Modular Beneficiation Complexes
for mineral deposits and technogenic materials worldwide.modular beneficiation complexes, GRAVICON has been engineering and delivering 22 yearsFor more than
Our systems are designed for coal, ferrous and non-ferrous ores, metallurgical and ferroalloy slags, coal waste dumps, and other deposits suitable for gravity separation — transforming low-grade or waste materials into commercially valuable products.
The core advantage of GRAVICON modular complexes lies in their high separation efficiency combined with deployment flexibility. Plants can be installed on unprepared open sites directly next to the feed source, operate in fully automated mode, and require relatively low energy input — forming a complete turnkey processing solution with minimal infrastructure demands.
Implementation, Operation & Resource Efficiency
Manufacturing of a modular complex takes up to 11 months, while installation is performed in parallel. Foundation works can begin 2–3 weeks after contract signing, and the total manufacturing and installation period typically amounts to 10–11 months, followed by commissioning, staff training, and achievement of guaranteed performance parameters.
GRAVICON complexes operate with a fully closed-loop water and slurry circuit. Sludge is dewatered before reaching settling units, eliminating the need for conventional tailings facilities. Elevator-free discharge reduces circulating water volumes by tenfold, down to 500–1,500 m³, allowing compact water reservoirs to be placed within the plant structure itself.
In standard configuration, complexes operate 20 hours per day, 25–30 days per month, requiring only 1–2 days of preventive maintenance. In temperate climates, operation is possible for up to 10 months per year without additional insulation. Continuous water circulation allows stable operation down to approximately –10 °C, while year-round operation is achieved using fast-assembly enclosures.
Each shift is обслуживается 4–6 operators, depending on plant capacity.
Energy Consumption & Economic Performance
Depending on configuration, installed electrical power ranges from 50 to 400 kW, with water consumption of 5–30 m³/h. Average energy demand is 1.2–1.6 kWh per ton of feed, while water losses carried with moist product amount to 3–7% of feed mass.
Thanks to modular scaling and optimized CAPEX, payback periods typically range from 2 to 8 months. Increasing capacity significantly shortens payback time, as doubling throughput raises capital and operating costs by only 30–40%. For example, a 100 t/h complex reaches payback approximately three times faster than a 50 t/h plant processing the same material.
In high-value applications, payback can be exceptionally rapid — a 25 t/h complex for lead-bearing waste achieved full return within three weeks after commissioning.
Advanced Moving Sieve Technology
In 2020, GRAVICON introduced a new generation of jigging technology based on a dynamic moving sieve with electric drive. This solution doubled throughput per square meter of screen area while improving separation quality.
The technology operates with zero air consumption and requires less than 0.8 kWh per ton of feed for the entire complex, including pumps, conveyors, and dewatering equipment. Such efficiency allows a 50 kW diesel generator to fully power a 50 t/h beneficiation complex (excluding crushing), making the system ideal for remote locations.
Factory-assembled modular delivery, pre-installed cabling and automation, and foundation-free installation reduce on-site монтаж from 1–3 months to just 5–7 days. Circulating water volumes are reduced 5–7 times compared to classical plants and 1.5–2 times compared to previous moving-sieve designs — for a 50 t/h complex, only three 250 m³ tanks are required instead of 5,000–10,000 m³ in conventional facilities.
Scalability, Applicability & Reliability
The technology processes material up to 50 mm, covering approximately 95% of gravity jigging applications, including coal, manganese and iron ores, technogenic slags, and diamonds. Larger size classes (50–150 mm) are addressed using GRAVICON air-pulsated jigging solutions.
Each project includes laboratory testing, custom equipment adaptation if required, full structural, hydraulic, and electrical design, manufacturing with quality control, supervised installation, commissioning, and personnel training.Decades of successful operation on diverse materials — from coal and ferroalloys to diamonds and tantalum-niobium ores — have confirmed the reliability of GRAVICON complexes. Many clients expand production by installing 2–4 additional complexes within 2–5 years, reflecting both technical stability and economic efficiency.