediment contains 33.2% heavy minerals in which the zircon is 0.32%. A common flowsheet with material balance is suggested to recover zircon by wet process and in combination of wet and dry process. Zircon concentrate recovered from beach‐dune sand contains 98.0% zircon with 79.6% recovery. The results of pre‐concentration of heavy minerals by judicious combination of magnetic separator and advanced air classifier reveal that about 63% of light heavy minerals can be rejected by which the use of fresh water in spirals can be minimized. Zircon concentrate recovered by traditional approach of India from red sediment sample contains 96.3% of zircon with 84.3% recovery and zircon recovered from alternate approach is 97.9% grade with 79.5% recovery. In depth characterization of zircon and their value addition is suggested. Keywords Beach and Dune Sands; Red Sediments; Badlands Topography; Total heavy Minerals; Zircon; Flowsheet

Introduction Zircon has been recognised as a valuable material because of its combination of physical and mechanical properties, such as excellent chemical stability, thermal shock resistance, strength retention at high temperatures and low thermal expansion and heat conductivity (Singh, 1990). High zircon demand has made the exploitation of zircon enriched deposits as a priority. Beach and dune sand deposits and red

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sediments of badland topography are reported to be potential sources of heavy minerals (Indian Minerals Year book, 2008; Laxmi and Bhima Rao, 2010). Hence, it has attracted the attention of scientists, engineers and users to exploit zircons from these deposits and in depth characterizations for end use. Zircon is used in industry with a wide range of applications, as zircon sand directly from the mine; as a milled product in the form of zircon flour (95% micronized to less than 45μm used in the manufacturing of frit) and opacifier grade (100% micronized to less than 6μm, used in ceramic glazes for tiles and sanitary wares). The most important market for zircon is as an opacifier for ceramic titles and sanitary ware. Zircon finds its application in ceramics (54%) and refractory industries (14%), which accounts for 68% of zircon’s total world consumption of 1.2 million tonnes. The rest (32%) is consumed in foundry, TV glass, zirconia chemicals and other applications (Murty et al., 2007). Lean placer deposits containing 2–5% Total Heavy Minerals (THMs) are first concentrated to 20–30% THMs by cone concentrators. The general practice to recover zircon from the Indian beach sands involves complicated flowsheet with processes such as gravity separation, magnetic separation, electrostatic separation and flotation (Bhima Rao et al., 2009). In India, the IMMT has also developed few flow sheets for different placer deposits to recover zircon by using different unit operations (Bhima Rao et al., 2002; 2006; 2008; 2009). This product is then fed to spirals, which may give a concentrate of more than 80% THMs from which zircon is separated. Some of the Australian industries employing spirals, magnetic separators,


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