Building a cheap flotation processing plant for tungsten requires cost-effective strategies in equipment selection, process optimization, and operational efficiency. Below is a practical approach to achieve this:
1. Simplified Flotation Process for Tungsten (Scheelite/Wolframite)
Tungsten ores (mainly scheelite (CaWO₄) and wolframite ((Fe,Mn)WO₄)) are typically processed via gravity separation followed by flotation. To reduce costs:
– Use bulk flotation instead of complex multi-stage processes.
– Combine gravity pre-concentration (spiral separators, jigs) to reduce feed to flotation.
2. Low-Cost Equipment Selection
| Equipment | Cheap Alternative |
|———–|——————-|
| Jaw Crusher | Used or small-scale models |
| Ball Mill | Second-hand or locally fabricated |
| Spiral Classifier | Simple screw classifiers |
| Flotation Cells | Small mechanical cells (used or Chinese suppliers) |
| Thickener | Small conventional or cone thickeners |
| Filter Press | Manual or low-cost membrane press |
3. Reagent Optimization (Cheap & Effective)
– Collector: Fatty acids (oleic acid) or cheaper sodium oleate.
– Modifiers: Sodium silicate (depressant for silicates), soda ash (pH control).
– Frother: Pine oil or MIBC (methyl isobutyl carbinol).
4. Energy & Water Savings
– Use solar power for small plants in sunny regions.
– Implement water recycling to cut costs.
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5. Small-Scale & Modular Design
– Consider a containerized/mobile pl
(~10–50 TPD capacity).
– Avoid overengineering; focus on essential steps.
6. Sourcing Cheap Tungsten Ore
– Process low-grade ores or tailings from old mines.
– Partner with artisanal miners for cheap feed.
Estimated Cost Range
| Component | Cost Estimate (USD) |
|———–|———————-|
| Small Jaw Crusher + Ball Mill | $20,000–$50,000 |
| Flotation Cells (4–6 units) | $30,000–$80,000 |
| Thickener & Filter Press | $15,000–$40,000 |
| Pumps & Piping | $10,000–$25,000