This technology involves using the ZCLA beneficiation machine to pre-select and discard tailings from crushed products (particle size: 0–15 mm) of black metal ores such as vanadium-titanium magnetite, hematite, magnetite, manganese ore, limonite, magnetite, and hematite—along with high-pressure roller mill products (particle size: 0–6 mm or finer) and semi-autogenous grinding products (particle size: 0–5 mm or finer). The coarse-grained tailings are directly sent for dry stacking or discharged into tailings ponds. The coarse-grained concentrate produced by the ZCLA is then ground further and subjected to a second round of tailings rejection using the ZCLA beneficiation machine, thereby enabling early rejection of gangue minerals and reducing the amount of grinding required.

Yangxian Vanadium-Titanium Magnetite Co., Ltd. has adopted the new ZCLA titanium roughing process to treat Yangxian’s vanadium-titanium magnetite resources, achieving a crude titanium concentrate grade of 7.79%, which is 1.57 percentage points higher than that obtained using the conventional vertical-ring high-intensity magnetic separator titanium roughing process. The recovery rate stands at 78.49%, closely matching the performance of the vertical-ring high-intensity magnetic separator. Based on processing 18 million tons per year of raw ore from Yangxian’s vanadium-titanium magnetite resources, this new process will yield 2.2 million tons of iron concentrate and 300,000 tons of titanium concentrate, while reducing the amount of first-stage grinding by 9.7 million tons and second-stage grinding by 5.44 million tons. Annual operating cost savings will amount to approximately 29.7 million yuan, and the cumulative benefits and cost savings generated will exceed 500 million yuan. The economic benefits are significant, and the energy-saving and consumption-reducing effects are remarkable.

The key technology for the sustainable development of black metal ores lies in the research and development of new, efficient, and rational pre-selection technologies. By using magnetic separation to pre-enrich coarse-grained ores and discarding qualified coarse-grained tailings, the grade of ore fed into the beneficiation process can be significantly improved, thereby achieving economic benefits. After years of research, this technology has been developed, centered around the ZCLA mineral processing machine, which is a highly efficient pre-selection technology capable of removing 20% to 60% of coarse-grained tailings and recovering 80% to 95% of the valuable minerals both before grinding and during staged grinding. Once widely adopted, this technology will promote the economically and rationally exploitative utilization of vast reserves of magnetite, hematite, manganese ore, and vanadium-titanium magnetite. It will also help existing black metal mines achieve energy savings, emission reductions, increased production, and enhanced efficiency. The widespread application of this technology can address both energy conservation and emission reduction challenges associated with black metal ores as well as the efficient utilization of low-grade ores. The core technologies, complete processes, and related equipment involved possess independent intellectual property rights and international competitiveness, making them highly valuable for broader implementation.