PRE-CONCENTRATION & ORE SORTING
The importance of process design in ore sorting
The success of a mineral processing project hinges on a meticulous and wellorchestrated process design , with Stark Resources , a specialised , privately held engineering group with a global mining footprint , looking to prove this out in the ore sorting space .
“ The team at Stark Resources excels in crafting comprehensive process designs tailored to the specific needs and challenges of each project ,” Dian Heinrich Page , Group Head of Advisory for Stark Resources , says . “ Its proficiency in The team at Stark Resources excels in crafting comprehensive process designs tailored to the conducting exhaustive metallurgical studies specific needs and challenges of each project enables it to provide the advisory services essential for navigating the complexities of mineral processing with confidence and precision .”
Central to Stark Resources ’ approach is the specialisation in developing flowsheets and implementing process designs for ore sorting – technology that can improve the efficiency and productivity of mineral processing operations and contribute towards reducing their environmental footprint .
By leveraging advanced technologies and strategic insights , Stark Resources says it empowers clients to optimise resource utilisation , enhance product quality and streamline production workflows . A foundation of the validation of a process design is the construction of pilot plants – a crucial testing ground where theories are put into practise on a smaller scale , and operational parameters are fine-tuned before full-scale implementation . Stark Resources says it possesses the expertise and capabilities to construct and operate pilot plants , enabling clients to identify potential bottlenecks and refine operational strategies while generating early cash flow .
Notably , an upgrade ratio of 1.1-1.3 times results in a 10-30 % increase in metal production without altering tonnage , thereby enhancing economic viability while meeting ESG objectives such as improved energy efficiency and reduced water consumption .
Rados added : “ To make these solutions accessible , clients can trial the technology without significant upfront investment . This trial period involves the temporary installation of the Rados Rapbos CB on the client ' s operational belt for three months .” During this time , extensive data is collected about the client ' s orebody and its unique characteristics .
By leveraging Rados ’ technology alongside MMD ' s machinery , clients can accurately assess the potential benefits and value of implementing such solutions within their operations , Rados says . In addition , to offering clients a low capital entry into the Bulk Ore Sorting Solution , the data generated from Rapbos CBs can be used within a digitalisation context , providing information on the elemental content , the mass and the volume of the ore stream to potentially facilitate improvements and optimisation of downstream processes and material handling solutions .
Comex reflects on ore sorting century
Comex is looking to tackle what it sees as the main problem in pre-concentration – high content material in waste fractions caused by inaccurate sorting – with a new patented sorting system able to , it says , achieve high precision separation at low mineral grades .
Comex has delivered almost 100 sorting solutions for mining applications worldwide , many of them for demanding applications in copper , gold and rare earth element ( REE ) ores , where high sorting precision is critical for sustainable plant operation .
Its system employs high selectivity X-ray detectors operating together with other sensors , like RGB and Short-Wave-Infra-Red cameras , installed in the same sorting unit . This combination , it says , significantly increases the number of parameters describing processed materials ,
allowing accurate identification of ores representing metals like nickel , copper , gold , zinc , tungsten , REEs and others .
By providing detailed analysis of the internal particle structure by XRT sensors and the particle surface through additional optical cameras , it is also possible to detect waste rock and minerals containing no valuable material , it says .
“ This is carried out via special correlation models , which compare data from different sensors ,” Comex explains . “ Advanced digital filtration tools with smart data fusion are used to compare information available in different formats and resolutions .”
This potentially huge data stream is difficult to analyse in an optimal way – where efficient data processing is carried out in short time intervals – so the company employs AI-based models with convolutional neural networks to achieve optimal decision making .
The most notable application of one of Comex ’ s sorters was seen at a gold mine where 85 % of the waste rock – in the form of large rock – was removed ahead of the processing plant without lowering metal production . “ This made it possible to eliminate 85 % of the fine flotation waste , obtain corresponding energy and cost savings , and increase the gold content from about 1 g / t to 5-6 g / t for further processing ,” it said . IM
MEI Conferences
PHYSICAL SEPARATION ‘ 24
June 10-12 , 2024 | Cape Town , South Africa
Sponsored by : Capstone Copper , Comex Group , International Mining , Minerals Engineering & the Critical Minerals Association
MILL CIRCUITS ‘ 24
June 13-14 , 2024 | Cape Town , South Africa
Sponsored by : Capstone Copper , International Mining , Minerals Engineering & the Critical Minerals Association
PROCESS MINERALOGY ‘ 24
November 11-13 , 2024 | Cape Town , South Africa
Sponsored by : Capstone Copper , ZEISS , Promet101 , AECI , International Mining , Minerals Engineering & the Critical Minerals Association
CRITICAL MINERALS ‘ 24
November 14-15 , 2024 | Cape Town , South Africa
Sponsored by : Capstone Copper , Promet101 , AECI , International Mining , Minerals Engineering & the Critical Minerals Association
COMMINUTION ‘ 25
Marcg 31 - April 3 , 2025 | Cape Town , South Africa
Sponsored by : King ’ s Beads , Russell Mineral Equipment , Global Met Tech , Glencore Technology , ME Elecmetal , Metso , Eracles , FLSmidth , Magotteaux , CiDRA Minerals Processing , Weir Minerals , Capstone Copper , Sino Grinding , Metcelerate , Nesch Mintec and CITIC Heavy Industries International Mining , Minerals Engineering , CEEC & the Critical Minerals Association
www . min-eng . com / conferences /
MARCH 2024 | International Mining 63