Tungsten recovery is increasingly influenced by how well a plant captures fine, high-density particles. Conventional gravity equipment such as shaking tables and spirals can still play a role in some circuits, but they often become less effective as particle size decreases. For projects focused on maximizing recovery and reducing losses to tailings, Falcon C offers a more modern and more efficient approach.
Falcon C Concentrator
What Is Falcon C?
Falcon C is a multi-stage gravity concentrator (the “C” stands for continuous) designed to operate at high centrifugal force, up to 300 G’s. This allows it to recover fine tungsten particles that conventional low G-force equipment may fail to capture. The result is a gravity separation step that is better suited to the realities of modern tungsten processing, where recovery in the fines can have a major impact on overall plant performance.
No Fluidization Water and High-Solids Concentrate
One of the key advantages of Falcon C is that it operates without fluidization water, unlike some competing technologies. This simplifies plant design and contributes to the production of a high-percent-solids concentrate. In most applications, Falcon C concentrate is typically in the range of 65% to 75% solids, which means it can be directed straight to regrind or adjusted easily to the required density for the next stage simply by adding water. In many cases, no separate dewatering step is required.
Operating Flexibility and Circuit Integration
Falcon C also provides flexibility in how the circuit is operated. By adjusting operating air pressure, the mass yield to concentrate can typically be controlled from about 1% to 40% of the feedrate.
In a tungsten flowsheet, Falcon C can be positioned in several high-value locations. It can be applied on classified fine feed as a primary gravity recovery stage, downstream of spirals to scavenge fine tungsten losses to the spiral tails, or on shaking table tailings where valuable dense mineral is still being discarded. It can also be used on flotation tailings to recover tungsten not captured upstream, or in retreatment circuits for historical tailings processed with older low G-force technologies.
Falcon UF for Ultra-Fine Tungsten
For ultra-fine tungsten streams, Falcon UF can also be considered. The “UF” stands for ultra-fine, and the unit is intended for applications where the feed particle size is -38 microns. Falcon UF provides an additional opportunity to recover ultra-fine, high-density particles that may be beyond the practical recovery range of conventional gravity equipment, making it a useful option where very fine tungsten values are present.
Design Studies and Flowsheet Optimisation
During scoping, prefeasibility, and feasibility studies, engineering firms have the opportunity to evaluate where Falcon C or Falcon UF can add the greatest value within the proposed flowsheet. When incorporated early in the design process, these units can improve projected recovery, reduce fine tungsten losses, simplify downstream handling, and support a more robust and modern process design.
Evaluating Benefits with the Falcon L40 Test Unit
A common question in project development is how to determine the benefit of Falcon C or Falcon UF in a circuit. The answer is testwork using the Falcon L40 test unit. With as little as 5 kilograms of representative sample, it is possible to assess performance, understand recovery potential, and identify the most effective location for Falcon technology within the flowsheet.
Falcon L40 Test Unit Scheelite in Falcon Under UV Light
Modern Gravity Solutions for Tungsten
As tungsten projects move toward finer liberation sizes and tighter recovery targets, gravity circuits must evolve accordingly. Falcon C and Falcon UF give project developers, engineers, and plant operators practical options to strengthen fine and ultra-fine particle recovery while maintaining operational flexibility. For any operation seeking to modernize its tungsten flowsheet, both technologies deserve serious consideration as part of the core recovery strategy.
Further Information
For more information about Falcon C and Falcon UF applications or testwork, visit seprosystems.com or contact your local Sepro office.
In addition, The Falcon C gravity concentrator has demonstrated significant benefits in upgrading lithium clay material from different projects. The recent testwork for Ioneer’s Rhyolite Ridge project indicates that using this technology prior to acid leaching can greatly improve lithium grade by rejecting gangue material, thereby increasing lithium yield per unit of acid consumption.
“Ioneer Announces Results of Initial Upgrading Testwork Demonstrating Growth Optionality”
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