OreScanner
Introducing Our Ore Sorting Solution for Improved Efficiency and Sustainability
Ore bodies are naturally diverse, and the degree of grade heterogeneity can be influenced by multiple factors such as ore deposit itself, mining methods, ore handling, crushing, and blending processes before being sent to the plant. This variability can significantly affect the product quality, recovery rate and result in losses amounting to millions of euros for mining operations. However, current mining practices tend to blend out the variation to create a consistent feed for the processing plant, which unfortunately results in lower mineral recovery rates.
Solution
One solution to enhance the efficiency and profitability of mining operations is the utilization of real-time ore sorting or ore grade blending approaches. The sensor technologies have advanced significantly in recent years and offer numerous benefits for such solutions.
We provide sensor-based ore classification at the early stage of mining, either before or after crushing.
Ore grade control before crushing or after the primary crusher is more efficient than in later ore processing steps. This is because, at this stage, the ore remains unmixed and is not broken into small fragments. Determining the ore grade becomes simpler, and the sorting process is less reliant on complex or expensive machinery.
How does it work
Pre-Crush Scanner
A sensor array is installed at the point of ore discharge to a primary crusher. Based on ore assessment the average grade of the truckload is calculated. This information is then used to divert the crushed ore to the appropriate grade silo or different processing lines.
Alternatively, when utilizing a single stockpile or production line for processing plant feed, the selective truck loading method can be employed. By selectively bringing truckloads from different zones in the mine to a crusher, the feed to the processing stage can be blended, ensuring maximal utilization of mined ore without compromising the overall quality of the plant feed.
Conveyor Belt Scanner
When the surface of rocks weathers, it may not accurately represent the entire bulk. To address this, OreScanner is installed on a conveyor belt after primary crushing. This setup allows for sorting ore in smaller batches, which is especially helpful when the ore body shows variations in quality within a single truck load.
Benefits
The benefits of real-time grade control vary depending on the specific mining operation and the type of ore being processed. However, here are some general estimates of the potential benefits of ore sorting:
Higher Ore Recovery:
Slashes low-grade ore waste piles by up to 20%, maximizing mining operation revenue.
Improved Product Quality:
Reduce the standard deviation of your raw material quality by up to 10%. This ensures stable mineral processing and guarantees the final product always meets the clients’ requirements.
Reduced fuel and energy consumption:
Reduce fuel and energy consumption in the calcination and beneficiation processes by up to 5%. This results in substantial savings in operational costs and leads to a more sustainable mining operations.
