Magnetic Separation and Enrichment of Fe–Ti Oxides from Iron Titaniferous Beach Sands: Process Design Applied to Coastal Ecuador

Abstract

Iron titaniferous sands, also called black sands, are a source of various magnetic minerals, such as iron and titanium (Fe–Ti) oxides, with countless scientific and industrial applications. Ecuador is deemed a geo-diverse country that contains deposits of black sands in the Andean and coastal regions; therefore, the industrialization of these magnetic sands might be of high interest. This study presents a preliminary industrial design for the magnetic separation process of Fe–Ti oxides from iron titaniferous Ecuadorian beach sands. Four stages are considered for the process, involving collecting, drying, screening, and magnetic separation. This proposal returns the large particles (>150 μm) and the non-magnetic fraction to the original place, generating a minimum environmental impact with the support of natural marine and coastal processes. The process design criteria are based on engineering guidelines, sampling, and characterization of eleven black sand samples. Using conventional techniques, the water content, granulometric distribution, particle size, and semi-quantitative Fe–Ti oxide concentration were determined for the different sand samples. It is estimated that Fe–Ti oxide production may reach 5.835 metric tons per day (5.835 mtpd) with a magnetic content of 97.50%, starting from 100 mtpd of black sands. Based on an economic analysis (Class V), a net profit of USD 835,875.63 is expected during the first year of production. Thus, the magnetic separation and enrichment of Fe–Ti oxides from iron titaniferous coastal sands exploitation should allow the commercial valorization of these resources in an eco-friendly way, i.e., with economic benefits and minimization of environmental impact in the source area.