An innovative high gradient permanent magnetic separator (referred here as ZCLA HGPMS) was developed for recovering weakly magnetic minerals. Effect of key operating variables on the separation performance of a full-scale ZCLA HGPMS for recovering ilmenite from Pan Steels Midi Concentration Plant was investigated. Results indicated that the rotation speed and slope of the separating cylinder played a major role in enhancing the concentrate grade and titanium recovery. A titanium recovery of 80.8% with a concentrate grade of 19.6% was obtained by ZCLA-Phi 500 x 400 HGPMS at 7.0 t/h feed volume. While the ZCLA-Phi 950 x 1800 HGPMS recovered of 77.5% at a concentrate grade of 19.5% at 30 t/h feed volume. These results outperformed the vertical ring high gradient magnetic separator installed in the plant due to achieving higher separation efficiency through containing and no separation matrix that can clog while utilizing less energy all reason why the ZCLA HGPMS was developed. (C) 2014 Elsevier Ltd. All rights reserved.