Coal Beneficiation
GRAVICON designs and supplies turnkey modular beneficiation complexes for processing thermal coal, coking coal, and anthracite with capacities ranging from 25 to 400 t/h. These complexes provide the full functionality of a conventional coal preparation plant while significantly reducing capital expenditure, operating costs, and implementation time. Typical project execution takes 6–8 months, with a required operating crew of 4–5 persons per shift, average energy consumption of 1.2 kWh per ton of feed, and circulating water volumes limited to 2 × 300–500 m³ within a fully closed water–slurry circuit. Among all widely used coal beneficiation methods—hydraulic jigging, flotation, heavy-media separation, and pneumatic separation—hydraulic jigging remains the most balanced solution for modular plants installed directly at the mining site or as a replacement for obsolete facilities, due to its low processing cost, environmental compatibility, moderate CAPEX, stable concentrate quality, and low sensitivity to feed properties.
The GRAVICON engineering team includes specialists who developed the industry-standard OM and MO series jigging machines, many of which became de facto benchmarks across the former USSR and later Kazakhstan, Russia, and Ukraine. Modern GRAVICOM jigging systems process feeds with ash content of 28–30% and clay content of 10–15%, achieving concentrate ash values of 6.9% (–3 mm), 8.1% (+3–10 mm), and 9.2% (>10 mm) in industrial operation. Compared with alternative technologies, flotation requires 5–7× higher CAPEX and 2–3× higher OPEX, uses chemical reagents, and demands large installation areas; heavy-media separation consumes 4–5 kWh/t, requires up to 15 operators per shift, continuous magnetite replenishment, and has payback periods of 3–4 years; pneumatic separation is limited by feed moisture (< 5%), reduces ash by only 5–10% per pass, and cannot produce low-ash concentrates. In contrast, GRAVICON modular complexes reduce project timelines from 3–4 years to 6–8 months, lower CAPEX by 5–7 times, and cut operating costs by 2–3 times, delivering typical concentrate ash levels of 12–16% for thermal coal, 7–10% for coking coal, and 4–8% for anthracite, with full adaptation to site-specific infrastructure and resource constraints.
Iron Ores Beneficiation
Advanced gravity solutions for higher iron content and lower losses.
Gravicon designs and delivers modular beneficiation plants for a wide range of iron ore types. Our gravity-based systems combine jigging and classification technologies to efficiently separate ore by density, maximizing metallic recovery with minimal water consumption.
Key Advantages:
- Accurate density separation for high-grade concentrate
- Low water usage – efficient hydraulic systems
- Ease of operatio, minimal maintenance and quick training
- Fast integration, plug-and-play modular setup
Each configuration is optimized to the specific feed characteristics and processing goals, ensuring consistent concentrate quality and yield.
Our technology relies purely on physical density separation, not chemical reagents.
That means stable, environmentally safe operation with low operating costs and no dependence on consumables.
Before project launch, our engineers conduct detailed feed analysis to tailor the process design.
When standard configurations don’t fit, GRAVICON develops customized solutions, fine-tuned for maximum metal recovery and optimal concentrate quality.
Manganese Ore Beneficiation
In the late 1990s, GRAVICON engineers, in close cooperation with leading beneficiation specialists of the Marganets Mining and Processing Plant, developed and subsequently modernized moving-sieve jigging technology for manganese ore beneficiation. Industrial operation demonstrated a separation factor approximately 30% higher than that of conventional jigging machines, resulting in significantly improved quantitative and qualitative performance. The solution proved so effective that the equipment fleet at Marganets GOK was continuously expanded and renewed over the following years. Further modernization included replacement of the pulsation mechanism, which substantially increased operational stability, and development of a new moving-sieve jig with electric drive, eliminating the need for high-pressure compressed air (6 bar) required by traditional designs. These upgraded machines have been successfully applied not only to manganese ores, but also to alluvial deposits under African operating conditions, including projects in Liberia and Guinea.
GRAVICON moving-sieve jigs operate on manganese ores in Ukraine and the Republic of Kazakhstan, where, at the initiative of local process engineers, the machines were further improved by introducing elevator-free discharge. Eliminating bucket elevators—known for high cost, maintenance complexity, and frequent replacement of guides—significantly increased reliability, reduced operating expenses, and shortened maintenance downtime. At the same time, laboratory beneficiability testing remains a critical prerequisite for manganese projects. A representative case occurred in 2008 during evaluation of ores from the Shkmeri deposit (Georgia): despite visual similarity to successfully beneficiated manganese ores and extensive sampling from 55 drill holes, test work showed virtually no layer separation, with concentrate Mn content of only 21%, exceeding tailings by just 0.5–1%, i.e. within statistical error. Detailed analysis confirmed extremely fine and uniformly distributed Mn inclusions, rendering beneficiation economically unjustified for those areas. For this reason, GRAVICON conducts mandatory laboratory studies to assess separation efficiency, expected industrial performance, CAPEX, and processing cost, and designs site-specific technological flowsheets, including treatment of low-grade ores and dumps, strictly based on measured beneficiation feasibility.
Gold Beneficiation
High-efficiency gravity recovery for fine and ultra-fine gold, no reagents, no compromises.
GRAVICON technologies enable effective recovery of gold not only from placer and technogenic materials, but also from refractory, sulfide, and fine-grained ores, reducing the volume of subsequent processing and increasing concentrate grade.
Our hydraulic jigging systems deliver exceptional separation precision and minimal losses, ensuring consistent concentrate quality. Each module is designed for durability, mobility, and easy integration into any production circuit.
Key Advantages:
- Reduced volume of secondary processing
- Higher gold content in concentrate
- Minimal metal losses
- Compact, mobile configurations
GRAVICON develops gravity separation systems based on proven hydraulic principles.
Each solution is engineered with a fully closed water-and-slurry cycle: reliable, safe, and efficient.
Our technology Ideal for:
- Primary (hard rock) deposits
- Alluvial and placer deposits
- Technogenic waste and tailings
- Legacy dumps and old mining sites
Our closed-loop water circuit keeps 100% of the process within a self-contained system.
The process water is continuously purified and recirculated, drastically lowering environmental impact and making GRAVICON plants ideal for arid or remote areas.
We don’t sell standard “off-the-shelf” equipment, we deliver engineered solutions.
Every GRAVICON installation starts with detailed laboratory analysis of your ore. When necessary, custom modifications are designed to achieve maximum recovery and purity, even from clay-rich or ultra-fine ores.
Diamond Beneficiation
Based on extensive operational experience in both Yakutia (Republic of Sakha) and African alluvial deposits, GRAVICON designs and supplies diamond beneficiation solutions ranging from standalone jigging machines with superimposed oscillation systems to modular processing complexes. Jigging units are supplied with capacities of 10–100 t/h, while modular alluvial diamond plants are designed for 10–50 t/h. Two such modular complexes have been successfully engineered and commissioned in Guinea and Liberia, including configurations for shore-based installations as well as systems mounted directly on dredges, allowing flexible deployment under varying geological and hydrological conditions.In addition to gravity separation, GRAVICON engineers, in cooperation with the Yakutniproalmaz Institute, developed the SL-series grease (adhesion) separators in 1989, with the first prototype installed at the Aikhal Mining and Processing Plant. These separators are applied at the final upgrading stage of diamond-bearing ores, utilizing differences in surface wettability between diamonds and gangue minerals. A key innovation—later patented (RU Patent No. 2038852)—was the implementation of forced oscillations of the grease belt, achieved by rigidly coupling the driven drum axis to a vibrator mounted on dampers with vertical mobility. Industrial trials conducted in 1991 defined optimal vibration frequency and amplitude and confirmed a substantial increase in recovery of oleophilic particles. Continuous modernization has led to the current SL-05M, SL-10M, and SL-20M models, providing feed capacities of 3–10 t/h, equipped with modern PLC-based automation and operator interfaces, ensuring stable performance and high recovery efficiency in diamond concentration circuits.