Enhancing iron recovery from tailings using spiral concentrator HM6.33: Implications for sustainable earth resource management and environmental stewardship

• Introduces technical innovations in spiral concentrator design, enhancing iron recovery efficiency. • Spiral concentrator HM6.33 shows improved efficiency in iron separation compared to traditional methods. • Unique two-stage circuit maximizes iron extraction from middling streams while minimizing waste. • Reduces iron content in tailings to 16.2 % helping lower environmental footprint of mining operations. • Pilot-scale tests from plants validate effectiveness and economic viability of method. In western Iran, tailings from iron ore processing contain 22.2 % iron, representing significant economic losses and environmental challenges. This study investigates the effectiveness of the innovative HM6.33 spiral concentrator for iron recovery from tailings of a Drum Magnetic Separator plant. The HM6.33 spiral concentrator's three-start design and adjustable splitters are highlighted as key innovations, enabling enhanced throughput capacity and precise control over particle separation compared to conventional single-start models. Iron ore tailings with 40 % solids content were processed through a two-stage spiral concentration system in a closed-circuit configuration. Results demonstrate that the spiral concentrator achieved 65.4 % iron recovery from the initial concentrate, with secondary processing yielding a concentrate grading 64.8 % iron. The final tailings product contained 16.2 % iron, achieving 12.3 % weight recovery from the initial feed. Advanced mineralogical characterization using SEM-EDS and XRD revealed that 85 % of iron minerals were liberated at particle sizes ≤150 µm, confirming effective separation efficiency. The closed-circuit configuration reduced freshwater demand by 40 % compared to conventional processing methods. Environmental impact assessment showed a 65 % reduction in tailings volume and a 60 % reduction in carbon emissions (1.0 kg CO₂/ton versus 2.5 kg CO₂/ton for traditional methods). These findings demonstrate that the HM6.33 spiral concentration technology significantly enhances iron recovery from tailings while substantially reducing environmental impacts, providing an effective approach for sustainable resource management in mining operations.