by Tonie » 22 Oct 2012, 23:30
My friend - this is a very good problem for a mine engineer.
You need a proper sample of the mine. This sample (maybe one or two tons) must be characterized (minerals, waste material, liberation). Each material have a density - then you can choose - for example - another way to separate then (a Jig, a heavy media separation etc.).
A vibration sand could be used - but they need huge areas (comparing with your spirals).
Do you have only one spiral circuit? You can try 3: a Rougher circuit (its concentrate goes to the cleaner wich produces the final product), a Scavenger (wich receives the reject of Rougher and produces a final reject or *; its concentrate could go to cleaner or return to Rougher or *...) and a Cleaner.
You can use Jigs or Tables or ... to treat the * intermediate materials.
It could be necessaire broke (in proper mills) same part of the ore (to liberate the zircon from othes useless material).
Do you have thorium ores (monazite sands) with the zircon? Rutile, ilmenite, tin, gold?
Look for a good mine engineer and save money, optimizing your plant!!