1,000 TPD Graphite Ore Processing Test & Complete Equipment Plant in Tanzania

Ore Crushing & Coarse Sorting:

• Flow: Two-stage crushing (Jaw Crusher + Hammer Crusher) to below 25mm.
• Equipment: X-ray Transmission (XRT) Sensor-Based Sorter (optional).
• Function: Early waste rejection to improve head grade and reduce downstream processing load.

Flake Protection & Classification:

• Equipment: Specialty Graphite Flake Protection Mill (low-speed attrition grinding) + Multi-stage Sieving & Gravity Classifier.
• Function: Separate flakes by size (+80 mesh, +100 mesh, -100 mesh) and remove slimes.

Concentrate Dewatering & Drying:

• Equipment: High-rate Thickener + Membrane Plate Filter Press + Low-temperature Belt Dryer.
• Function: Efficient moisture reduction to ≤ 10% while preventing oxidation.

Modular & Containerised Design: Major equipment pre-assembled in container modules for rapid deployment and commissioning in remote Tanzanian sites.

Flexible & Data-Rich Pilot Circuit: The plant is fully instrumented for variabile ore tests, providing accurate scale-up data for a future 5,000–10,000 TPD commercial plant.

Water-Efficient & Dry Stack Tailings: Tailings are fully dewatered for safe dry stacking, minimising environmental footprint and water consumption—critical for water-sensitive regions.

Grinding & Liberation:

• Flow: Closed-circuit grinding with Ball Mill + Hydrocyclone Cluster.
• Target Grind Size: P80 = 0.3–0.5 mm (protecting flake structure).
• Function: Liberate graphite flakes while minimizing over-grinding.

Multi-Stage Flotation:

• Flow: 1x Rougher + 3x Cleaner + 1x Scavenger flotation circuit.
• Equipment: Mechanical Agitation Flotation Cells with tailored frother/collector dosing system.
• Function: Achieve high-purity concentrate through repeated cleaning; scavenger recovers middlings.

Tailings & Water Management:

• Equipment: Deep Cone Thickener + Filter Press for tailings; Water Recycling System with clarifier.
• Function: Dry stacking of tailings, >85% process water recycled.

High-Efficiency Flotation with Smart Control: Automated reagent dosing and air flow control based on real-time pulp density and grade analysis.