Heavy Minerals Sands

About

Heavy mineral sands are rich sources of valuable minerals such as ilmenite, rutile, zircon, and monazite, which are essential in various industrial applications.

In the early 2000s, the heavy mineral sands industry was characterised by stable production levels, primarily dominated by operations in Australia and South Africa. These regions benefited from extensive ore reserves and well-established mining infrastructures.

However, as emerging economies, particularly in Asia, began to industrialise rapidly, the demand for minerals like ilmenite and rutile surged. These minerals are primary sources of titanium dioxide (TiO₂), a pigment extensively used in paints, plastics, and paper due to its brightness and opacity. The construction boom and increased manufacturing activities in countries like China and India significantly contributed to this heightened demand.

Zircon, another critical mineral derived from heavy mineral sands, saw its demand escalate with the growth of the ceramics industry. Zircon's high melting point and resistance to corrosion make it indispensable in producing ceramic tiles and sanitary ware. The urbanisation trends in developing nations led to a robust expansion of the ceramics market, thereby amplifying the need for zircon.

The supply side, however, faced challenges in keeping pace with this increasing demand. Environmental regulations became more stringent, particularly in traditional mining hubs, leading to increased operational costs and, in some cases, mine closures.

Ilmenite

Ilmenite is the main source of titanium dioxide which is used in paints, fabrics, plastics, paper, food and cosmetics.

Zircon

Zircon is used in ceramics, furnace linings and foundry bricks

Rutile

Rutile is the most common form of titanium dioxide which is used as a source for titanium metal. It is also used for paint pigments, glass and ceramics.

Monazite

Monazite is used in a variety of renewable energy applications such as solar panels. battery storage and wind turbines.

Technical Advancements & Geopolitical Factors

Technological advancements have also played a pivotal role in reshaping the heavy mineral sands sector. The development of more efficient extraction and processing techniques has enabled the industry to tap into lower-grade deposits that were previously considered uneconomical. These innovations have not only expanded the resource base but also reduced the environmental footprint of mining activities. Companies have invested in research to improve beneficiation processes, enhancing the quality of extracted minerals and ensuring compliance with environmental standards.

Geopolitical factors have further influenced the sector's dynamics. The concentration of heavy mineral sands production in a few countries has led to supply vulnerabilities, prompting importing nations to diversify their sources. For example, the United States has been assessing the extent of heavy mineral sand resources within its borders, particularly in the southeastern regions, to reduce reliance on foreign imports. Countries in Africa, including Malawi, are seeing an increase in HMS exploration and development.

Mineral Sands in Malawi

In addition to the Chilwa Critical Minerals Projects, there are several other mineral sands projects in Malawi, at various stages of development.
Sovereign Metals owns the Kasiya Rutile-Graphite with a mineral resource of 1.8Bt at 1.0% rutile and 1.4% graphite for 17.9Mt contained rutile and 24.4Mt contained graphite.

In the Manchogi District, Chinese company Mawei Mining holds the Makanjira Heavy Mineral Sands Project. The project has a mineral resource of 354 million tonnes containing ilmenite, magnetite, zircon, rutile and monazite.

The Tengani Heavy Mineral Sands Project, located in Nsanje District, is another significant venture targeting the extraction of rutile and ilmenite.
Additionally, the Kanyika Niobium Project, managed by Globe Metals & Mining Ltd., focuses on niobium extraction but also involves the recovery of zircon, a valuable heavy mineral. Situated in the Northern Region's Mzimba District, the project boasts estimated resources of 60 million tonnes.