Experienced industry leaders joined TOMRA Mining’s experts as guest speakers in a seminar designed to provide a solid, pragmatic grounding on sensor-based sorting. The event highlighted the important role of sensor-based sorting technologies in green mining and their potential to unlock significant value in mining projects, as well as the possibilities of digitalization for supporting customers and managing connected equipment.
Group shot of the TOMRA-specialists and the highly qualified guest speakers. Photo: Tomra
TOMRA Mining’s seminar on sustainable mining solutions through sensor-based sorting covered a wide range of topics, starting with an introduction to the various sorting technologies, and including different applications, test work, design and economic considerations. Every topic was backed up with practical examples from case studies of ore sorting projects. The presentations gave rise to interesting discussions about the state of the art of sensor-based sorting in mining today and its potential for the future as the industry transitions to green mining.
The seminar highlighted the value of considering these technologies in the first phases of preliminary feasibility. Jordan Rutledge, Area Sales Manager at TOMRA explains: “sensor-based sorting should be considered in the flowsheet from the beginning and evaluated in pre-feasibility studies to see if it is suitable for the project and will add value to the plant. In many cases sorting works really well and, as we continue to go towards a green economy, the use of our resources is vitally important. In order to make the best use of them, sorting plays a critical role.”
The seminar attracted around 40 participants from across Canada. They included representatives from operator mining companies such as Agnico Eagle, Capstone Mining and Cheetah Resources; from laboratories such as testing and certification company SGS and the Saskatchewan Research Council (SRC); from engineering companies such as DRA Global, Primero, CIMA and Halyard; as well as students from the University of Toronto.
This was the first live event in almost two years for many of the participants, who appreciated the opportunity to meet face to face with their peers, as Justin Taylor, President and CEO of Halyard Inc. expressed very well: “I think live events offer a much deeper look and a different dimension into how people can communicate and connect. Part of the experience is learning about things and the other half is interacting with people, building networks and relationships.”
The breadth and variety of topics covered by the speakers was a key element in the seminar’s success: “It was a good mix of speakers and topics that range from academia to on-site real case studies that were very well presented. The speakers were very knowledgeable and very easy to listen to. The seminar allowed me to gain more understanding of the basics behind the technology, the different applications, in a variety of different parts of the industry,” said Sean Kautzman, Principal Consultant at SRK Consulting.
“It’s good to get all the different perspectives,” added Ryan Cunningham, Process Engineering Director at CIMA+ “We’ve had the innovators, the laboratories, the implementers, different engineering firms. It encourages us to seek out new solutions and to collaborate, and use the technology in the best way possible.”
Justin Taylor concluded: “Most importantly, I think that the seminar put forward a whole lot of concepts or topics that aren’t usually discussed. Sorting has always been a buzzword, but it’s been spoken about in non-defined terms in previous conferences, and I think this was really focused on the type of technology that TOMRA puts forward. TOMRA being a world leader in this type of technology certainly makes it clear to people what can be done, and I think there is a lot if scope for people to understand what can be done with sensor-based sorting to optimize their sites.”
Climate change, environmental pollution, resource scarcity, global population growth: these are the defining issues of the 21st century. Approaching them by transitioning to a circular economy is one of the central challenges of our time. TOMRA Sorting Mining, Wedel/Germany, a global leader in sensor-based technologies with more than 50 years’ experience in diverse sectors such as the food, recycling and mining industries, has understood that technology alone is not enough to create a closed-loop circular economy. Public policy, consumer engagement and collaboration across the value chain are necessary too. Making the shift from linear to circular to build thriving economies requires radically lessening the environmental impact of extracting raw materials, reducing the use of primary resources, designing waste-free products, harnessing materials to keep them in use and implementing technologies to ensure the system is regenerative.
TOMRA is excellently positioned to contribute to the transition to a circular economy by collaborating with key players across the value chain to develop new methods, processes, technologies and business models. To this end, it has created ReSociety, a global collaborative initiative to re-think, re-act and re-start our world for a more sustainable future. It is a place for industry, policymakers, companies and consumers to share ideas, increase awareness, collaborate with solution enablers and drive impactful change. It is also a hub in which TOMRA proactively shares its vast research and multi-national studies on holistic waste management systems, which have been indispensable in developing the circular value chains.
“Our commitment to the circular economy is unequivocal,” says Volker Rehrmann, Head of Circular Economy, TOMRA. “Until recently, it was unheard of having players from the entire value chain at one table. From chemical companies to converters, retailers and brand owners, waste management companies and recyclers – there’s true dedication in finding solutions. We take pride in doing our part: sharing our know-how, developing new solutions and striving to make our planet more sustainable every day. We have started with the recycling sector, and in particular in addressing the plastics waste issue, where the collaboration with the different stakeholders is proving very fruitful. However, if we want to leave a better world to future generations, we can’t stop at recycling; all sectors need to do their part. That is why at TOMRA we aim to build on the experience we developed in recycling and collaborate with the mining industry to reduce the environmental impact of its operations. This means finding green mining solutions that use less energy and water to recover resources – with a consequent reduction in CO2 emissions – and ways to turn waste into value. With the recycling sector, we are working on reducing the mountains of plastic waste; we want to do the same in mining and address the dumps and tailings building up in mines.”
As the world addresses the environmental challenges of our time, the mining industry has an important contribution to make. Mining companies need to find ways to maximize the efficiency of their operations to cut back on the use of water and other resources, while reducing waste and the total impact on the environment as much as possible. Amongst other challenges, they need to effectively address the storage and handling of tailings which pose a potential physical and chemical environmental risk.
TOMRA’s advanced sensor-based sorting technologies can not only significantly reduce the environmental impact of mining operations and, at completion, fully rehabilitate the site. They also enable a much more efficient use of resources. These solutions bring the dual benefits of greater sustainability and better profitability for the mining company.
TOMRA’s sensor-based sorting technology has been shown to significantly reduce the amount of energy and water used compared to traditional methods like Dense Media Separation (DMS), while maximizing the efficiency and recovery of valuable ores. An extensive study conducted by Alchemy Process Plants (AlcPro) comparing these processing methods has concluded that TOMRA’s solution also brings multiple cost benefits.
Water consumption is a key consideration when assessing the environmental impact of a mine, as it can severely affect local supply. Water management strategies are key to reducing the mine’s usage and ensure future water security for the communities in the mine’s surrounding areas. The Water Research Commission in South Africa has commissioned a project to compile a compendium of best practices and technological innovations in the mining industry with regards to Water Conservation and Water Demand Management. In her study, Youlita Vemblanathan identified TOMRA’s X-Ray Transmission (XRT) sorting technology as a solution that would lead to substantial improvements in water use efficiency.
Fig. 2. Wolfram tungsten mine in Mittersill. Photo: TOMRA
TOMRA’s sensor-based sorting technology can contribute to circular economy practices at the mine and processing plant, turning marginal waste into value with a positive impact on both the sustainability and profitability of the operation. This is the case at Wolfram’s tungsten mine in Mittersill/Austria (Figure 2), where TOMRA has installed two COM Tertiary XRT sorters. Alexander Mosser, Manager Ore Dressing Plant, explains: “The sorting system in the scheelite processing in Mittersill sorts out waste material with a size range of 16 to 60 mm. This eliminates the grinding and flotation that would otherwise be required for this material. This results in the following savings for the coarse waste material compared to grinding and flotation: 75 % lower power consumption and no water and no flotation reagents are required. Another resource conservation: the separated waste is a saleable product to the local construction industry. The sewage ponds are relieved and the impact on nature through local gravel pits is reduced. The sorting system thus not only reduces the footprint of the mine but also of the surrounding gravel pits.”
The proven environmental benefits of TOMRA’s sensor-based sorting solutions bring mining operations additional advantages. They can facilitate obtaining the licenses needed to start a mining project by proving the efficient use of water and energy, the significantly reduced amount of waste materials, chemicals/reagents, and lower environmental risks such as tailings dam collapse.
Rare earths mining company Cheetah Resources has obtained a loan from the Canadian Federal Government to purchase a TOMRA sorter for its Nechalacho Demonstration Project in Yellowknife (Figure 1) on the strength of the sustainable performance of its XRT technology. The sorting solution will significantly reduce the amount of water and fuel used and eliminate chemicals and tailings from the mining process. Leftover waste rock can be stockpiled for future use or used on infrastructural projects, such as road construction. The aim of the project is to create a low-impact facility for the production of rare earth minerals used in green technologies, that will generate employment and economic benefits in the region.
“We anticipate that with this project we will demonstrate the economic feasibility as well as the technical and environmental advantages of sensor-based sorting of rare earth to produce a value-added mixed rare earth concentrate in the Northwest Territories,” said David Connelly, Vice President of Corporate Affairs and Strategy at Cheetah Resources.
Overcoming environmental pollution by enabling the transition to a circular economy is one of the central challenges of the 21st century. Mining has a key role to play as the supplier of the raw materials, but a holistic approach is necessary. Beyond efficient operation and waste management in extracting the primary resources, it is necessary to curtail excessive consumption and ensure products are designed to be reused, and once at the end of life, easily recycled. Such a holistic approach also includes raising global awareness within the industries and with the consumers.
As a global frontrunner in empowering the circularity of resources, TOMRA has committed to taking post-consumer plastic packaging waste management to a new level worldwide. It has pledged to enable 40 % of all post-consumer plastic packaging produced globally each year to be collected for recycling by 2030. With a similar holistic approach, establishing collaboration and partnerships across the value chain, equally ambitious goals can be achieved in addressing the environmental impact of the mining sector.
TOMRA’S XRT sensor-based sorting technology unlocks significant value for Gem Diamonds at its Letšeng Diamond Mine. It delivered an effective solution for coarse fractions in historical tailings dumps, recovering 15 times the initial investment in 4 years. This success has led to the installation of the first TOMRA Final Recovery sorter in the world, now in its final commissioning stage. Projects to further upgrade the mine’s Recovery Plant with more TOMRA XRT sorters are in the pipeline.
Fig. 2. Letšeng mine, located in the Maluti Mountains of Lesotho. Photo: TOMRA
Gem Diamonds, a leading global diamond producer of large high value diamonds, owns 70% of the Letšeng mine, located in the Maluti Mountains of Lesotho (Figure 2). It is one of the largest open pit diamond mines in the world, it processes ore from two kimberlite pipes – the Main pipe (17.0ha) and the Satellite pipe (5.2ha) – and is known for the recovery of Type II diamonds. The ore is treated through two plants with conventional crushing, scrubbing, screening and Dense Medium Separation (DMS) processes. The DMS concentrate is split into three fractions that are sent to be processed with XRT (X-Ray Transmission) and XRF (X-Ray Fluorescence) technologies.
In 2017, the company undertook several activities to unlock the mine’s full potential and contacted TOMRA Mining to explore ways of improving its Coarse Recovery process.
A trial of TOMRA’s XRT technology quickly reveals its potential
Jaco Houman, Senior Manager Technical and Projects at Gem Diamond Technical Services, explains: “We had quite a lot of historic tailings material. We had a view that, since we had commissioned a new Coarse Recovery in 2015, we weren’t quite getting all the diamonds we were looking for. We worked with our supplier to improve, but we felt we had reached a ceiling point. That’s when we decided to augment the installed base and contacted TOMRA.”
Gem Diamonds rented a TOMRA COM Tertiary XRT sorter, which was deployed in the second half of 2017 to process historic tailings. “Our objectives were to audit the Coarse Recovery Plant performance, increase diamond recovery, improve the recovered revenue and evaluate the TOMRA unit as a recovery and bulk sorting unit,” says Jaco Houman.
The initiative was a success and the TOMRA sorter delivered on all the objectives Gem Diamonds had set: “During the 6-month rental of this unit, we got a better understanding of our primary recovery efficiencies, we were able to conduct off-line auditing and scavenging activities, we increased our diamond recovery and revenue, and we effectively introduced bulk treatment of historical recovery tailings.”
TOMRA’s XRT sorter exceeded all expectations: “The unit showed that it recovers consistently from the tailings material. The value that came from it spoke volumes about the technology and the potential that could still be obtained with the material available. It cemented the realisation that we needed a recovery unit for scavenging, auditing and second-pass recovery.”
High Value Recoveries and excellent ROI with TOMRA COM XRT 2.0 sorter
On the back of the excellent results achieved with the rental unit, Gem Diamonds purchased a TOMRA COM XRT 2.0 sorter to replace the rental unit at the end of the contract (Figure 1). Featuring a bigger ejection chamber, higher belt speed and throughput, this unit was perfectly suited to the large diamond recovery set up the company was looking for, and they didn’t have to wait for it to deliver:
“In January 2018, we had pretty much just finished commissioning this unit and we recovered the biggest stone Letseng had ever seen, the 910-carat Lesotho Legend (Figure 3). There was no question about performance after that,” says Jaco Houman. “Since 2017, we have recovered 6 diamonds that were sold for more than 1 million US$ with the two TOMRA XRT sorters.”
Fig. 3. The 910-carat Lesotho Legend. Photo: TOMRA
Since installing the TOMRA COM XRT 2.0, the mine’s +5mm historic material has been depleted and the company is now focusing on scavenging and auditing the existent tailings. Jaco Houman explains: “About 10 tonnes a day of coarse fractions are stockpiled per export period, and we do roughly 8 exports a year. Over an average of about 45 days, we accumulate 450 to 500 tonnes, which we process at the end of the export period. We are seeking confirmation that all economical value has been recovered and  that nothing has been missed in our recovery process. By having this unit in place, we are now able to recover all the diamonds that are present in our concentrate, either through a first or a second pass.”
With its performance, the TOMRA COM XRT 2.0 sorter has more than paid for itself, as Jaco Houman points out: “To date, we have recovered about 15 times the investment value over the 4 years it has been in operation.”
Gem Diamonds purchases the first TOMRA XRT Final Recovery sorter in the world
Gem Diamonds has been so impressed with TOMRA’s XRT technology that they have become early adopters of its ground-breaking Final Recovery solution, purchasing a TOMRA COM XRT 300 /FR sorter (Figure 4) before it was even launched, so that the Letšeng mine is home to the first unit to be installed in the world.
Fig. 4. TOMRA COM XRT-300-FR. Photo: TOMRA
Having found an effective solution for Coarse Recovery with the TOMRA COM XRT 2.0 sorter, Gem Diamonds turned their attention to the Fines Recovery Circuit. “We sent some samples for testing to an independent facility and our assumptions of under-recovery in certain size fractions were confirmed,” says Jaco Houman. “We wanted to find a solution to increase our revenue from the treatment of historic material. We were looking for a compact machine we could use as a final recovery sorter, and the TOMRA COM XRT 300 /FR performs very well in that duty, or even as a single particle sorter. Also, it is a sorter that will treat a super-concentrate and work very well as a scavenging unit.”
“The diamond industry had been waiting for 20 years for a way to introduce XRT directly into the Diamond Final Recovery instead of the bulk concentration stages where the DMS modules exist,” explains Ryan Szabo, Sales and Project Manager Diamonds at TOMRA Mining. “The TOMRA COM XRT 300 /FR is a compact sorter that can function within the diamond recovery and sort house environment, and it is the first to accurately sort diamonds based on their properties and not their proxies, achieving market leading recovery with the highest recovery factor to date. This made it ideal for Gem Diamonds’ requirements at the Letšeng mine.”
TOMRA’s Final Recovery sorter is now in the commissioning stage, and performing well, as Jaco Houman states: “We are getting consistent recovery from the TOMRA COM XRT 300 /FR, which is performing to our expectations from this perspective. The overall throughput has not been attained due to deficiencies in the drying system upstream, which are making feeding the sorter at higher throughput rates difficult. However, design corrections are in the process of being implemented and I am confident that we will be able to demonstrate performance of the Final Recovery sorter at the higher capacities.”
“The Final Recovery sorter has functioned exceptionally well,” adds Ryan Szabo. “To date the sorter has never failed a performance test at the Letšeng Diamond Mine. It has already had successful results in the commissioning stage. In fact, it’s the most successful first implementation of a new solution that TOMRA has ever had.”
The installation of the TOMRA COM XRT 300 /FR is the first in a series of three projects that Gem Diamonds is planning in order to upgrade its Recovery Plant with the addition of further TOMRA XRT sorters. The company is also working on a project for the construction of a second recovery circuit that would combine the TOMRA COM XRT 2.0 sorter currently on site, a new TOMRA COM Tertiary sorter and a COM XRT 300 /FR sorter to create an off-line scavenging facility. This will be followed by a third project, which will look at implementing TOMRA XRT technology through the remainder of the Final Recovery.
TOMRA: invested in the client’s success
The last four years have seen the successful introduction of TOMRA’s XRT technology at the Letšeng Diamond Mine, where it has provided effective solutions in different stages of the process, improving the operation’s profitability and efficiency. For Jaco Houman, this success stems not only from the advanced technology, but also from TOMRA’s approach to serving its customers: “What I like about TOMRA, is that for them it’s not just about selling you a piece of equipment. If the equipment doesn’t work in the solution or the system that you want, they’d walk away from the sale. For me, this testifies to the fact that they have a vested interest in the success of your business.”
The support that TOMRA has provided throughout the projects also stands out: “My experience has only been positive. We’re dealing with an organisation with experienced, professional people. I can see that they love what they do, they’re very diligent in their work. The technical people on site have spent hours and hours not just setting up the equipment, but also imparting knowledge and getting the operational staff up to the required levels, so that when they walk away, we know that there’s going to be continuity. I believe that when TOMRA makes a commitment , you can bank on the fact that they will deliver on that.”
Climate change, environmental pollution, resource scarcity, global population growth: these are the defining issues of the 21st century. Approaching them by transitioning to a circular economy is one of the central challenges of our time. TOMRA, a global leader in sensor-based technologies with more than 50 years’ experience in diverse sectors such as the Food, Recycling and Mining industries, has understood that technology alone is not enough to create a closed-loop circular economy: public policy, consumer engagement and collaboration across the value chain are necessary too. Making the shift from linear to circular to build thriving economies requires radically lessening the environmental impact of extracting raw materials, reducing the use of primary resources, designing waste-free products, harnessing materials to keep them in use and implementing technologies to ensure the system is regenerative.
A holistic approach to achieving a circular economy: ReSociety
TOMRA is excellently positioned to contribute to the transition to a circular economy by collaborating with key players across the value chain to develop new methods, processes, technologies and business models (Figure 1). To this end, it has created ReSociety, a global collaborative initiative to re-think, re-act and re-start our world for a more sustainable future. It is a place for industry, policymakers, companies and consumers to share ideas, increase awareness, collaborate with solution enablers and drive impactful change. It is also a hub in which TOMRA proactively shares its vast research and multi-national studies on holistic waste management systems, which have been indispensable in developing the circular value chains.
“Our commitment to the circular economy is unequivocal,” says Dr. Volker Rehrmann, Head of Circular Economy, TOMRA (Figure 2).
Fig. 2. Dr. Volker Rehrmann, Head of Circular Economy, TOMRA. Photo: TOMRA
“Until recently, it was unheard of having players from the entire value chain at one table. From chemical companies to converters, retailers and brand owners, waste management companies and recyclers – there’s true dedication in finding solutions. We take pride in doing our part: sharing our know-how, developing new solutions and striving to make our planet more sustainable every day. We have started with the recycling sector, and in particular in addressing the plastics waste issue, where the collaboration with the different stakeholders is proving very fruitful. However, if we want to leave a better world to future generations, we can’t stop at recycling; all sectors need to do their part. That is why at TOMRA we aim to build on the experience we developed in recycling and collaborate with the mining industry to reduce the environmental impact of its operations. This means finding green mining solutions that use less energy and water to recover resources – with a consequent reduction in CO2 emissions – and ways to turn waste into value. With the recycling sector, we are working on reducing the mountains of plastic waste; we want to do the same in mining and address the dumps and tailings building up in mines.” (Figure 3)
Fig. 3. Waste into Value. Source: TOMRA
Advanced mining technology with a small environmental footprint
As the world addresses the environmental challenges of our time, the mining industry have an important contribution to make. Â Mining companies need to find ways to maximize the efficiency of their operations to cut back on the use of water and other resources, while reducing waste and the total impact on the environment as much as possible. Amongst other challenges, they need to effectively address the storage and handling of tailings which pose a potential physical and chemical environmental risk.
TOMRA’s advanced sensor-based sorting technologies can not only significantly reduce the environmental impact of mining operations and, at completion, fully rehabilitate the site. They also enable a much more efficient use of resources. These solutions bring the dual benefits of greater sustainability and better profitability for the mining company.
TOMRA’s sensor-based sorting technology has been shown to 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. An extensive study conducted by Alchemy Process Plants (AlcPro) comparing these processing methods has concluded that TOMRA’s solution also brings multiple cost benefits. Erik Bruggink explains: “although capital costs of the separation circuits are similar, with DMS the additional cost of handling the resultant water from the circuit needs to be taken into consideration together with the associated water use licencing and tailings facilities. In addition, TOMRA’s sensor-based sorting technology requires no reagents, and maintenance costs are limited to the sorting unit and the associated conveyors, screens and chutes.”
Water consumption is a key consideration when assessing the environmental impact of a mine, as it can severely affect local supply. Water management strategies are key to reducing the mine’s usage and ensure future water security for the communities in the mine’s surrounding areas. The Water Research Commission in South Africa has commissioned a project to compile a compendium of best practices and technological innovations in the mining industry with regards to Water Conservation and Water Demand Management. In her study, Youlita Vemblanathan identified TOMRA’s X-Ray Transmission (XRT) sorting technology as a solution that would lead to substantial improvements in water use efficiency.
Sustainability with profitability: turning waste into value
Fig. 4. Aerial view of Wolfram’s tungsten mine in Mittersill, Austria. Photo: TOMRA
TOMRA’s sensor-based sorting technology can contribute to circular economy practices at the mine and processing plant, turning marginal waste into value with a positive impact on both the sustainability and profitability of the operation. This is the case at Wolfram’s tungsten mine in Mittersill, Austria (Figure 4), where TOMRA has installed two COM Tertiary XRT sorters. Alexander Mosser, Manager Ore Dressing Plant, explains: “The sorting system in the scheelite processing in Mittersill sorts out waste material with a size range of 16-60 mm. This eliminates the grinding and flotation that would otherwise be required for this material. This results in the following savings for the coarse waste material compared to grinding and flotation: 75% lower power consumption and no water and no flotation reagents are required. Another resource conservation: the separated waste is a saleable product to the local construction industry. The sewage ponds are relieved and the impact on nature through local gravel pits is reduced. The sorting system thus not only reduces the footprint of the mine but also of the surrounding gravel pits.”
Sustainability as a facilitator and opportunity creator
The proven environmental benefits of TOMRA’s sensor-based sorting solutions bring mining operations additional advantages. They can facilitate obtaining the licenses needed to start a mining project by proving the efficient use of water and energy, the significantly reduced amount of waste materials, chemicals/reagents, and lower environmental risks such as tailings dam collapse.
Rare earths mining company Cheetah Resources has obtained a loan from the Canadian Federal Government to purchase a TOMRA sorter for its Nechalacho Demonstration Project in Yellowknife on the strength of the sustainable performance of its XRT technology (Figure 5).
Fig. 5. Aerial view of Cheetah Resources’ Nechalacho Rare Earth Mine in the North West Territories. Canada’s first rare earth mine started producing rare earth concentrate using TOMRA’s XRT sensor-based sorter as a single step to beneficiate the bastnaesite ore. The first barge of 40% ROE concentrate will depart for the port of Hay River in September for onward shipment to Saskatchewan, where Cheetah Resources’ parent company, Vital Metals Ltd. (ASX: VML), will produce a mixed Rare Earth Carbonate for export to Europe. Photo: TOMRA
The sorting solution will significantly reduce the amount of water and fuel used, and eliminate chemicals and tailings from the mining process. Leftover waste rock can be stockpiled for future use or used on infrastructural projects, such as road construction. The aim of the project is to create a low-impact facility for the production of rare earth minerals used in green technologies, that will generate employment and economic benefits in the region.
“We anticipate that with this project we will demonstrate the economic feasibility as well as the technical and environmental advantages of sensor-based sorting of rare earth to produce a value-added mixed rare earth concentrate in the Northwest Territories,” said David Connelly, vice president of corporate affairs and strategy at Cheetah Resources.
The path to a more sustainable future starts today
Overcoming environmental pollution by enabling the transition to a circular economy is one of the central challenges of the 21st century. Mining has a key role to play as the supplier of the raw materials, but a holistic approach is necessary. Beyond efficient operation and waste management in extracting the primary resources, it is necessary to curtail excessive consumption and ensure products are designed to be reused, and once at the end of life, easily recycled. Such a holistic approach also includes raising global awareness within the industries and with the consumers.
Dr. Mathilde Robben, Key Account Manager at TOMRA Sorting Mining, explains: “The raw materials supplied by mining are vital for our modern way of living and are critical for the energy transition technologies. With mining as the entry point for these necessary materials, the circle will never be closed completely. However, this should be seen as an opportunity for the mining industry to re-think the way it fulfils this essential role with minimal impact on the environment, and for sectors downstream to shift focus from the core business to the chain around it, without losing sight of profitability. Re-using can be prioritized by the use of certain metals that are infinitely recyclable and whose inherent durability and anti-corrosive properties contribute to the longevity of the products they are used in.”
As a global frontrunner in empowering the circularity of resources, TOMRA has committed to taking post-consumer plastic packaging waste management to a new level worldwide. It has pledged to enable 40% of all post-consumer plastic packaging produced globally each year to be collected for recycling by 2030. With a similar holistic approach, establishing collaboration and partnerships across the value chain, equally ambitious goals can be achieved in addressing the environmental impact of the mining sector.
There are economically viable solutions available today that can accelerate the path towards a truly green mining industry. The perfect time to start is now – with the technologies, proven strategies, and collaborations between all stakeholders to make our future more sustainable.
TOMRA is tapping the potential of digitalization with a constantly expanding offer of digital services to help mining operations improve their efficiency and profitability – most recently with the introduction of the new augmented reality tool for remote assistance, TOMRA Visual Assist.
In a challenging market, mining companies under increasing pressure to improve the environmental performance, efficiency, and safety of their operations are turning to digitalization and advanced analytics. Data captured in their mines provides valuable insights, enabling them to make fact-based strategic decisions, improve their processes, reduce downtime, shrink their environmental footprint, and enhance safety. Virtual Reality and Augmented Reality are proving useful in training and problem solving on-site.
The mining sector is in the early stages of digitalization, but the Covid-19 crisis has dramatically accelerated the process as companies have looked for solutions to protect employees and address mobility restrictions to maintain effective sales and service support to customers. For example, in October 2020, Management consulting firm McKinsey wrote that mining companies seeking to mitigate the impact of the pandemic had started to relocate around 15 to 20 percent of their on-site workforce by setting up “control towers” to facilitate remote working. It noted a renewed interest in remote operating centers that build on remote working capabilities, with some companies implementing cloud-based systems that enabled the collection and analysis of data from the mines for decision support. The process of digitalization is set to continue, as more mining companies become aware of the huge potential in operational and financial benefits.
TOMRA Sorting Mining: a constantly expanding offering of digital services
TOMRA is applying its holistic approach to helping customers to unlock the potential of digitalization, with digital services covering the complete customer journey – from sales support and technical consultations to remote service and training. All its digital solutions collect, manage and store data securely following data security best practices.
The cloud-based data platform, TOMRA Insight, turns sorting machines into connected devices that generate valuable process data, which is gathered in near real-time and can easily be accessed on a desktop computer or mobile device. It transforms sorting into a strategic management tool that helps processors in near real-time and retrospect.
TOMRA Insight, turns sorting machines into connected devices. Photo: TOMRA
On the one hand, machine operators can take prompt action in response to changes in material composition on the line. On the other hand, managers can make operational and business decisions based on more complete information. They can also make more accurate comparisons between multiple sites or lines, and monitor remotely difficult-to-reach operations.
TOMRA is constantly expanding its portfolio of digital services, and it is now introducing the new Augmented Reality tool for remote assistance, TOMRA Visual Assist. It enables remote experts to provide specialist support to a customer or a TOMRA Field Service Engineer on-site.
Klaus Berns, Head of Service at TOMRA Sorting Mining Photo: TOMRA
“Our service teams cover large areas, generally with one hub per continent, so giving troubleshooting, maintenance and guidance remotely can be a great help,” explains Klaus Berns, Head of Service at TOMRA Sorting Mining. “It enables us to be more efficient and ensure a fast response. If the technical expert is a far away, the customer doesn’t have to wait for qualified and detailed feedback. Some mines are particularly difficult to reach, for example at high altitudes, 4,000m above sea level, or in harsh climates with temperatures well below zero. In some cases, it may take 2 or 3 days for the technical expert to arrive on site. TOMRA Visual Assist can save time, and long and difficult journeys.”
TOMRA Visual Assist can be used on standard devices like cell phones or tablets, but also with advanced tools such as Smart Glasses, which provide an Augmented Reality experience, so that the technician on-site can follow the remote expert’s guidance with their hands free, working in maximum safety. “TOMRA Visual Assist can also make a big difference for diamond operations where the equipment is located in a red area, where mobile phones or cameras are not allowed, as we can use the headset linked to the local network,” adds Klaus Berns.
TOMRA has also harnessed digital technology to provide mining companies with a Virtual Demonstration and Test Solution to enable them to test the sorting solutions on their samples without leaving their office. By providing them remote access to its Test Center in Wedel, Germany, which has capabilities for all applications, it enables them to identify the best sorting solution for their mine, discuss the options with TOMRA’s experts, and make a fact-based decision.
TOMRA is also proactively engaged in spreading knowledge about the potential of sensor-based sorting solutions in mining through regular webinars. The sessions explore the various technologies, discuss financial and technical aspects, and analyze how they can add value to different mining operations.
About TOMRA Sorting Mining
TOMRA Sorting Mining designs and manufactures sensor-based sorting technologies for the global mineral processing and mining industries.
As a world market leader in sensor-based ore sorting, TOMRA is responsible for developing and engineering cutting-edge technology made to withstand harsh mining environments. TOMRA maintains its rigorous focus on quality and future-oriented thinking with technology tailor-made for mining.
With the new introduction, TOMRA is the first company in the industry able to supply a full diamond recovery solution using X-Ray Transmission (XRT) technology from 2mm to 100mm, coupled with all the benefits of cloud computing for monitoring and managing the entire process.
TOMRA Sorting Mining has launched the new TOMRA COM XRT 300 /FR Final Recovery sorter, which delivers concentration factors up to 1 million with limited stages and is the only solution on the market that guarantees >99% diamond recovery. The new sorter stands out for the high sorting efficiencies, the high diamond-by-weight concentrate, and the benefits deriving from its focusing on a single consistent detection principal, Diamonds. With this new introduction, TOMRA offers a complete partnered diamond recovery ecosystem with a flowsheet covering the entire process – from Concentration to Final Recovery and Sort House – and includes custom development with the end-user all the way to installation, then continued management of the asset and support with specialized services and training.
The TOMRA COM XRT 300 /FR is the latest step in TOMRA’s long-term strategy for the diamond sector, which aimed to provide its customers with a complete recovery solution. “We always had this clear objective, but the technology just didn’t exist,” explains Geoffrey Madderson, Diamond Segment Manager for TOMRA Sorting Mining (Figure 2). “We knew that to achieve our goal, we would need extremely advanced sensor technology. We have been working in-house on the development the new ultra-high resolution sensor more than 5 years, and now we are able to close the loop: the COM XRT 300 /FR is the last piece within our recovery process, covering the Final Recovery and Sort House applications to produce an ultra-high diamond-by-weight concentrate.”
TOMRA’s holistic approach and unique offering has earned a strong market trust in its XRT technology. As a result, the first three TOMRA COM XRT 300 /FR sorters produced have already been sold to customers who purchased the machines on the back of their excellent experience of previous TOMRA sorters.
Input material is evenly fed via a vibration feeder onto a conveyor belt. An electric X-Ray tube creates a broad-band radiation, which penetrates the material and provides spectral absorption information. This is measured with an X-Ray camera using DUOLINE® sensor technology, which focuses on a single, constant property of the material, density.
The advanced ultra-high resolution sensor information is processed and analyzed by our new Image Processing Pipeline to provide a detailed “density image” of the material, allowing it to be separated into high- and low-density fractions. If diamonds are detected it commands the control unit to open the appropriate valves of the ejection module at the end of the conveyor belt. The detected diamonds are separated from the material flow by jets of compressed air. The sorted material is divided into two fractions in the separation chamber.
The tight tolerances and accurate alignment of the new ultra-high resolution sensor results in a high quality picture that ensures a clear discrimination between diamonds and low-density materials down to 2mm. The sorter features high speed valves with a fine nozzle pitch, which significantly reduces non-diamond material in the concentrate. The result is ultra-high diamond by weight concentrate with a guaranteed recovery of more than 99%.
High efficiency, better grade and security with fewer sorting stages
It is possible to replace multiple sorting stages with a single TOMRA COM XRT 300 /FR sorter all the way down to hand sorting. In Final Recovery application, the sorter targets the highest tonnage through the sorter that can be achieved with the highest recovery efficiency, which ranges from five tons to one. As a result, the operation benefits from a smaller footprint and achieves much better grade.
It is also possible to replace hand sorting with a TOMRA COM XRT 300 /FR (Figure 1). In Sort House application, it targets the highest diamond-by-weight concentrate possible, with about half the tonnage than final recovery, bringing multiple benefits. It removes the traditional bottlenecks around hand sorting efficiencies and eliminates the human error factor. In addition, it provides a high level of security by protecting the product from human intervention.
A unique offering: a complete partnered recovery ecosystem coupled with cloud computing
The TOMRA COM XRT 300 /FR sorter completes TOMRA’s partnered diamond recovery ecosystem, which is unique in the market for offering a full recovery service from 2mm to 100mm coupled with all the benefits of cloud computing. It includes consultation services during the development of the system and throughout the life cycle of the equipment, support running the sorters, and help with specialized services and training. TOMRA has also leveraged digital technologies to provide effective support, through its Virtual Demonstration and Test Solution and features such as the TOMRA Visual Assist Augmented Reality tool for remote assistance.
“With TOMRA, the customer’s entire recovery system falls into one ecosystem,” explains Geoffrey Madderson. “This allows for better compatibility and interconnectivity between the different applications of the recovery process. It gives our customers the full benefit of using cloud computing through our TOMRA Insight platform, which turns our sorters into connected machines. This enables customers to monitor and manage their recovery process in one easy-to-access place for both on-site and off-site management teams.”
A dedicated showroom to provide a first-hand experience of the new Final Recovery sorter
TOMRA has set up a showroom dedicated to demonstrations of the TOMRA COM XRT 300 /FR sorter at its Test Center in Wedel (Hamburg), Germany. The facility will be open to interested customers able to visit in person from the beginning of May. Visitors will be able to see first-hand what >99% recovery looks like in the material coming out of the machine. They will also experience the comfortable work environment created by the compact size and quiet operation of the sorter.
Later in the year, TOMRA will also offer virtual demonstrations for those unable to travel to the Test Center.
Fig. 1. TOMRA Sorting Mining’s new diamond microsite enables diamond producers to under-stand the possibilities offered by its recovery solutions. Source: TOMRA
TOMRA Sorting Mining’s, Wedel/Germany, approach in developing its new diamond microsite reflects the company’s holistic approach to supporting its customers. By opening easy access to comprehensive technical information, it enables diamond producers to understand the possibilities offered by its recovery solutions, how they would fit within their operations, and how they would be adding value.
“We want to allow our potential clients and end-users better access to all of our technical information so that they can understand our solutions and best implement them,” states Ryan Szabo, Sales and Project Manager Diamonds at TOMRA. Navigation of the diamond microsite is intuitive and the detailed information is presented in a clear and easy-to-understand format. “We developed it based on the questions our customers ask during our meetings” explains Szabo.
The microsite’s homepage opens with a clear statement of TOMRA’s promise to diamond producers: 100 % detection in the specified range, irrespective of luminescence profile or coating, and a guaranteed diamond recovery greater than 99 %. Scrolling down, viewers can see at a glance the stages of the process where TOMRA sorters can add value: Concentration with its XRT sorters and Pre-concentration with its Color and Near Infrared (NIR) solutions – and they will discover that a solution for final recovery will soon be available. This will be an industry first: XRT recovery technology down to the size of a 2 mm rough diamond, which will deliver concentration factors up to 1 million with a much-reduced number of concentration stages.
In the Applications section of the microsite, a flowsheet shows where the different TOMRA machines fit in the recovery process and how they add value (Figure 1). Further detail is provided in animations of process flow diagrams in Kimberlite, Alluvial batch fed and Alluvial continuous feed applications. “With these flowsheets we want to help our customers to navigate and understand where the equipment goes, adds Szabo. “We show the locations where the sorters fit within different types of operations. This will give the customers an understanding of how the process can be simplified and the number of stages that can be replaced by the TOMRA sorters.”
The product page provides detailed technical information – product sheets, general arrangement drawings and 3D CAD drawings. Customers can even download a 3D model and place it in their plant’s 3D drawings to see exactly how it would fit, what it would change in their set-up and how.
Details of TOMRA’s Service Level Agreements are also on the microsite. Unique on the market, these plans offer tailored solutions to match client requirements and protect their investment. The Service section includes information about TOMRA Insight, the cloud-based solution that turns the customer’s sorters into connected devices and provides secure, real-time monitoring.
Customers considering the integration of TOMRA’s solutions in their operation can also find information about existing installations. They can hear from diamond producers about their experience with TOMRA and learn about the potential benefits in an interview with Geoffrey Madderson, Diamond Segment Manager for TOMRA. They can also view photographs of remarkable diamond recoveries and existing installations such as the one at Karowe mine in Botswana, where record-breaking diamonds have been recovered with TOMRA’s XRT technology.
TOMRA introduces the TOMRA ACT ground-breaking new user interface (Figure 1), together with a new image processing pipeline and additional process data for TOMRA Insight, enabling improvements in the overall sorting process for greater productivity and profitability.
TOMRA ACT: Control without complexity
The new TOMRA ACT graphical user interface (UI) heralds a fundamental change in the way customers interact with their machines (Figure 2), making it extremely easy to control the work flow in their sorting process with simple, intuitive, touch gestures and actions on the screen.
TOMRA ACT provides sorting information and real-time process data at a glance through easy-to-understand graphics (Figure 3). With this clear information, the operator is able to better monitor the sorting process and make fast adjustments at any time. The quick feedback on the machine performance and throughput enables them to optimize the process, maximizing productivity and efficiency. With the new state-of-the-art UI, the tasks of controlling the sorter feel natural and part of the production process.
Ines Hartwig (Figure 4), TOMRA Product Manager, explains: “Throughout the development process of TOMRA ACT, we conducted many in-depth discussions with our customers to ensure we provided them with an interface that would improve the performance of their sorters, benefiting their business. We have been testing it with customers and the feedback has been very positive, in particular about the ease of use, also remotely, which facilitates controlling the process and adjusting settings. With the new interface, customers interact with their sorters in a much more intuitive way and they have better guidance on how to improve the overall handling of the sorters. As a result, they will be able to improve the productivity of their sorting plant and the profitability of their mining operation.”
TOMRA is introducing the new UI on all its current X-Ray Transmission (XRT) sorters, and is planning to extend it to other machines in its offering at a later stage. Upgrade packages to update previous models of its XRT sorters will also become available.
Enhanced Image Processing: The heart of the sorter
The new Image Processing Pipeline analyzes the data sent by the sorter’s sensors and cameras. This solution provides TOMRA with even more flexibility to adjust and customize the image calculations according to the application and the customer’s specific requirements in order to achieve the best possible sorting results.
Additional parameters for TOMRA Insight
The new enhanced image processing solution also collects detailed process data, such as information on particle size distribution of the feed, belt occupancy which gives useful insights on feed tonnages, or data relating to the health of the sorter. All these statistics are fed to TOMRA Insight, the cloud-based data platform, adding to the process information it has already received. This enables customers to improve the overall sorting process further, taking fast action when changes occur in upstream equipment or in the material’s composition. They are able to better monitor and control their processes, the feed material and the sorted fractions, improving their profitability.
The new enhanced Image Processing Pipeline, and additional data fed to TOMRA Insight, are now introduced on TOMRA XRT sorters and will be extended to other products.
Further information: TOMRA Sorting Solutions www.tomra.com
Fig. 2. The new TOMRA Diamonds microsite. Photo: TOMRA
TOMRA’s approach in developing its new diamond microsite (Figures 1, 2) reflects the Company’s holistic approach to supporting its customers: by opening easy access to comprehensive technical information, it enables diamond producers to understand the possibilities offered by its recovery solutions, how they would fit within their operations, and how they would be adding value.
“We want to allow our potential clients and end-users better access to all of our technical information so that they can understand our solutions and best implement them,” states Ryan Szabo, Sales and Project Manager Diamonds at TOMRA Mining.
Easy-to-navigate comprehensive information
Navigation of the diamond microsite is intuitive and the detailed information is presented in a clear and easy-to-understand format. “We developed it based on the questions our customers ask during our meetings” explains Ryan Szabo.
The microsite’s Homepage opens with a clear statement of TOMRA’s promise to diamond producers: 100% detection in the specified range, irrespective of luminescence profile or coating, and a guaranteed diamond recovery greater than 99%. Scrolling down, viewers can see at a glance the stages of the process where TOMRA sorters can add value: Concentration with its XRT sorters and Pre-concentration with its Color and Near Infrared (NIR) solutions – and they will discover that a solution for Final Recovery will soon be available. This will be an industry first: XRT recovery technology down to the size of a 2mm rough diamond, which will deliver concentration factors up to 1 Million with a much-reduced number of concentration stages.
Process flowsheets highlight how TOMRA sorters can add value
Fig. 3. The applications section of the new TOMRA Diamonds microsite. Photo: TOMRA
In the Applications section of the microsite (Figure 3), a flowsheet shows where the different TOMRA machines fit in the recovery process and how they add value. Further detail is provided in animations of process flow diagrams in Kimberlite, Alluvial batch fed and Alluvial continuous feed applications. “With these flowsheets we want to help our customers to navigate and understand where the equipment goes, adds Ryan Szabo. “We show the locations where the sorters fit within different types of operations. This will give the customers an understanding of how the process can be simplified and the number of stages that can be replaced by the TOMRA sorters.”
Open access to detailed product information
The product page (Figure 4) provides detailed technical information – product sheets, General Arrangement drawings and 3D CAD drawings. Customers can even download a 3D model and place it in their plant’s 3D drawings to see exactly how it would fit, what it would change in their set-up and how.
Fig. 4. The product page of the new TOMRA Diamonds microsite. Photo: TOMRA
Details on TOMRA’s service and connectivity offering to ensure maximum uptime
Details of TOMRA’s Service Level Agreements are also on the microsite. Unique on the market, these plans offer tailored solutions to match client requirements and protect their investment. The Service section includes information about TOMRA Insight, the cloud-based solution that turns the customer’s sorters into connected devices and provides secure, real-time monitoring.
TOMRA’s promise backed up by customers
Customers considering the integration of TOMRA’s solutions in their operation can also find information about existing installations. They can hear from diamond producers about their experience with TOMRA and learn about the potential benefits in an interview with Geoffrey Madderson, Diamond Segment Manager for TOMRA Sorting Mining. They can also view photographs of remarkable diamond recoveries and existing installations such as the one at Karowe mine in Botswana, where record-breaking diamonds have been recovered with TOMRA’s XRT technology.
K+S Minerals and Agriculture GmbH, Kassel/Germany, a major salt producer, turned to TOMRA Sorting Mining, Wedel/Germany, for a solution for the replacement of the existing sorting system at its rock salt mine in Grasleben, in Lower Saxony/Germany. The two companies have a long-standing research and development relationship, focused on exploring the application of TOMRA’s technologies to salt sorting.
K+S Minerals and Agriculture operates in a sector that is recording a growing trend. According to the “Global salt market size 2019 – 2025” report published by market and consumer data provider Statista, the global salt market was valued at about 28 bn US$ in 2019 and is forecast to exceed 32 bn US$ by 2025. The industry growth is driven by a rise in the demand for salt applied in the chemical manufacturing industry – especially in chlorine-alkali chemicals production.
At the Grasleben mine, rock salt is extracted from a high-quality underground deposit that stretches across two federal states. It is processed into a wide range of products, from de-icing salt for winter road services to food-grade table salts and lick stones for livestock and domestic animals. For K+S, consistently achieving certified and guaranteed high purity, compliant with the strict standards of the food industry, is a priority.
“The sorting of rock salt is complex and demanding due to its crystalline properties. This leads to strong fluctuations in the appearance of the material”, states Sven Raabe, Technisches Büro Mechanik, K+S Minerals and Agriculture.
TOMRA recommended using COLOR sorting technology: “With a customized set-up of the light sources we can detect the difference in transparency of the different particles, ensuring the high quality of the rock salt,” explains Mathilde Robben, Key Account Manager at TOMRA. The team also advised installing the sorter in the underground mine as requested (Figure 1), so that “after an initial underground sorting stage, only the coarsely crushed rock salt undergoes further grinding and sieving above ground. Only the valuable product needs to be transported in the shaft, and the final result is high-quality, pure rock salt products in various grain sizes, which are ideal for this application. Furthermore, waste rejects can be backfilled underground, avoiding storage and emissions on the surface.”
TOMRA conducted a demonstration of the proposed solution at its Demonstration and Test Center in Wedel. Raabe attended the test with colleagues from K+S’s technical team. Seeing the technology in action was decisive: “The tests were very well prepared,” says Raabe. “The on-site team quickly developed a feel for our product. The uncomplicated adaptation of the program to the different material qualities also convinced us. An important factor in our purchasing decision was the positive test result achieved with the system, using transmitted light to obtain more efficient separation. This has the added benefit of resource conservation. It is possible to react quickly and individually to changing situations during dismantling. We expect this to be more effective, and the ease of use of the system was also convincing.”
Following the positive experience at the Test and Demonstration Center and the results of the test, K+S placed the order for TOMRA’s solution, with installation planned for September 2020. The negotiations were conducted via video conference due to the Covid-19 travel restrictions and lockdown. The order was entered in TOMRA’s production plan and the Factory Acceptance Test was conducted on 23rd September 2020. The sorter was transported to the Grasleben mine, where it was placed in position underground on 30th September 2020 and installation was completed on schedule.
“This is the first solution we provide for underground sorting, which raises specific challenges due to the dimensions and weight limitations of the mine shaft,” concludes Robben. “In this project we also had to contend with the difficulties created by the Covid-19 pandemic. I am very pleased that we have been able to meet K+S’s requirements and deliver on schedule.”
Further information: TOMRA Sorting Solutions www.tomra.com
