Enhanced Chromite Recovery from Tailings via a Custom-Designed Shaking Table: Optimization and Performance

Significant chromite losses to tailings in gravity separation plants arise from both suboptimal separator design and inefficient beneficiation processes, posing major challenges to resource utilization, energy efficiency, and environmental sustainability. These losses are particularly critical because the material, already comminuted to liberation size, is discarded, leading to reduced concentrate yield, wasted energy input, and increased environmental pollution. To address this issue, an industrial-scale custom-designed shaking table was developed and tested to recover marketable-grade chromite concentrate (≥42% Cr2O3) from processing plant tailings containing 3.25%–4.25% Cr2O3, which had accumulated over years of chromite beneficiation. Experimental results showed that, under optimized operating parameters (320 rpm stroke frequency, 13 mm stroke length, 1° deck slope, 1300 g/L pulp density, 800 kg/h feed rate, and 7 tph wash water flow rate), Cr2O3 recovery increased from 8% to 27% for the first and second floor operations and from approximately 17% to 41% for the third and fourth floor operations compared with existing plant performance. The results revealed a strong interdependence between Cr2O3 recovery and concentrate grade, both of which are critical indicators of process efficiency. Intermediate particle sizes (−0.250 + 0.150 mm) provided the most favorable balance, yielding high recovery rates without substantially compromising the concentrated grade.