TOMRA Sorting Solutions

The underground X-ray Transmission (XRT) sorting pilot plant at the Zielitz mine, developed by TOMRA in collaboration with K+S, sets a new benchmark for efficient, sustainable potash mining. The pilot project, which has been running since 2022, has successfully addressed its main objective of removing barren waste underground, with the potential of reducing stockpiling and improving ore grade of hoisted material through the shaft, while enhancing overall operational efficiency. The project is ongoing, exploring ways to optimize the separation performance, increase throughput and implement the new technology into the mine planning process.

TOMRA Mining and K+S Minerals and Agriculture have reached a major milestone in their ongoing technological collaboration at the Zielitz mine in Germany with the successful underground sorting pilot plant for rock salt pre-separation. The project aims to minimize stockpiling, reduce the bottleneck at the mineshaft, and accommodate further mine expansion. The underground pilot plant is equipped with a TOMRA XRT sorter specially adapted to achieve K+S’s objectives – a unique solution specifically developed for the mine’s conditions and requirements.

This pilot project is the latest development in the long-standing collaboration between TOMRA and K+S, Europe’s leading salt producer and a global supplier of potash minerals. Their collaboration began in 1998, when the first TOMRA color sorter was installed at the Braunschweig-Lüneburg site at Grasleben. Over the years, the two companies have worked together on numerous projects and conducted extensive testing for various plants.

The underground mining challenge at Zielitz

K+S initiated the project as part of its focus on identifying practical, long-term solutions to improve sustainability and enhance productivity in its production and supply chains. The company partnered with TOMRA to explore ways of removing barren waste underground, significantly reducing stockpiling – hence reducing the mine’s environmental impact – and improving grade through the shaft.

“The handling of backfill has been an important issue in mining for decades. The ever-increasing demands of deeper and more complex deposits, the economic necessity for economies of scale and increasing environmental regulations must be met. The lean manufacturing approach of removing worthless minerals from the material stream as early as possible and further processing the valuable minerals in a concentrated form promises numerous advantages,” said Dr. Isabell Pfaffe and co-authors in a recent technical paper on the project.

The sorting plant was installed underground and commissioned in 2022. It features TOMRA’s XRT technology to identify and remove waste material – predominantly halite (NaCl) – with a potassium (K₂O) content below 2%.

By sorting the mined material underground to remove waste material and redirect parts of it for backfill, the pilot plant successfully addresses the three key challenges at the Zielitz site. The first one is stockpile reduction: as the large quantity of stockpiled material implies a major environmental protection effort. Through this project, K+S aims to find a solution to reduce the amount of barren material going to the stockpile as much as possible. The second is the bottleneck at the mineshaft: the main shaft hoists up to 45,000 metric tons per day, leaving no capacity for future expansion or return of processed waste underground. Finally, the project aims to resolve infrastructure constraints in view of a future mine extension planned over 40km, as there is no transport capacity or facilities to return processed waste as backfill into the mined-out areas.

Innovative approach and collaboration for a custom solution

For the Zielitz pilot project, TOMRA developed a unique solution based on a TOMRA COM XRT 2.0 1200 sorter featuring a sensing system adapted with setup and algorithms specially designed to achieve the goals set by K+S. The process begins with a feed system equipped with an adjustable flow divider at the main belt, which directs the raw salt feed to a double-deck vibration screen. The material is separated into defined size fractions, and the oversize and undersize fractions are returned to the main belt. The screen mats are interchangeable, allowing operators to try different size ranges. Once screened, the material is conveyed to the XRT sorter, which identifies potash rocks and removes unwanted sodium salt, which has a lower atomic density. The material identified as waste, with a potassium content below 2.0%, is diverted to a conveyor for backfill, while the concentrate is fed back to the main belt and from there to the shaft.

The installation of the pilot sorting system underground came with its own set of logistical challenges, most notably transporting the 18-ton XRT sorter through the shaft. The machine had to be carefully disassembled, lowered in components and reassembled onsite. TOMRA’s experience in the underground installation of sorting equipment was extremely valuable in successfully addressing this challenge together with the K+S personnel on site.

Impressive results and a vision for the next phase

The pilot project has successfully achieved all the objectives and has demonstrated that the TOMRA XRT sorter can successfully remove liberated halite. The pilot plant currently processes 50 tons per hour. It removes up to 50% of the feed as barren rocks underground, reducing the load to the shaft and allowing for an increase in mining capacity. Part of the barren waste, which has a potassium content below 2,0%, is used as backfill, reducing the amount going to stockpile. The remaining 50% of the feed, with a nearly doubled ore grade compared to the previous set-up, is blended into the main material stream to the shaft and hoisted to the processing plant.

With the successful results achieved by the pilot plant, the companies are looking at the next phase: exploring the scaling up of capacity and integrating TOMRA’s AI-powered technology, OBTAIN. This groundbreaking technology leverages Deep Learning to accurately identify the properties of each individual particle, even when they are touching on the belt – consequently, irrespective of the sorter’s capacity – achieving unparalleled precision and reliability. The result is single-particle precision in high-throughput ore sorting.

“Our vision of what can be achieved in a further stage, introducing more sorters with OBTAIN, is to sort as many tons of ROM as possible. The sorted waste, which is about half of the sorter feed, is used for backfilling, and the remaining amount of high-grade product is conveyed to the shaft,” explains Jens Michael Bergmann, Global Segment Manager Industrial Minerals at TOMRA Mining. “The aim is to further increase the K₂O grade at the shaft, which will mean hoisting the same tonnage but at a higher grade in the future. This will automatically reduce stockpiling, and the downstream processing steps at the surface installations will be more efficient due to the higher potassium grade of the hoisted raw material. We have started testing OBTAIN to see how much we can increase the sorter capacity while maintaining the same performance. The initial trials at the TOMRA test center have shown very promising results.”

The Zielitz pilot plant project has already attracted the interest of other mining companies with similar situations and environmental challenges. By combining advanced engineering and sensor technology, AI-powered data processing, TOMRA’s extensive experience and the solid collaborative relationship with K+S, this project demonstrates the transformative potential of sensor-based underground pre-separation.

Further information:
TOMRA
www.tomra.com/mining

A year after Pilbara Minerals commissioned the world’s largest lithium ore sorting plant, TOMRA Mining’s sensor-based sorting technology is delivering measurable value at the Pilgangoora Operation in Western Australia, contributing to the strongest quarterly production of FY25, significantly reduced costs, and enhanced resource utilization.

Powered by TOMRA Mining’s advanced sensor-based sorting technology, the Pilgangoora Operation has achieved impressive results, boosting production, reducing costs, and unlocking value from previously uneconomical ore. In its June Quarter FY25 results, Pilbara Minerals reported a 77% increase in production volume and a 10% reduction in unit operating costs (FOB) compared to the previous quarter. These gains stem from the ramp-up of the P1000 expansion and the integration of TOMRA Mining’s cutting-edge sorting technology.

Commissioned in August 2024 as part of the P680 Expansion Project, the crushing and sorting plant is the largest lithium ore sorting facility in the world, with a capacity of more than 1,000 tonnes per hour. TOMRA Mining’s sensor-based technology enables early waste rejection, significantly improving lithium recovery and final product quality while reducing energy consumption and environmental impact.

“The June Quarter marked the strongest performance of the year, clearly demonstrating the impact that TOMRA’s technology can deliver at scale,” said Gavin Rech, Area Sales and Technical Manager Australia at TOMRA Mining. “By unlocking value from lower-grade contact ore previously considered uneconomical, the operation now accesses more lithia units from the pit, enhancing resource utilization and mine flexibility.”

The sorting plant successfully addresses a key challenge in lithium mining: managing spodumene ore within barren host rock. It includes 10 high-precision TOMRA sorters – 4 TOMRA COM Tertiary XRT for fines, 3 TOMRA COM XRT 2.0 for mid-sized particles, and 3 TOMRA PRO Primary Color for coarse-sized particles. By removing barren material upstream, the plant enhances the efficiency of downstream processes, reduces energy use by 8–15 GWh annually, and ensures consistent product quality.

This success is the result of several years of collaboration between TOMRA Mining, Pilbara Minerals and engineering partner DRA Global. The project was delivered on time and on budget, following extensive testwork at TOMRA’s Sydney Test Center that demonstrated the technology’s capability to deliver high lithium recovery and effective waste separation across varied ore domains.

This strategic choice supports Pilbara Minerals’ long-term goals of cost optimization and sustainable growth. The ore sorting facility boosts Pilgangoora’s production capacity and lays the foundation for future expansions under the P2000 project. As the lithium market evolves, the company is well-positioned to lead through innovation and resilience.

With the P1000 expansion now complete and the P2000 feasibility study underway, TOMRA Mining’s proven technology and industry-leading expertise continue to support Pilbara Minerals’ long-term strategy for scalable, cost-efficient and responsible lithium production.

Further information:
TOMRA
www.tomra.com/mining

Vertex Minerals (ASX: VTX) is revolutionizing gold processing at its Hill End project in New South Wales by integrating TOMRA Mining’s advanced LASER ore sorting technology. This strategic move enhances operational efficiency and aligns with Vertex’s commitment to environmentally sustainable mining practices.

A Historic Goldfield Meets Modern Innovation

Located approximately 200 km northwest of Sydney, between Bathurst and Mudgee, the Hill End project encompasses a significant portion of the historic Hill End goldfield. This region, part of the Eastern Lachlan Fold Belt, has historically yielded over 1.6 million ounces of gold and is renowned for producing large gold nuggets, including the famous Holtermann Nugget.

The project’s geology features gold mineralization associated with quartz veins within the Chesleigh Formation and Crudine Group. These characteristics make the ore amenable to gravity separation techniques, allowing for high recovery rates without the use of chemicals.

The Hill End goldfield is also the site of the discovery of the Holtermann Nugget, the largest single mass of gold ever found. Unearthed in 1872 at the Star of Hope Mine, this specimen weighed approximately 285 kilograms and contained an estimated 93 kilograms of gold. Although commonly referred to as a nugget, it was actually a gold-bearing quartz specimen. This monumental find brought international attention to the region and remains a significant part of Australia’s gold mining heritage.

“The reason why this site is so historically significant is that it was one of the first places where the gold rush started. They found this incredible deposit of high-grade gold, very significant for the Australian mining industry,” explains Roger Jackson, Executive Chairperson, Vertex Minerals. “Vertex decided to open up this mine because it was already permitted, it was a high-grade gold mine, and we could see an opportunity to have one of the best high-grade gold mines in Australia.”

“What excites me about this project is to work with a team like Vertex and this beautiful historic site, and mine in a more efficient and intelligent way,” says Gavin Rech, Area Sales and Technical Manager Australia at TOMRA Mining.

Integrating TOMRA’s LASER Technology

In pursuit of enhancing ore processing efficiency and reducing environmental impact, Vertex Minerals has incorporated TOMRA Mining’s LASER ore sorting technology into its processing workflow. This sensor-based technology enables precise separation of ore from waste rock, improving feed grade and reducing the volume of material processed downstream.

The integration of LASER sorting complements the existing gravity-based processing plant, which includes crushing, ball milling, and concentration equipment. By pre-concentrating ore before it reaches the mill, Vertex achieves higher throughput and lower energy consumption.

To evaluate the suitability of the Reward Gold Mine’s ore for sensor-based sorting, Vertex transported 160 kilograms of material to TOMRA’s test facility in Sydney. The testwork involved screening the sample to a 20–60mm size fraction and processing it through TOMRA’s LASER sorter, which targets quartz-rich particles associated with gold.

Test Results:

Size Fraction	Category	Au Grade (g/t)	Mass (kg)	Mass (%)
20–60mm	Feed	3.71	94	100%
20–60mm	Product	16.2	19.4	21%
20–60mm	Waste	0.46	74.6	79%

 

“The tests’ findings indicate a 337% increase in gold grade and a 79% reduction in mass, with minimal gold loss, demonstrating the technology’s effectiveness in upgrading ore prior to processing,” explains Gavin Rech.

“We can mine bigger stopes and then sort it all and still get the same gold back through the process plant,” adds Roger Jackson.

Environmental and Operational Benefits

The adoption of TOMRA’s LASER technology aligns with Vertex’s vision of producing “green gold.” By enhancing ore quality before processing, the company reduces the need for chemical treatments and minimizes tailings. The coarse liberation size of the gold also means less energy is required for crushing and grinding, further decreasing the environmental footprint. “The material discarded by the sorter is proper barren material that can be used as road base or aggregate and disposed of responsibly,” adds Gavin Rech.

“The TOMRA ore sorter has been a game-changer for this site,” says Roger Jackson. “We have reduced power, water and time we’ve got to run the plant because it’s so efficient in sorting out the waste from the gold ore.

Looking Ahead

With the successful implementation of TOMRA’s LASER sorting technology, Vertex Minerals is poised to increase gold production while maintaining its commitment to sustainable practices. The company continues to explore further innovations to optimize its operations and reduce environmental impact.

“It’s important that TOMRA is part of the industry change we’re seeing, with companies like Vertex stepping in to take an old traditional system and mine it in a more efficient way, with low energy, zero chemicals, no tailings dam. That’s something TOMRA definitely wants to be a part of,” concludes Gavin Rech.

Watch this video showing TOMRA Mining’s Laser technology at the Vertex mine

Further information:
TOMRA
www.tomra.com/mining

TOMRA Mining’s advanced technology and unique experience in designing and installing large-scale ore-sorting plants were key to the successful completion of the world’s largest lithium sorting plant. The sorting installation, part of Pilbara Minerals’ P680 Expansion Project, has a capacity of more than 1,000 tonnes per hour, and demonstrates the power of TOMRA’s cutting-edge technology to improve overall ore recovery and reduce energy consumption through early and effective waste reduction.

Pilbara Minerals, a major player in the global lithium supply chain, has successfully commissioned the world’s largest lithium ore sorting plant at its Pilgangoora Operation in Western Australia. Powered by TOMRA Mining’s cutting-edge sensor-based sorting technology, the facility breaks new ground in hard-rock lithium processing, improving lithium recovery and increasing final product quality, while significantly reducing energy consumption through the elimination of waste early in the process. The new facility is part of Pilbara Minerals’ P680 Expansion Project.

The large-scale project for the design and installation of the new crushing and ore-sorting plant was delivered on schedule, within the deadlines set by Pilbara Minerals.

The successful delivery hinged on the effective collaboration and coordination of the teams from TOMRA Mining, Pilbara Minerals, international companies involved in the manufacturing and shipping of components, and multiple contractors on the work site.

“The success of this project is a testament to TOMRA Mining’s collaborative approach and capacity to deliver innovative, large-scale, high-capacity sorting solutions tailored to the unique demands of our clients, providing continuous support from the testing and design phases right through to installation, commissioning, and beyond,” says Gavin Rech, Area Sales and Technical Manager Australia at TOMRA Mining. “What’s more, the scale and success of this plant have demonstrated to the mining industry the benefits and capacity of sorting.”

Successfully addressing a key challenge: processing ore

One of the challenges in lithium mining is managing spodumene ore whithinn barren host rock. These non-lithium-bearing materials, some with densities similar to lithium-rich spodumene, complicate traditional metallurgical methods and can reduce the efficiency of downstream processes.

TOMRA Mining tackled this challenge with its high-precision sensor-based sorting technology: 10 sorters — 4 TOMRA XRT COM TER for fines, 3 TOMRA XRT COM2.0 for mid-sized particles, and 3 TOMRA PRO Primary Color for coarse-sized particles.

The commissioning of the world’s largest lithium ore sorting plant has delivered a sorting capacity of 1,000 tonnes per hour. The facility’s ability to remove barren material upstream enhances the efficiency of downstream processes, reducing energy consumption by 8–15 GWh annually, and ensuring consistent product quality.

“The ore sorters enable a better utilisation of the resource as they remove contamination from the ore upstream,” explains Gavin Rech. “This means that the wet plant does not use energy, water, and reagents to process barren ore, and that the contamination doesn’t reduce the efficiencies and recovery of the downstream plant. In addition, our sorters’ high availability and efficiency ensure consistent quality feed for the processing plant.”

Collaboration: The Cornerstone of Success

The successful completion of this project owes much to TOMRA Mining’s collaborative approach, which emphasized partnership and adaptability throughout the process.

TOMRA’s involvement began in 2017 with geological assessments and bulk test work conducted at its Sydney Test Center. These tests validated the performance of the sorting equipment under operational conditions and formed the basis of the sorting plant design.

The TOMRA team worked closely with Pilbara Minerals and engineering partner DRA Global on every aspect of the project from equipment testing to plant layout and operational integration.

During installation and commissioning, TOMRA mobilized a global team of specialists from Australia, South Africa, Germany, and beyond to ensure the project met the deadlines. This effort culminated in a seamless ramp-up to full operation.

This hands-on support continues with a 24-month service contract, providing on-site support 7 days a week, 365 days a year to optimize sorter performance and address any operational challenges.

“The global collaboration on this project has been an excellent demonstration of the core TOMRA value set of Passion, Innovation, and Responsibility,” concludes Gavin Rech.

Further information:
TOMRA
www.tomra.com/mining

The Customer Survey, conducted for TOMRA Mining’s Service Team by market research company B2B Research, revealed a standout level of overall satisfaction with a remarkable average score of 6.3 on a 7-point scale and an outstanding Net Promoter Score of +57 – significantly higher than the typical scores in B2B sectors. This extremely positive feedback is a testament to the Service Team’s dedication, technical expertise and partnership approach to supporting its customers. It demonstrates the unique strength of TOMRA Mining’s Service as a key element of its success.

TOMRA Mining sees service as a critical element of its offer to mining operations and is constantly evaluating the best way to support its customers by listening to them. As part of this effort, it has engaged B2B Research, a reputed Business-to-Business market research company, to conduct a Customer Survey in 2018 and a second one in the first quarter of 2024 to assess the quality of its service and collect feedback from customers. The surveys covered the different aspects of TOMRA Mining’s service activities – from the back-office’s availability and the competence of its technical support team to the quality of work of its service engineers. The respondents represented a variety of roles within the customers’ organizations, including maintenance, operations, plant and process management, parts sourcing and service planning.

Outstanding customer satisfaction with TOMRA Mining’s Service Team

The recent survey revealed extremely high levels of satisfaction among its customers, with 93% of respondents being satisfied with the availability and competence of TOMRA’s technical support team and the quality of work and competence of its service engineers. Overall, the Service Team was awarded an average score of 6.3 on a 7-point scale, a further improvement on the already high score of 6.0 achieved in 2018.

The surveys also asked customers how likely they would be to recommend TOMRA Mining to calculate the company’s Net Promoter Score (NPS). Paul Walsh, Director at B2B Research, explains: “TOMRA Mining’s NPS (Likely to Recommend) increased from +38 in 2018 to a very strong +57 in 2024, which shows hard work and dedication from the Service Team. An NPS of +40 or above in a B2B industry is already considered high when most companies’ NPS ranges from +10 to +30. So, a really great achievement!”

Klaus Berns, Head of Service at TOMRA Mining, is delighted with the feedback: “The survey has shown an improvement in all areas of service and all regions. I am proud of this strong customer rating. It reflects the value our customers place on the passion and dedication of our Service Team, and the close communication we maintain with them. A very strong Service team, combined with expert advice from our Sales and Applications teams, and our exceptional technology and performance, are the key factors in gaining our customers’ trust and driving their choice of TOMRA. Our mission to deliver an extraordinary customer experience will continue!”

TOMRA Mining is constantly looking at ways to further improve its service to customers, listening to their feedback through surveys and the everyday contact of its team members. Over the last five years, it strengthened its team of field service engineers as well as the back-office support. “We expanded and trained our service team, ensuring we all share the mindset that puts the customer at the center of everything we do, prioritizing the principles that are important to them. This enables us to gather precise insights about their operation in a meaningful timeframe and develop packages that perfectly match their needs,” says Berns. The excellent feedback in this year’s survey is a clear recognition of the Service Team’s efforts to continuously improve and deliver the best possible experience.

TOMRA Mining’s unique service approach: beyond technical support, a true partnership

Service is a core part of TOMRA Mining’s business and is deeply interlinked with its Sales and Technology departments. It doesn’t stop when the equipment is installed, or a technical intervention is resolved: it is a partnership based on effective communication. “We are very close to our customers,” explains Berns. “Communication is key: we talk to them on a regular basis – weekly, monthly or quarterly, depending on the customer’s actual needs.”

This close communication enables TOMRA’s Service Team to identify opportunities for continuous improvement in customers’ operations. “We bring them our expertise when they are setting up operations, advising them on material preparation and how to operate the machines to get the best results. And then we go the extra mile: for example, our technical engineers talk to their staff and report back about possible improvements, and we can help the customer to address them.  Also, new technologies are constantly coming on stream. In the last two or three years our portfolio has been enhanced with great innovations, such as the new TOMRA ACT interface, the new fines ejection system that significantly reduces air consumption, and TOMRA OBTAIN. As new solutions become available, our service engineers can spot opportunities to further enhance our customers’ operations and we can start a discussion with the customer. This is where our close collaboration with our Sales and Technology teams comes in.”

A recent example of the benefits of TOMRA’s approach was when its Service Team visited a customer sorting iron ore in Brazil and saw that the input material had drastically changed since the previous visit a few months earlier. It suggested a change in the sorting approach, which doubled product output when implemented. “This is the kind of support that can only happen when you are in close contact with the customer,” comments Berns.

Customer proximity with strong backing from Headquarters

To maintain its close relationship with customers, TOMRA Mining has set up on each continent a self-sufficient Service Team that includes Service Management, Field Service, Field Application, and back-office functions and spare parts supply. They operate with the backing of the company’s headquarters in Germany, which provides advanced technical support, parts proposals and any other help they may need.

“Regular weekly communication between Headquarters and the regions ensures we are always aligned. It is extensive communication, but this effort pays off from a technical and commercial point of view,” explains Berns. “We deal with our customers directly across the globe. Regional proximity, local language, culture and mindset are crucial for us to deliver the best experience and ensure our customers’ major satisfaction. Our customers trust us to be easily accessible, to resolve any issues, and do it fast.” 

Taking service to a new level with digitalization

TOMRA Mining is always looking ahead at where opportunities to raise the level of service to its customers lie. “With the development of digitalization and Deep Learning, as more sorter data and analysis capability become available through our web-based portal TOMRA Insight, we see many ways to help our customers achieve better sorting performance, and higher equipment efficiency and availability,” says Berns.

“TOMRA Mining is already at an advanced stage in offering connectivity-enabled services through TOMRA Insight, and we in the Service team are working to further develop this area.  Our plans in the short term include a Digital Operations Center, which will open soon to provide continuous system monitoring for enrolled customers. Our approach to service is in constant evolution, taking in new technologies that become available, and anticipating the evolving needs of our customers,” concludes Berns.

Further information:
TOMRA
www.tomra.com/mining

The mining industry has an essential role to play in the modern world and its future. In its new brand video, TOMRA Mining outlines its mission to support the industry and enable a sustainable starting point for future businesses, industries and societies by harnessing its leading sorting technology and know-how to transform how natural resources are extracted and processed – Sorting tomorrow’s resources.

Minerals and metals are essential enablers of almost every aspect of our daily life – from the copper in our lightbulbs and electrical wiring to the steel and aluminium for our vehicles and machines; from the raw materials to build our houses and roads to the phosphates used for fertilizers in agriculture. The technology that has become an integral part of our daily lives depends on the rare earth elements, lithium and tungsten in electronics, batteries, and all the devices that have become indispensable, such as our smartphones and laptops.

Very importantly, minerals are critical to the energy transition because clean energy technologies require much bigger quantities than fossil-based ones. According to an IEA report, “a typical electric car requires six times the mineral inputs of a conventional car and an onshore wind plant requires nine times more mineral resources than a gas-fired plant.” These technologies are driving an increase in the demand for minerals such as lithium, nickel, cobalt, manganese and rare earths – a trend that is accelerating as the energy transition gathers pace. Recycling rates for these materials are low and even if they were to increase, recycling alone would not be able to meet the demand, so mining will continue to be the main supplier of these resources. Mining efficiently and sustainably is key.

“Mining is an essential industry enabling our modern world and faces the challenge of meeting the huge rise in demand driven by the energy transition with sustainably mined resources. As we look to the future, it’s clear that what we mine and how we process it must be transformed,” states Albert du Preez, Head of TOMRA Mining.

Meeting the surging demand for minerals with financially and environmentally sustainable mining

The mining industry faces the challenge of supplying the vast amounts of minerals that will be required to decarbonize the global economy while reducing its environmental footprint and ensuring its profitability. TOMRA Mining is already helping mining operations across the world maximize resource recoveries and minimize their impact on the environment with its sensor-based sorting technologies. It brings to bear its extensive knowledge of the different mineral resources and experience in developing industry-leading sorting technologies.

“At TOMRA Mining, we truly believe that our technology and innovation can transform the mining business and help future-proof the industry,” continues Albert du Preez.

TOMRA’s sensor-based sorting solutions can be used to eliminate waste effectively in the early stages of the process, so that less barren or low-grade ore is processed, with consequent cost savings. These technologies significantly reduce the amount of energy and water used compared to traditional methods like DMS (Dense Media Separation), while maximizing the efficiency and recovery of valuable ores. In addition, its sensor-based sorting technologies enable mining operations to extract value from existing stockpiles of contaminated rock as well as turning waste into certified clean aggregates, generating a new income stream. The benefits are efficient mining, lower costs, improved profitability and a reduced impact on the environment.

“As mining operations strive to meet the demand and ensure their profitability, the mining process will become more and more automated,” explains Kai Bartram, Global Sales Director at TOMRA Mining. “At TOMRA we have the knowledge to advise them on how to integrate our sorting technologies into their process to optimize its efficiency and reduce their running costs. We have built a strong track record in helping mines maximize their resource recovery while reducing their environmental footprint and ensuring their profitability, and we believe that we have a key role to play in the mining industry’s shift towards automation.”

“There is a solid business case for TOMRA sorters in the mining industry: they have proved to pay for themselves quickly through the increased efficiency and reduced costs they deliver. The environmental advantage is an important added value, as mines are increasingly under pressure to operate sustainably,“ adds du Preez.

Future-proofing mining: digitalization and Artificial Intelligence

Digital technologies are transforming mining, helping mines run their operations more efficiently and profitably. Digitalization has opened up opportunities with innovations such as the TOMRA Insight, the cloud-based data platform that turns TOMRA sorters into connected devices that collect valuable performance metrics from the materials they process. This enables mines to continuously monitor and optimize their sorting line’s output quality, as well as provide useful insights into their operation.

Artificial Intelligence (AI) has been operating in TOMRA’s sensor-based sorting solutions for many years, automating the process and improving the accuracy and efficiency of the sorters, playing an increasingly important role as the technology has developed. Most recently, TOMRA has opened a new era of sorting with its Deep Learning (DL) OBTAIN™ solution, which brings single-particle precision to high-throughput particle sorting. This technology also unlocks value for the mining operation with a wealth of extremely detailed and accurate data for better-informed decision-making.

“At TOMRA we are constantly exploring the potential of AI and DL to provide solutions for sorting applications that were previously impossible for sensor-based sorters or to improve further our existing technology to provide better customer support, deeper analysis of the sorted material, or data for predictive maintenance, for example,” says Stefan Jürgensen, Software Team Leader TOMRA Mining and responsible of the latest company launch OBTAIN^TM.

Enabling a sustainable starting point for the resources that will transform our world

As the mining industry faces the daunting challenge of supplying the vast amounts of metals and minerals the modern world will require, TOMRA Mining is ready to support it with its advanced sorting knowledge and technology.

“We see ourselves as the movers who lead the way with our resource knowledge and leading sorting technologies, the makers who transform how natural resources are extracted and mined sustainably, and the caretakers of our natural resources who work to maximize recovery and minimize environmental impact with our customers and partners. We believe that TOMRA Mining has a role to play in the future of mining, and have set ourselves a clear mission: to enable a sustainable starting point for the resources that will transform future businesses, industries and societies. We sort tomorrow’s resources,” concludes Albert du Preez.

Further information:
TOMRA
www.tomra.com/mining

Andrada Mining has purchased TOMRA XRT sorters as part of its expansion plans at the flagship Uis Mine in Namibia. The sorters feature TOMRA’s latest innovation launched earlier this year at the Mining Indaba exhibition: the groundbreaking OBTAIN™ software that leverages Deep Learning to bring single-particle precision to high-throughput particle sorting.

Andrada Mining, the African technology metals mining company, owns the open-pit Uis tin mine, which represents one of the largest tin reserves in Namibia. It is in the course of implementing expansion plans at the mine, which include introducing a pre-concentrating circuit of ore sorters with the aim of increasing tin concentrate from 1,500 to 2,600 tpa. It has purchased TOMRA COM Tertiary XRT sorters for the ore sorting pre-concentration circuit in the dry process section of the plant, expecting to increase the tin content of the feed to the wet processing plant by 50%.

A COM Tertiary XRT 1200 will be dedicated to the coarse size fraction. For the small particle sizes, two COM Tertiary XRT Fines sorters are equipped with the high-resolution TS100C ejection module, which delivers high precision in high-capacity applications. The module uses 90% less compressed air to eject the particles, reducing energy consumption dramatically and consequently significantly cutting operating costs while delivering a high-quality product.

These XRT sorters feature TOMRA’s groundbreaking AI-powered OBTAIN™ software which leverages Deep Learning to deliver single-particle precision in high-throughput ore sorting – an industry first. It uses a Neuronal Network to identify the properties of each particle accurately and independently of the sorter’s capacity, achieving unparalleled precision and reliability in detection and ejection. In addition to enhancing the sorters’ performance, taking capacity, quality and recovery to a new level, OBTAIN™ will provide Andrada Mining with a wealth of detailed and accurate data, which will help them optimize the process with better-informed decision-making.

Anthony Viljoen, Chief Executive Officer at Andrada Mining, said: “Andrada Mining is proud to partner with TOMRA, a market leader in ore sorting technology. TOMRA’s proven ability to adapt solutions for fast-growing companies like Andrada ensures a smooth and swift implementation process. TOMRA’s XRT sorters are a game-changer, combining high-tech sensors, powerful sorting valves, and industry-leading software for exceptional reliability. With TOMRA’s OBTAIN™ imaging software, we can boost production output while maximizing mineral recovery and ore quality which is a win-win for efficiency and earnings.”

Helga van Lochem, Area Sales Manager for Southern Africa at TOMRA Mining concludes: “We are excited about teaming up with Andrada Mining and helping them unlock value at their flagship Uis mine our XRT sorters,  the first to incorporate our OBTAIN™ Deep Learning feature unveiled just a few months ago. We will be at their side throughout the installation process and beyond, ensuring the sorters perform as required, meeting and even exceeding expectations.”

Further information:
TOMRA
www.tomra.com/mining

The Mothae mine, located in the Maluti Mountains of Lesotho is known to produce large, high-value diamonds which command the second highest dollar per carat for kimberlite diamonds worldwide. The company relies on TOMRA’s XRT sorting technology and digital solutions – the TOMRA Insight platform and TOMRA ACT user interface – to recover large unbroken diamonds from the mine with high sorting efficiency and high throughput, while benefiting from lower operational costs.

Global diamond producer Lucapa Diamonds owns 70% of Mothae Diamonds, an open-pit mine located in the diamond-rich Maluti Mountains of Lesotho, which started commercial operation in 2019 following the commissioning of its kimberlite processing plant. The mine is known to produce large, high-quality diamonds, and has had significant gem-quality recoveries including a 215 carat D-colour Type IIa, a 204 carat Type IIa, and rare pink, blue and yellow fancy-colored diamonds.

When planning the recovery plant, Mothae turned to TOMRA Mining for a solution: “We wanted to recover large diamonds at the highest sorting efficiency with the highest throughput, and TOMRA met Mothae’s requirements with its modern and innovative technology,” says Macobone Semelane, Recovery Superintendent.

The recovery plant operates two TOMRA COM Tertiary XRT 1200 sorters: one for fines from 10mm to 20mm, and the other for coarse materials from 20mm to 45mm. The ore extracted from the mine is treated through primary crushing, scrubbing and screening, then transferred to the recovery area: “That’s where the TOMRA sorters separate diamonds from the ore,” explains Kothalo Matoli, Recovery Mechanician. “TOMRA sorters are the best of the best. With them, we are able to recover large diamonds prior to secondary and tertiary crushing, hugely reducing the risk of breakages, and our throughput is high, with 98% efficiency guaranteed.”

TOMRA Insight with TOMRA ACT: unlocking the power of data

The two TOMRA XRT sorters at Mothae are connected to the TOMRA Insight cloud-based data platform that turns the machines into connected devices that generate valuable data and puts operators in control of the sorting process. They also feature the TOMRA ACT user interface, which facilitates the optimization of the workflow and improves productivity.

Macobone Semelane explains: “As a relatively small and low-grade mine, we are always investigating the latest technologies. With our sorters operating 24 hours a day, seven days a week, we were looking to maintain and upgrade our sorters to the latest compatible software and hardware.”

“We wanted a portal that is user-friendly so our operators can easily interact with the sorters. TOMRA ACT now provides clear visualization of events and alarms, and captures the images of the belt occupancy. It also shows the ejection activity.”

“TOMRA Insight has changed the way we are running our production because we can monitor our sorters remotely and we can access reports from both machines in one interface,” says Kothalo Matoli. “All the alarms and events are logged on the sorter in real time, enabling me to troubleshoot very fast. My troubleshooting skill has improved a lot.”

TOMRA Insight also stores and backs up all the data generated by the sorters so that the operator can analyze the complete history of each machine. “Digital data is crucial. TOMRA Insight has exceeded my expectations because I can access data whenever I want, wherever I am. I have at my fingertips the learnings about my sorters, their operation and maintenance. We can see the belt occupancy and our ejection rate, and understand if a machine is over-ejecting due to foreign objects in the material, for example. The utilization of the sorters has improved, enabling us to process more tons and recover more carats.”

“I can monitor the sorters’ operational and health status from the office or offsite. TOMRA Insight captures and compiles all the data in one interface, generating reports and data analyses, improving data management and analytics for better decision-making. With TOMRA Insight, I see advanced sorting solutions in the future and automated recovery plants,” adds Macobone Semelane.

Macobone Semelane is also very impressed with the support received from TOMRA: “The TOMRA team has been very supportive since day one and their service is outstanding.” Kothalo Matoli agrees: “They are always available whenever we need them. They help us remotely and if we need somebody on site, they are always ready to come.

Further information:
TOMRA
www.tomra.com/mining

The accelerating increase in global demand for copper, zinc and lead poses a challenge for mining operations:  increasing their efficiency and productivity to meet the demand while ensuring their profitability and sustainability. Sensor-based ore sorting can be an invaluable asset for optimizing the process and achieving this goal, as Rasoul Rezai, Global Segment Manager Metals at TOMRA Mining, explains.  

Sulfide minerals are the source of metals such as copper, zinc and lead, which have a key role to play in our modern lifestyle – with uses ranging from the energy supply, electronics and transportation to construction and infrastructure. The increase in demand for these three metals is expected to accelerate, driven by a variety of factors, such as infrastructure development, the rising demand for electronics and, very importantly, the transition to a low carbon economy.

In fact, they are among the critical raw materials required for the electrification of the economy, moving from fossil fuels to wind and solar power generation, and battery or fuel-cell electric vehicles (EVs). Copper is an essential driver of the energy transition for its uses in electrification, including the charging infrastructure for EVs and, according to a report by the International Energy Agency, the world will need between 1.7 to 2.7 times as much copper in 2040 as it produces today. The global zinc demand for renewable energy technologies is forecast to increase consistently to reach 364,000 metric tons in 2030, up from 109,300 in 2020, as stated in a Statista report.  The value of the global market for copper and zinc is expected to reach $394 billion and $49.6 billion respectively between 2027 and 2030. The lead market is also expected to flourish, driven by the growing demand for energy storage, the accelerating adoption of EVs, and integration of smart-grid technologies.

The next ten years will be decisive for the decarbonization of world economy, and mining companies face the challenge of supplying the raw materials such as copper, zinc and lead, which are critical to the process. This means finding ways of extracting these minerals as efficiently as possible to meet the booming demand, while maintaining their operation financially profitable and minimizing their impact on the environment.

The main sorting challenge with copper, zinc and lead sulfides: waste removal

When processing sulfide ores to extract copper, zinc or lead, the focus is on ensuring that the mill is always operating at full capacity. The challenge is to optimize the process by eliminating waste in the early stages and maintain a high recovery rate. This means that less barren or low-content rock will be processed, consequently increasing the metal content in the input of the mill. The result: significant cost savings and reduced environmental impact per produced ton-metal.

In the case of copper, the mineralogy and lithology of the ore will affect how effective sorting can be at removing waste. When sorting copper sulfides with a non-disseminated texture, the focus is on waste removal to maximize recovery. However, three quarters of global copper production come from porphyry deposits, where very small grains of the metal are disseminated, making detection particularly challenging. Zinc and lead sulfides present similar sorting challenges to non-disseminated copper, although the metal content in the mineral is typically higher, so the focus will be on waste removal while maintaining the recovery levels.

The technology to sort copper, zinc and lead sulfides effectively to optimize the process is available from TOMRA Mining.  Its industry-leading X-Ray Transmission (XRT) sensor-based sorting technology can effectively detect sulfides in mineralized run of mine material, as they carry elements with higher atomic densities than non-mineralized waste rocks. After crushing, the ore in a size range from +8mm to 80mm is fed into the sorters and the barren and low content rocks are eliminated, resulting in a higher head grade of the mill feed. In addition, the eliminated waste can be replaced in the mill with more upgraded sulfides, increasing the efficiency of the mineral process. However, in order to maintain the capacity of the mill, it is necessary to increase the amount fed to the crusher. This will have an impact on the mine and extraction planning. Due to the lower processing costs of sensor-based sorting, it is also possible to bring this in the calculation of the resource evaluation and the final pit design.

The solution: powerful, high-resolution, high-capacity XRT ore sorting 

TOMRA’s XRT sorters scan the individual rocks fed into the machine on a conveyor belt with overhead X-Ray sources. At the same time, detectors located inside the belt collect data from the ore. The position of sensors, close to the rocks, combined with the strong X-Ray power sources result in extra high-resolution images. This enables TOMRA’s XRT sorters to effectively process even most of the challenging porphyry copper disseminated deposits. Waste rocks are ejected by high-precision, fast pneumatic module, which adds to the sorter’s efficiency.

In copper sulfides with disseminated texture, a TOMRA XRT sorter can achieve an upgrade ratio of copper content in the mill feed ranging from 20 to 100%, while separating 20%-45% of mass as the waste material. With porphyry copper, the cut-off grade is typically 0.5%, but in view of the surging demand, it is now often as low as 0.2-0.3%. With TOMRA’s XRT technology, it is possible to achieve high recovery rates even at the lower grade, as shown by the tests conducted on run-of-mine samples from at OZ Minerals’ Antas Norte mine. The sorter demonstrated its ability to achieve recovery rates of at least 90% or reduce the waste grade down to 0.3% copper.

Heitor Mesquita Carmelo, Plant Manager at OZ Minerals Brazil, explains: “A bulk test was conducted to evaluate TOMRA’s XRT technology, and subsequently, the company decided to test it continuously in a pilot installation at the Antas Norte site. The results were consistent in both tests, demonstrating that the technology is effective for industrial application. TOMRA’s technology holds significant potential for OZ Minerals Brazil’s strategic plan, with the possibility of making deposits with lower ore grades viable, reducing operational costs, enhancing transportation safety for pre-concentrated ore, as well as decreasing the CO2 emission resulting from this activity.”

In lead and zinc sulfides, tests conducted by TOMRA have shown that it is possible to achieve an upgrade ratio of 2 to 3 times lead or zinc in the output of the sorter. Here the mineralization plays an important role and can dramatically affect the upgrade ratio.

TOMRA’s XRT sorter delivers multiple benefits for copper, zinc and lead mining operations, beginning with its uniquely high capacity, which can be as high as 150-200t/h per sorting width meter –  a Unique Selling Point of TOMRA’s which also meets the requirements for medium- and large-size operations.  The sorter’s operational efficiency can be further improved with TOMRA Insight, a cloud-based subscription service that turns the sorter into a connected device that generates process data. It enables mining operations to monitor and measure performance in real time and optimize the process as well as tracking faults to improve maintenance and keep the plant always operating at its best.

Another important benefit of the sorter is the capacity to lower operating costs through its efficiency and energy saving features such as its cutting-edge ejection module that uses compressed air to eject the particles – up to 80% less compared to other ejection systems – dramatically reducing energy consumption compared to conventional sorting machines.

Optimizing the process also reduces its impact on the environment. In addition, TOMRA’s XRT technology is a dry process, so that the overall use of water and chemicals is also reduced.

Testing and a customized approach are key to successful sorting

“In ore sorting, there is no one-size-fits-all solution,” explains Rasoul Rezai, Global Segment Manager Metals at TOMRA Mining. “You can’t buy and install a sorter ‘off the shelf’. Selecting mineral processing equipment such as a crusher or a screen, where the mechanical parameters and process related interactions and data evaluation are simpler, cannot be compared to choosing and operating a sorter. That’s why we need to look at each individual project.”

Testing plays a key role in identifying the most suitable sorting system: “In the majority of cases, we test ore samples from our customer’s mine because we need to understand the behavior of the material under the sensors to develop a tailored solution for each project.” adds Rasoul Rezai.

Having completed the tests at one of its Test Centers in Germany, South Africa or Australia, TOMRA provides the customer with a detailed technical report, discusses the flowsheet and how to integrate sorting in their existing plant, and review its effect on the downstream process. Customers can choose to join TOMRA’s technical team at their nearest Test Center, attend the test virtually, or view a video. When making the decision, they are also able to see one of the many TOMRA sorters currently operating in mines across the world.

“In some cases, having completed the tests, we may find that sorting is not a suitable solution,” adds Rasoul Rezai. “For example, there are some porphyry deposits where copper is in very small grains and very disseminated, with all of the rock containing small amounts of the metal, but above the cut-off grade. With no barren rock to eliminate, the ore is not sortable. Cases like these highlight the importance of testing.”

Further information:
TOMRA
www.tomra.com/mining

QMAG Pty Limited, part of the Refratechnik group, owns the Kunwarara deposit of cryptocrystalline magnesite – one of the world’s largest – located in Central Queensland, Australia. It mines the ore using and open-pit method and processes it into high quality fused (FM), dead burnt (DBM) and caustic calcined (CCM) magnesia products at the nearby Parkhurst facility. It supplies the refractory, chemical, agricultural, environmental and hydrometallurgical sectors with its high-quality magnesia products.

QMAG was an early adopter of sensor-based ore sorting, and is in fact the longest continuous user of this technology in Australia, having installed its first Ultrasort laser machine in 1994 and a second one a few years later. The ore was fed through a Dense Media Separation (DMS) system, using drum and Cyclone separators, then the Ultrasort sorters removed the sandstone, gravel and dark coloured dolomite from the product.

After over 22 years in operation, the Ultrasort sorters were becoming antiquated and could no longer be supported. “It came to a point where the Ultrasort sorter was removing the dolomite, but the background lime was still quite high, and this was not giving us the best opportunity to create the product that was required by the Parkhurst processing plant,” explains Josh Dawson, Production Superintendent at the QMAG mine. A new solution was needed, and TOMRA suggested its X-Ray Transmission technology.

TOMRA’s XRT sorter halves heavy media usage and extends the life of the deposit

In 2016, a TOMRA XRT sorter was installed as a stand-alone plant on site. “It was a trial that management at the time got very excited about: they could see that this could be the future moving forward,” says Josh Dawson. “It was a success story: we could now process very high calcium content material that we couldn’t do as effectively with the DMS or laser sorting equipment.  This gave the ability to produce much lower calcium content magnesite grades suitable for our customers,” adds Alex Padya, Process Engineer.

In view of these results, in 2018 the XRT machine was moved into the sorting plant, where it replaced the remaining Ultrasort that had reached the end of its life, and the DMS drum was decommissioned: “With this decision, we halved our heavy media usage in that part of the circuit and went to a standalone XRT circuit,” says Josh Dawson. As a result, the XRT circuit has delivered significant savings in energy and water usage, and increased the plant’s efficiency.

The TOMRA XRT sorter has exceeded expectations, as Josh Dawson explains: “When we originally made the business case, we thought that it would be used to upgrade the lower quality magnesite ores to produce grades suitable for agricultural purposes, while the heavy media cyclones would make our lower silica materials for other applications. However, by collaborating with TOMRA to optimize the performance of the XRT unit, we can now turn agricultural products into much higher grades required by the Parkhurst processing plant.”

TOMRA’s XRT sorter has also extended the life of QMAG’s deposit: “We were at the point where we thought that a lot of our ore body wasn’t going to achieve the grade for some of our lower end products. The TOMRA XRT machine proved that we could now mine those deposits and turn them into useful product for the higher end applications”

TOMRA XRT technology with TOMRA support: agility, simple operation, easy maintenance

“It’s a very easy machine to operate,” explains Alex Padya. “We have three specific sorting programmes depending on the feed material to get a very intensive, mild or slight rejection rate. Once set up, you virtually leave the sorter to do its job.” Josh Dawson adds: “Having programmes pre-set in the machine instead of using the slidescale takes out human error and makes it all very seamless for us.”

Switching programmes is very simple and quick, which makes the TOMRA XRT sorter exceptionally agile in responding to the frequent variations in the material that comes from the ore body at QMAG’s deposit. If the material coming from a particular part of the deposit doesn’t yield the desired results, TOMRA’s team is always ready and quick to make the necessary adjustments to the programmes.

XRT sorting:  opportunities for future

The results were so positive that QMAG updated its plant replacing the 6-year-old unit with a new TOMRA XRT sorter. In addition, a second unit has now been added to further increase production capacity through this process route. QMAG is currently considering the possibilities that ores sorting technology can open up for the future.

“We see that the technology is improving to the point where we’re starting to consider that XRT can potentially do what the heavy media can do, and in some respects better.” affirms Josh Dawson. Alex Padya agrees: “Over the last few years we have done a lot of runs without going through the cyclone, going straight to the XRT sorter, and ending up with the final product.”

Josh Dawson concludes: “We are looking as a business for our next stages, potentially moving away from the traditional heavy media, and I see a future of a lot more ore sorting technology at QMAG. The technology is moving fast and TOMRA is a leader in this technology.  We are excited to see what technology TOMRA develops next.”

Further information:
TOMRA
www.tomra.com/mining