The 50 TPH tungsten ore processing plant is designed for medium-scale mining operations. The flowsheet follows the “stage crushing + stage grinding + stage recovery” principle to minimize over-grinding and slime generation—the single largest source of tungsten loss in processing .
Stage
Function
Key Outcome
Stage 1: Feeding
Controlled ore delivery with grizzly screening
Steady 50 TPH feed rate, fines bypass
Stage 2: Two-Stage Crushing
Jaw + Cone crushing with closed-circuit screening
Product size: 0-25 mm
Stage 3: Rod Mill Grinding
Rod mill with classification (preferred over ball mill to reduce fines)
Output size: 0-2 mm, minimal slime generation
Stage 4: Coarse Gravity Recovery
Mineral jig for coarse liberated tungsten
Recovers coarse tungsten early to prevent over-grinding
Stage 5: Fine Gravity Recovery
Shaking tables for intermediate sizes (0.074-2 mm)
Recovers medium and fine tungsten particles
Stage 6: Slime Recovery
Centrifugal concentrator for ultra-fine particles (0-74 μm)
Recovers tungsten fines that would otherwise be lost
Stage 7: Purification
Dry magnetic separation to remove cassiterite and iron impurities
Concentrate grade: 65-75% WO₃
Stage 8: Dewatering
Thickening + filtration
Concentrate moisture: <10%
This configuration is suitable for:
Wolframite ((Fe,Mn)WO₄): High density (7.0-7.5 g/cm³), weakly magnetic. Uses gravity + magnetic separation
Coarse-grained Scheelite (CaWO₄): Density (5.9-6.1 g/cm³), non-magnetic. Uses gravity + flotation (with Petrov Process for fine scheelite)
Polymetallic tungsten ores with cassiterite, molybdenite, or pyrite
Critical Note: For fine-grained scheelite or complex calcium-bearing ores, a flotation circuit (with heating cleaning process) should replace or supplement the gravity circuit .
2. Complete Equipment List with Detailed Parameters
2.1 Crushing Section
Equipment
Model
Key Parameters
Qty
Function
Vibrating Grizzly Feeder
ZSW380×96
Capacity: 50-80 TPH, feed size ≤300 mm, grizzly gap: 50-80 mm, power: 11 kW
1
Evenly feeds ore, removes fines before primary crushing
Primary Jaw Crusher
PE-500×750
Feed opening: 500×750 mm, max feed: 425 mm, discharge: 50-100 mm, capacity: 50-120 TPH, power: 55 kW
1
Primary crushing to ≤80 mm
Secondary Cone Crusher
PYB1200
Feed: ≤100 mm, output: 10-25 mm, capacity: 60-100 TPH, power: 110-132 kW
1
Secondary crushing to grinding feed size
Vibrating Screen
2YK-1548
Decks: 2-3 layers (2 mm, 8 mm, 25 mm), screen area: 7.2 m², capacity: 50-150 TPH, power: 15-22 kW
1
Closed-circuit screening, returns oversize to crusher
Belt Conveyors
DT75-650/800
Width: 650-800 mm, length: 15-20 m, belt speed: 1.25-1.6 m/s
Diameter: 1500-1800 mm, length: 3000-3600 mm, capacity: 30-50 TPH, output: 0-2 mm, power: 75-110 kW, rotation speed: 20-24 rpm, rod charge: 10-15 tons. Critical: Rod mills preferred over ball mills for tungsten to minimize slime generation
1
Primary grinding with line-contact action reduces over-grinding
Supplies air for flotation (if used) and instrumentation
Laboratory Equipment
Custom
Assay equipment, particle size analyzer
1 set
Process control and quality monitoring
3. Process Selection: Wolframite vs. Scheelite
The flowsheet above is primarily designed for wolframite ores. If your ore contains scheelite, significant modifications are required .
3.1 Wolframite Beneficiation (Gravity + Magnetic)
Stage
Method
Equipment
Coarse Recovery
Gravity
Jig, Shaking Table
Fine Recovery
Gravity
Shaking Table, Centrifugal Concentrator
Purification
Magnetic
Three-Disk Magnetic Separator
Characteristics: Wolframite is dense (SG 7.0-7.5) and weakly magnetic. Cassiterite (tin) has similar density but is non-magnetic—magnetic separation is critical for separation .
3.2 Scheelite Beneficiation (Gravity + Flotation)
For scheelite ores, particularly fine-grained or those associated with calcium-bearing gangue (calcite, fluorite), the flowsheet requires a flotation circuit:
Heating to 85-90°C for 1-2 hours to depress calcite/fluorite
Sulfide Removal
Bulk Flotation
Flotation Machine
Xanthate collectors to remove pyrite, molybdenite
Critical for Scheelite: The “Petrov Process” (heating cleaning) is often required to achieve high-grade concentrate when scheelite is associated with calcium gangue .
4. Site Requirements & Utilities
Item
Specification
Remarks
Total Installed Power
500-750 kW
380/415 V, 3-phase, 50/60 Hz
Power Consumption
10-15 kWh per ton
Approximately 500-750 kWh per hour at full load
Water Consumption
150-250 m³/h
Closed-loop recycling reduces makeup to 15-25 m³/h
