JXSC has successfully delivered a 50TPH alluvial chrome beneficiation plant in Zimbabwe. We designed the processing plant flowchart and plant layout drawing in accordance with the client’s requirements. We provided a complete set of plant machines to the mine site. Upon installation, the client requested technical support from our team. In response, we dispatched engineers to provide on-site guidance—though the client already had their own engineering team, they sought additional expertise when needed. Currently, the plant is operating smoothly under normal conditions.
EPCS
Engineering, Procurement & Construction Services
Case Study: Alluvial Chrome Processing Plant Project
Project Overview
Minerals
Alluvial Chrome
Capacity
50 TPH
Feed Size
≤ 50 mm
Location
Zimbabwe
Year
2025
Project Process
Solutions & Process
We are delivering a 50TPH alluvial chrome washing plant to a licensed mine owner in Zimbabwe. The plant is designed to upgrade low-grade chrome ore (25-27% Cr₂O₃) to a marketable 48% chrome concentrate while addressing iron contamination through integrated magnetic separation.
Raw Ore Conditions & Design Basis
| Parameter | Specification |
|---|---|
| Processing Capacity | 50 TPH |
| Max. Feeding Size | ≤50 mm |
| Ore Type | Alluvial chrome (non-sticky soil) |
| Target Concentrate Size | 0-2 mm |
| ROM Chrome Grade | 25-27% Cr₂O₃ |
| Target Concentrate Grade | ≥48% Cr₂O₃ |
| Special Consideration | Magnetic separator for Cr/Fe ratio control |
Process Flowchart
Process Design Solution
Stage 1: Primary Screening & Classification
- Feeding: ROM ore is dumped into a grizzly-hopper (40mm spacing) to remove oversize waste (stones/roots).
- Trommel Scrubbing: Sub-40mm material enters a wet trommel screen (2mm aperture) for:
- Soil flushing & disaggregation
- Size split: 0-2mm (chrome-bearing) vs. +2mm (waste conveyed to stockpile)
Stage 2: Gravity Concentration
- Spiral Chute Beneficiation:
- Rougher Spirals: Primary upgrade of 0-2mm slurry to discard low-density impurities.
- Cleaner Spirals: Secondary processing of rougher middlings to boost recovery rate.
Stage 3: Iron Removal & Product Finishing
- Magnetic Separation: Concentrate from spirals passes through a dry/wet magnetic separator to reduce Fe content and optimize Cr/Fe ratio.
- Dewatering: Final concentrate is dewatered via a hydrocyclone for storage/transport.
Process Features & Advantages
- Proven Technology: Combines screening, gravity + magnetic separation for reliable performance.
- Grade Control: Dual-stage spirals + iron removal ensure consistent 48% Cr₂O₃ concentrate.
- Low Operating Cost: Water recycling system minimizes consumption; modular design reduces maintenance.
- Tailings Management: Waste streams are sorted for environmental compliance.
This alluvial chrome solution has been successfully deployed in African markets, offering high ROI with <12-month payback periods.
Optional Upgrades:
- High-intensity magnetic separator for ultra-low Fe requirements
- Concentrate drying system for direct shipment
Customer Questions & Our Answers
1. Can you conduct beneficiation tests at your factory before production?
Yes, we provide comprehensive beneficiation testing in our in-house laboratory:
- 200kg sample processing capacity per test batch
- Multi-stage analysis: Scrubbing → Gravity separation → Magnetic separation
- Data reporting: Detailed recovery rates, grade uplift metrics, and tailings analysis
- Process optimization: Test results determine ideal screen apertures/spiral configurations for your specific ore
2. What is the expected recovery rate for this chrome wash plant?
50-60% recovery rate under standard feed conditions (25-27% Cr₂O₃ ROM), achievable through:
- Dual-stage spiral separation (Rougher + Cleaner = +8% recovery vs single-stage)
- Targeted waste rejection: Trommel screen removes 100% of +2mm waste upfront
- Iron removal efficiency: Magnetic separator boosts effective Cr recovery by reducing Fe dilution
Note: Recovery may vary ±5% depending on clay content and liberation degree.
3. What final concentrate grade can your wash plant achieve?
Guaranteed 48%+ Cr₂O₃ concentrate from 15-20% ROM ore via:
- Precision classification: 2mm trommel screening ensures optimal feed for spirals
- Gravity upgrading: Two-stage spirals produce 42-45% intermediate concentrate
- Magnetic purification: Removes ferrous contaminants to push grade to target 48%
4. How do you address iron contamination in chrome ore?
Drum-type wet magnetic separator (1600-2000 Gauss) with:
- Adjustable intensity: Handles variable Fe content (3-8% in feed)
- Counter-current tank design: Maximizes Fe recovery (>90% iron removal efficiency)
- Low maintenance: Ceramic magnet assembly resistant to chrome abrasion
Optional: High-intensity roll separator (3000+ Gauss) for ores requiring Cr/Fe ratio >2.5
5. What dewatering solutions do you offer for spiral wash plants?
Hydrocyclone cluster (3-stage) with 85-90% water recovery:
- Capacity matched: Handles 50TPH slurry flow at 30-35% solids density
- Energy efficient: 7.5kW pump requirement vs 22kW for filter presses
- Compact footprint: 2m² installation space vs traditional thickeners
Upgrade available: Vibrating screen + centrifuge for <8% moisture in final concentrate
Why Choose JXSC?
- Mining project processing consulting at the beginning.
- Customize the customer’s chrome ore processing plant solution and design the optimal beneficiation flowchart according to raw ore conditions & customer’s requirements.
- Provide a complete set of processing
- Provide detailed 3D layout drawing and foundation drawing for the whole plant.
- Provide professional engineer after sales installation and commissioning service.
- Provide technical support service online.
Equipment In This Project
Related Cases
We are a leading provider of innovative and efficient mining equipment and solutions. With years of experience in the industry, we specialize in designing and manufacturing high-quality machines tailored for various mineral processing needs, including gold, diamond, copper, tin, manganese, chrome, titanium, and other ore separations. Our commitment to technology and customer satisfaction drives us to deliver customized solutions that enhance productivity and ensure environmentally sustainable practices. Explore our extensive portfolio of successful case studies and discover how JXSC can transform your mining operations, helping you maximize your profitability while minimizing your ecological footprint. Choose Us—where technology meets efficiency in the world of mining!
