Limestone Sorting
Application Case: Real-Time Limestone Sorting
How Automated Ore Sorting Extends Quarry Lifetime and Unlocks Additional Revenue for Limestone Producers
The Hidden Costs of Conventional Ore Sampling in Limestone Processing
Traditional methods for assessing blasted ore quality often rely on drill dust or shavings from blast hole sampling. While these methods provide a rough estimate of ore grade, they are prone to significant errors due to contamination, loss of fines, and inconsistent operator practices. These factors compromise sample representativity, reducing the accuracy and reliability of ore quality assessments (Engström, 2017).
Recognizing these limitations, many mining companies are shifting away from conventional blast hole sampling in favor of more precise and reliable techniques. This transition is driven by the need for more accurate, real-time data to support better decision-making and operational efficiency (Engineering & Mining Journal).
The shortcomings of traditional sampling methods directly impact profitability and efficiency (Geomet, Queen’s University), leading to missed opportunities:
Recognizing these limitations, many mining companies are shifting away from conventional blast hole sampling in favor of more precise and reliable techniques. This transition is driven by the need for more accurate, real-time data to support better decision-making and operational efficiency (Engineering & Mining Journal).
The shortcomings of traditional sampling methods directly impact profitability and efficiency (Geomet, Queen’s University), leading to missed opportunities:
- Revenue Loss: Contamination can lead to misclassification, where high-grade ore is undervalued, reducing the potential for premium product generation.
- Increased Energy Cost: Processing mixed or lower-grade ore requires more energy, driving up operational expenses.
- Operational Inefficiencies: Undetected ore quality variations within a blast block cause inconsistent kiln feed, reducing kiln performance.
- Resource Waste: Misclassified high-grade ore may be discarded or underutilized, shortening quarry lifespan and diminishing sustainability.
To address these issues, mining operations must adopt advanced sampling and analysis technologies that improve resource utilization, enhance operational efficiency, and drive better financial outcomes.
The Solution: How OreScanner Works
The OreScanner system, installed immediately after the primary crusher, offers real-time analysis and automated sorting and blending:
- Real-Time Ore Quality Analysis: As ore passes through the primary crusher, OreScanner continuously scans the material, providing instant, precise CaCO₃ content data.
- Automated Ore Sorting: The integrated conveyor diverter system uses real-time data to sort ore into designated silos based on CaCO₃ content.
♦ Silo 1: 80–85% CaCO₃
♦ Silo 2: 85–90% CaCO₃
♦ Silo 3: Above 90% CaCO₃This precise sorting isolates high-grade material, enabling the creation of premium products for high-end markets.
- Optimized Blending: Sorted materials can be blended according to kiln requirements, ensuring optimal burning and reducing operational disruptions.
The Benefits: What OreScanner Delivers
- Unlocks Revenue Opportunities
Isolates high-grade ore for premium products, allowing producers to access high-margin markets. - Reduces Energy Costs
Processing the right material for the right application reduces energy usage, cutting costs and emissions. - Improves Operational Efficiency
Automation reduces manual intervention, enabling automated ore handling with no repeated hauling, which leads to fuel savings. - Prolongs Quarry Lifetime
Maximizes quarry lifespan by ensuring no high-grade material is wasted. - Seamless Integration
Minimal capital investment required, with simple installation into existing processing lines.
Why Choose OreScanner?
- Cost-Effective Investment: Provides rapid return on investment through operational savings and new revenue streams.
- Real-Time Precision: Instantly measures and sorts ore based on actual CaCO₃ composition, eliminating reliance on averages.
- Adaptive Automation: Intelligent conveyor diverter system adjusts sorting dynamically in real time.
- Sustainable Solution: Reduces waste and energy consumption, supporting long-term sustainability goals.
OreScanner addresses ore quality variability in processing and helps unlock the full value of mined ore. Installed after the primary crusher, it ensures optimal blending, reduces energy consumption, and enables premium product generation, boosting profitability and sustainability.
Unlock the Full Potential of Your Limestone Quarries
Contact OreScanner at info@orescanner.com to learn more!