Limestone Sorting
Application Case:
Real-Time Limestone Sorting for Enhanced Ore Processing
How limestone sorting improves Efficiency, Reduces Costs, and Unlocks Revenue Potential for Limestone Producers
The Pain: Key Challenges in Limestone Processing
Limestone producers frequently encounter raw material challenges that impact operational efficiency and profitability:
- Revenue Loss: Traditional assessment methods using drill dust samples from blasting holes provide only average grade data, overlooking variations within the block. As a result, high-grade ore can be mistakenly classified as lower-grade due to contamination, missing opportunities for premium product generation.
- Increased Energy Consumption: Processing mixed or lower-grade limestone increases energy usage, raising operational costs.
- Operational Inefficiencies: Ore quality variations within the blast block go unnoticed, causing inconsistent kiln feed and reduced kiln performance.
- Resource Waste: Misclassified high-grade ore may be discarded or underutilized, reducing quarry lifespan and sustainability.
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 three 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!