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Acceptable zircon for composite formulation in the aerospace industry requires that the mineral contains a minimum of 65% zirconia (ZrO₂). Despite having vast deposits of zircon, Nigeria’s aerospace industry has historically relied primarily on imported mild steel tubes for solid rocket motor cases (SRMCs) construction, resulting in three major challenges: low strength-to-weight ratio, pressure, and temperature containment. In this study, the Arikya zircon deposit located in northern Nigeria was investigated with the aim of upgrading low-grade zircon ore using magnetic and gravity separation processes for use in composite formulation for SRMCs. The dry high-intensity magnetic separator (DHIMS) produced a ZrO₂ grade of 52.48%, recovery of 57.99%, and an enrichment ratio of 0.78 with a separation efficiency of 0.56, while the air-floating separator (AFS) generated the highest of 65.52% ZrO₂ grade with 70.81% recovery and enrichment ratio of 1.25 with a separation efficiency of 0.25. The ZrO₂ content increased from 40.77 to 65.52% after beneficiation. Iron oxide and titanium dioxide contaminants at 0.73 and 0.83% were reduced to 0.66 and 0.54%, respectively, while the specific gravity increased from 4.4 to 4.6 g/cm³. The ZrO₂ content and specific gravity were improved to the minimum standard specified for zirconia-reinforced composite application and competed effectively with industrially/globally accepted zircon. These results demonstrated the efficacy of combining DHIMS and AFS to upgrade the low-grade zircon ore from Arikya, Nasarawa State.