Zimbabwe Chrome Beneficiation & Wash Plant Dashboard
CurrencyUS$1 = ₹95.1906
Technical, commercial and regulatory screening for a modular chrome wash and gravity-concentration plant in Zimbabwe. All values are preliminary screening assumptions, not vendor quotations or a bankable feasibility study.
1. Executive Investment View
Proceed to validation and pre-FEED; do not move directly to EPC.Installed CAPEX
Indicative first commercial module
Processing OPEX
Per tonne of ROM
Contained Recovery
72%
Base case; range 55%–85%
Mass Yield
45.8%
At 28% feed and 44% concentrate
Decision Summary
Conditional
Technically feasible Commercially unproven
A complete wash and gravity-concentration plant is feasible for suitable ore. Approval depends on representative testwork, water security, a domestic smelter or toll-smelting route, and written product-specific regulatory confirmation.
Recommended Business Model
Mine-controlled or contracted ore → 50 TPH modular wash plant → verified concentrate quality → domestic smelter sale or toll smelting → expansion to 100 TPH after stable operating proof.
2. Project Basis
Operating Hours
16 h/day
300 operating days/year
Annual ROM
240,000 t/y
Range 108,000–600,000 t/y
Head Grade
28% Cr₂O₃
Range 18%–40%
Concentrate Output
≈110,000 t/y
Ore-specific
Base Parameters
| Parameter | Base | Range / note |
|---|---|---|
| Throughput | 50 TPH | 30–100 TPH |
| Recovery | 72% | 55%–85% |
| Concentrate grade | 44% Cr₂O₃ | 40%–48% |
| Project life | 10 years minimum | 7–15+ years |
Core Feasibility Question
Can a specific ore produce a consistent, smelter-acceptable concentrate at sufficient recovery and margin after mining, transport, water, tailings, power, statutory charges and working capital?
Do not purchase a standard plant package from a throughput brochure alone.
3. Metallurgical Testwork Programme
Mandatory before final equipment selection.| Test | Purpose | Minimum output |
|---|---|---|
| Representative sampling | Capture seam, pit, depth and supplier variability | Composite plan and chain of custody |
| Chemical assay | Measure Cr₂O₃, Fe, SiO₂, Al₂O₃, MgO, P and S | Head, fractions, products and tails |
| Mineralogy / QEMSCAN / MLA | Identify locking and liberation | Mineral associations by size |
| Scrubbing and sizing | Measure clay removal and fines generation | Water demand and retention basis |
| Jig / DMS | Assess coarse pre-concentration | Coarse yield and grade |
| Spiral rougher-cleaner-scavenger | Develop main fines circuit | Grade-recovery curve |
| Fine recovery / magnetic separation | Assess ultrafines and Cr/Fe improvement | Incremental recovery versus cost |
| Settling and dewatering | Size thickener, pumps and filtration | Settling rate and product moisture |
4. Recommended 50 TPH Process Design
1. ROM ReceivingHopper, grizzly and controlled feeder
2. Size ReductionJaw crusher or sizer
3. ScrubbingRotary scrubber or log washer
4. ScreeningTrommel and multi-deck screens
5. Coarse RecoveryJig or DMS if justified
6. ClassificationHydrocyclones and sumps
7. Rougher SpiralsPrimary gravity recovery
8. Cleaner/ScavengerBalance grade and recovery
9. Fine RecoveryTables, MGS or magnetic separation
10. DewateringScreen, thickener or filter
11. Water ReturnThickener and return-water dam
12. Product HandlingStockpile, sampling and weighbridge
5. Base-Case Mass Balance & Product Quality
Illustrative Annual Mass Balance
| Stream | Tonnes/year | Cr₂O₃ grade |
|---|---|---|
| ROM feed | 240,000 | 28.0% |
| Concentrate | 109,964 | 44.0% |
| Tailings / rejects | 130,036 | 14.5% |
Commercial Product Targets
| Parameter | Target | Importance |
|---|---|---|
| Cr₂O₃ | 40%–48% | Contained chrome |
| Cr/Fe ratio | Often >1.5 | Furnace economics |
| SiO₂ | As low as practical | Slag and power |
| P and S | Low and controlled | Buyer acceptance |
| Moisture | Below agreed maximum | Transport and stability |
| Variability | Narrow batch range | Pricing and burden control |
6. Plant Sizing Alternatives
Installed CAPEX by Plant Size
Scale Comparison
| Size | Annual ROM | Installed CAPEX | Best use |
|---|---|---|---|
| 30 TPH | 108,000–144,000 t/y | Pilot-commercial | |
| 50 TPH | 180,000–300,000 t/y | Recommended first module | |
| 100 TPH | 360,000–600,000 t/y | Multi-mine hub | |
| 200 TPH | 720,000–1.2M t/y | Large integrated producer |
Recommendation: Start with 50 TPH and size shared infrastructure for a second module.
7. CAPEX Estimate
Low
Installed plant
Base
Conservative planning basis
High
Higher infrastructure case
Decision Rule
Pre-FEED first
Competitive bids and contingency
Base CAPEX Breakdown
Low / Base / High
8. Processing OPEX
Low
Per tonne ROM
Base
Per tonne ROM
High
Per tonne ROM
Largest Drivers
Wear + Power
Ore variability and water recycle matter
Base OPEX Breakdown
OPEX Range
9. Water, Tailings, Power & Staffing
Process Circulation
120–250 m³/h
High recycle
Fresh Make-up
10–35 m³/h
≈50,000–170,000 m³/y
Connected Load
350–800 kW
Average 250–600 kW
Employment
35–65
Direct jobs
Tailings Options
| Option | Advantage | Constraint |
|---|---|---|
| Wet TSF | Simple | Water loss and footprint |
| Thickened tailings | Better water recovery | Pumping complexity |
| Dry stack | Maximum water recovery | High CAPEX |
| In-pit / co-disposal | Lower footprint | Mine-plan integration |
Operating Model
- Two 8-hour shifts plus maintenance.
- Backup generation for pumps and safe shutdown.
- Weekly and monthly planned maintenance.
- Batch laboratory control and umpire assays.
- Critical spares for pumps, screens and spirals.
10. Commercial Sensitivity
Downside / Base / Upside
| Variable | Downside | Base | Upside |
|---|---|---|---|
| Head grade | 22% | 28% | 34% |
| Recovery | 60% | 72% | 82% |
| Concentrate grade | 42% | 44% | 46% |
| Utilisation | 55% | 75% | 88% |
Management Sensitivities
| Sensitivity | Approximate effect |
|---|---|
| 5 percentage-point utilisation change | ≈16,000 t/y ROM |
| 5 percentage-point recovery change | Large impact on concentrate tonnes |
Obtain a binding term sheet covering specification, sampling, pricing, penalties, transport, payment security and off-spec treatment.
11. Regulatory & Compliance Pathway
Mining Title
Verify authority to mine and process owned or third-party ore.
Legal gateBeneficiation Approval
Obtain written approval for the exact plant and product scope.
Product-specificESIA & Effluent
Complete environmental and effluent licensing.
Before implementationWater Allocation
Secure ZINWA or Catchment Council agreement.
Critical pathMMCZ Registration
Register production, sales and sampling controls.
Commercial prerequisiteCustody & Weighing
Use auditable weighbridge, sampling and stock controls.
Control systemRegulatory warning: A wash plant does not automatically create a right to export concentrate. Obtain a current written Ministry/MMCZ position before committing capital.
12. Implementation Schedule
| Stage | Timing | Main work | Gate |
|---|---|---|---|
| Ore and title screen | Month 0–2 | Sampling, title, logistics, buyer discussions | Representative feed and clean rights |
| Laboratory testwork | Month 2–4 | Mineralogy, sizing and gravity tests | Target grade and recovery |
| Pilot qualification | Month 4–6 | Bulk sample and buyer testing | Accepted product and mass balance |
| Pre-FEED | Month 5–8 | Layout, water, tailings, power and civils | No fatal flaw |
| Permits & contracts | Month 6–10 | ESIA, water, Ministry/MMCZ and offtake | Written approvals and binding route |
| Tender & financing | Month 8–11 | Competitive bids and financing | CAPEX approved |
| Construction | Month 11–17 | Civils, erection and commissioning | Performance test |
| Ramp-up | Month 17–20 | Campaign control and optimization | Three stable months |
13. Final Recommendation
Proceed Now
Approve a six-month validation phase: sampling, mineralogy, pilot gravity testwork, buyer qualification, water/tailings studies and a product-specific regulatory opinion.
Do Not Approve Yet
Do not approve EPC until buyer specification, economic recovery, water, permits, offtake and funding are secured.