Tag Archives: TOMRA

TOMRA’s XRT recovery tech come up trumps for Lucara Diamond Corp at Karowe

Diamond mining, Mine operation news, Mineral processing, Sustainable mining, , , ,

One of the largest rough diamonds in recorded history, a 2,492-ct stone, was recovered recently by Lucara Diamond Corp. with TOMRA X-Ray Transmission (XRT) technology aiding the recovery at the Karowe mine in Botswana.

This extraordinary diamond is the latest of many impressive record-breaking recoveries achieved at the mine’s Mega Diamond Recovery Plant since the installation of the two TOMRA COM XRT 1200 / D 2.0 sorters in 2017, when Lucara initiated a transformation in the diamond mining industry’s recovery process. By integrating XRT early into the flowsheet, post primary crushing, it is possible to recover liberated and free exceptionally large diamonds earlier in the process, thereby extracting revenue from the flowsheet faster and safeguarding diamond value from potential downstream damage or breakage.

The 2,492-ct stone is historically the second-largest diamond ever discovered, following the 3,106.75-ct Cullinan diamond found in 1905. However, it is the largest diamond ever recovered directly from run-of-mine ore. It was followed, just a few weeks later, by a 1,094-ct diamond – the sixth rough diamond weighing more than 1,000 ct to be recovered at the mine, and one of the top 10 largest diamonds in history.

“We at TOMRA Mining are immensely proud to be part of Lucara’s incredible journey,” Albert du Preez, Head of TOMRA Mining, says. “Our XRT technology has played a pivotal role in their historic recoveries, including the 1,758-ct Sewelô and the 1,109-ct Lesedi La Rona diamonds. These milestones are a testament to the power of innovation and collaboration in the mining industry. This achievement underscores the exceptional capabilities of our XRT technology and the dedication of our team. We are committed to supporting Lucara, and ensuring they continue to achieve remarkable success.”

Corné de Jager, Diamond Segment Manager TOMRA Mining, said: “15 of the top 23 largest diamonds, bigger than 400 ct, recovered since TOMRA XRT bulk concentration installations commenced fully in the diamond industry in 2014, were recovered with our technology – 13 of them at Lucara’s Karowe mine, which holds record-breaking finds in various categories. In fact, our TOMRA XRT technology has contributed to the recovery of seven of the top 10 largest diamonds in history at the Karowe mine.”

The exceptional find at Lucara’s Karowe mine was swiftly followed by the announcement of another remarkable recovery with TOMRA’s XRT technology in Sierra Leone. The 391.45-ct diamond was unearthed at the Meya mine in Kono District. In 2017, the famous and historic Type IIa 476.7-carat Meya Prosperity was also recovered with TOMRA’s XRT.

TOMRA’s innovative high-capacity XRT technology offers precise detection and ejection of exceptionally large and even the smaller particle sizes, and proprietary image processing deliver 100% detection in the specified size range irrespective of luminescence or surface coating, with a guaranteed diamond recovery rate above 98% and remarkably low yields, according to the company. In addition, the unique TOMRA COM XRT 300 / FR final recovery sorter featuring TOMRA’s proprietary ultra-high resolution sensor technology and precise ejection has revolutionised final recovery processing to efficiently deliver an ultra-high diamond-by-weight concentrate, thereby contributing to improved & focused downstream security and reduced hand sorting.

Today, TOMRA says it is the only manufacturer to offer a full recovery service from 2mm to 100mm with a flowsheet covering the entire process – from high-capacity concentration (+4-100 mm) to Final Recovery and Sort House applications (+2-32 mm), which includes a detailed analysis of customers’ requirements and the collaborative development of an XRT technology-based flowsheet. With its holistic approach and XRT technology, TOMRA is helping diamond operations in Africa, Canada, Brazil and other countries around the world to maximise recovery while optimising costs – with the additional benefit of a smaller environmental footprint.

Australia’s AMGC accelerating muon detection, hyperspectral imaging mining work

Base metals, Energy minerals, Environmental, Mine operation news, Mineral project development, Mining services, Precious metals, Sustainable mining, , , , , , , , , , , , , ,

Cosmic rays and hyperspectral imaging are central features in two mining technology projects backed by the Advanced Manufacturing Growth Centre, with major implications for safety and access to strategically important materials, the centre says.

mDetect is a Swinburne University (Melbourne, Australia) spinout specialising in astrophysics research into muons, a type of subatomic particle that results from the Earth’s atmosphere being hit by cosmic rays. They are sometimes described as the heavy cousin of electrons, with their mass helping them pass deep into objects; much further, for example, than ground penetrating radar.

The company has commercialised telescopic devices and software in a system that uses muon behaviour to monitor and map tailings dams, providing real-time information on stability of the critical infrastructure in mining operations.

Assisted by A$248,191 ($161,354) in co-funding from AMGC’s Commercialisation Fund, mDetect has trialled its muography-based imaging system at OZ Minerals (now part of BHP) operations, and leveraged key partner Swinburne to assist with development, documentation, design for manufacture, production automation and other input ahead of scale manufacture. Back in 2021, the AMGC said OZ Minerals was expected to trial this at Carrapateena in South Australia.

Co-founder of mDetect, Dr Jerome Donovan, said: “Thanks to AMGC, we’ve gone from idea to impact, developing our product for commercial sales, securing key agreements and developing our design for scaling manufacturing – it has by far been our best government-funded program experience. With high-profile partnerships secured, mDetect is set to revolutionise global industries and enhance mining safety.

“Taking highly-technical IP – and which has heritage in dark matter research, no less – and delivering a market-ready product is never easy. But we are very nearly there thanks to the support from AMGC.”

The project is expected to lead to A$7.7 million in revenues in the fifth year after completion and has already resulted in new jobs at the growing company, according to the centre.

AMGC Managing Director, Dr Jens Goennemann, added: “An Australian manufacturer harnesses the power of space to protect lives on Earth. That’s Australian manufacturing at its best – globally relevant, collaborative and highly complex. mDetect is truly a leader in their field, poised to make a global impact.”

From using space particles to leveraging electromagnetic imaging, EQ Resources, the owner of the formerly dormant Mount Carbine tungsten mine in north Queensland, has devised a method to identify and extract tungsten from waste sources, following its discovery at the site in the year 1895.

AMGC supported EQ Resources through A$600,000 in co-investment to support a project to recover tungsten from a mine waste stockpile and low-grade deposits, incorporating hyperspectral imaging sensors on a wheel loader, artificial intelligence-assisted decision making, and X-ray sorting technology.

The project linked EQR with Mt Carbine Quarrying Operations, Plotlogic, TOMRA, Cronimet and the University of Queensland. It has helped deliver an additional A$3.6 million in revenues since completion of the project, according to the centre.

Photography for EQ Resorces at Mt Carbine Operations, 21 Sep 2022.

Kevin MacNeill, CEO of EQ Resources, said, “Early co-investment form AMGC allowed EQ Resources to accelerate the commercial development of our technology, furthermore it gave us the credibility to apply for follow-on programs and secure a A$6 million grant from the Critical Minerals Accelerator Initiative to move from pilot to operational scale.

“EQ Resources’ hyperspectral imaging technology demonstrates that there is still significant life in historical mines where waste piles are mountains of opportunity – in this case 130-year-old piles of tungsten containing waste.”

Goennemann said: “In taking a step back two centuries ago and looking at the resources we already have a hand, EQ Resources will be able to extract greater value from resources long-thought unusable both here in Australia and abroad.”

TOMRA taps into deep learning AI network for latest ore sorting advances with OBTAIN

Automation, Comminution of minerals, Environmental, Mineral processing, Mining services, Mining software, Sustainable mining, , , , , , , , ,

TOMRA is looking to leverage artificial intelligence as part of a plan to unlock new opportunities for mining operations using its sensor-based sorting technology.

The company explained: “The ability of computer systems to mimic human thought and decision making to perform tasks that traditionally required human intelligence has played an important role in TOMRA’s sensor-based sorting solutions for decades, automating the process and improving the accuracy and efficiency of the sorters, unlocking value for mining operations.

“Over the years, sensor-based sorting technology has developed, and TOMRA has been using machine learning in its X-ray Transmission (XRT) and Near-Infrared (NIR) sorters for the last 10 years.”

Now TOMRA Mining is opening a new era in sorting with its latest innovation, OBTAIN™, which leverages deep learning to bring single-particle precision to high throughput particle sorting, it says. This solution takes capacity, quality and recovery to a new level, and unlocks value through a wealth of extremely detailed and accurate data for better-informed decision making, it added.

This software uses a neuronal network to identify the properties of each particle accurately and independently of the sorter’s capacity, achieving new-found precision and reliability in detection and ejection. Based on its specific requirements, the mining operation has the flexibility to either enhance the throughput of the sorter while maintaining consistent sorting efficiency or improve sorting precision without compromising the existing throughput.

TOMRA says: “OBTAIN proves advantageous for a fully operational mine by enhancing recovery rates and elevating product quality within the existing throughput. Conversely, in mines with additional capacity, it facilitates increased throughput without compromising product quality. Furthermore, this innovative technology has the capability to unlock untapped value from low-grade ore, waste dumps, or materials previously deemed uneconomical for processing.”

OBTAIN will also add value to a mining operation with a wealth of extremely detailed and accurate data, such as precise online particle size distribution of the feed.

When used in combination with TOMRA Insight, it can provide the customer with detailed reporting on the performance of the sorter and its components to help them optimise the process, as well as enable them to plan for predictive maintenance, the company says.

The OBTAIN software has been developed for TOMRA’s XRT sorters. It will be available on new models, but there will also be an upgrade package available for existing machines, providing a significant opportunity for customers already operating TOMRA XRT sorters, to substantially enhance the sorting performance where it proves to be a suitable solution.

TOMRA has partnered with two customers to test the OBTAIN in real working conditions. The software has been operating for close to 18 months at the Wolfram Bergbau & Hütten tungsten mine in Mittersill, Austria, where it has delivered consistent and reliable performance. The vicinity of the mine to TOMRA’s development team, based in Germany, has made it a suitable testing ground for the first phase, as they have been able to monitor it closely. A second phase of testing to quantify the improvements has been carried out with a trusted long-standing customer in a magnesite application. The successful tests have shown that OBTAIN is ready to transform sensor-based XRT sorting in numerous applications, according to TOMRA.

TOMRA Mining complete diamond solution attracts interest of operations

Diamond mining, Mineral processing, Mining equipment, Mining services, Mining software, ,

The priority at the top of the list of every diamond producer is to maximise diamond recovery, while optimising costs as well as acting on the growing pressure to address corporate social responsibility and environmental issues. This is where TOMRA Mining says it can help.

TOMRA’s holistic approach and cutting-edge technologies have proven to deliver consistently exceptional recovery rates, significant cost savings, operational advantages and a smaller environmental footprint, the company says. In particular, its complete diamond recovery solution is attracting fast-growing interest of diamond producers of all sizes – from large-scale operations to small mines – from different parts of the world. TOMRA is receiving increasing enquiries from existing and new customers, looking to update their plant or complete the process with TOMRA’s revolutionary Final Recovery sorter.

A key element of TOMRA’s full solution is the COM XRT 300 /FR Final Recovery sorter, which the company has been demonstrating at its Demo Rooms in Wedel, Germany, and Johannesburg, South Africa. These demonstration facilities are proving particularly valuable for diamond operators, who have the opportunity to experience first-hand the unique benefits of this revolutionary and easy-to-operate compact final recovery sorter, the company says. They can watch accurate demonstrations of typical final recovery, sort house and single particle sorting functions, across various size fractions with either kimberlite or alluvial ore, and experience sorter outputs at various feed rates exhibiting actual on-mine conditions. The TOMRA operator can show them how their unique operational requirements would be addressed on a live easy-to-use HMI (Human Machine Interface) panel.

“The biggest advantage of these demonstrations is that the customer experiences the extremely low yield – that is the ultra-high diamond-by-weight concentrate – delivered by the sorter,” Corné de Jager, Diamond Segment Manager TOMRA Mining, says. “This in turn highlights the significant downstream benefits with regards to hand sorting and security. What’s even more impressive for them to see is the exceptionally low amount of gangue ejected with the diamond concentrate, even for the difficult-to-sort ultra-fine size fractions.”

TOMRA has also demonstrated the COM XRT 300 /FR sorter at the Electra Mining Show 2022, performing simulated operational production runs for the entire duration of the exhibition. The sorter was fed with fine alluvial ore, which had diamond dust tracers and diamonds added.

“This realistic and live operation drew a never-ending stream on show goers,”  de Jager says. “The live demo show has resulted in numerous enquiries and sales. In fact, a ‘hands-on’ CEO of a large diamond operation had lengthy discussions with the TOMRA team on site. In front of the crowd, he asked us to process 1 kg of alluvial gravel and to include 150 diamond tracers and 10 diamonds. The sorter delivered a perfect result, ejecting all 160 added tracers and diamonds, with minimal ore particles. The crowd cheered, while the CEO shook hands with our TOMRA design specialist.”

Corné de Jager, Diamond Segment Manager TOMRA Mining

TOMRA’s complete partnered diamond recovery solution

TOMRA says it is the only manufacturer to offer a complete Partnered Diamond Recovery Ecosystem – a full recovery service from 2-100 mm with a flowsheet covering the entire process – from high-capacity Concentration (+4-100 mm) to Final Recovery and Sort House applications (+2-32 mm). It includes a detailed analysis of the diamond producer’s requirements and operational needs, the collaborative development of an X-Ray Transmission (XRT) technology-based flowsheet, all the way to installation. After commissioning, TOMRA remains at the side of the diamond producer, to provide on-site and advanced remote support with specialized services and training. The complete solution can also include secure cloud computing benefits of the optional web-based TOMRA Insight service, that offers onlineand near real time performance metrics of all the sorters.

TOMRA is today, it says, the world’s leading supplier of XRT diamond recovery technology, having recovered some of the largest and rarest gemstones in history. The extremely precise detection and ejection of even the smaller particle sizes, proprietary image processing and large capacity of TOMRA’s XRT sorters deliver exceptionally high concentration factors and recovery rates in high tonnage diamond concentration applications. In fact, its promise to customers is simple: 100% detection in the specified size range, irrespective of luminescence profile or coating, and a guaranteed diamond recovery greater than 98%. This consistent performance has allowed diamond mines to revolutionise the entire process plant design.

In Final Recovery, the performance of TOMRA’s XRT proprietary ultra-high resolution sensor and precise ejection technology has revolutionised this stage of the process to efficiently deliver recovery rates greater than 99% along with an ultra-high diamond-by-weight concentrate with yields as low as 0.05%. This in turn has created a unique proposition for the significant reduction of traditional hand sorting, with higher capacities than existing single particle sorters.

TOMRA XRT ore sorters providing Mt Carbine with tungsten upgrade, circular economy advantages

Comminution of minerals, Energy minerals, Mine operation news, Mineral processing, Mining equipment, Sustainable mining, Water management, , , , , , , , , , ,

TOMRA X-Ray Transmission (XRT) sorters are providing a game-changing solution for the EQ Resources-owned Mt Carbine mine in Queensland, Australia, reducing costs and achieving high-purity tungsten ore for follow-on processing while contributing to a circular economy by producing green aggregates for sale, the ore sorting company says.

The Mt Carbine mine, northwest of Cairns, Queensland, was acquired by EQ Resources in 2019. The company entered a joint venture with Cronimet Group to set up tungsten extraction from the mine’s large waste dump and tailings. It is also planning to operate the open pit and underground mine, of which it has full ownership.

EQ Resources management has a long-standing relationship with TOMRA, having used its sorters with success on a variety of projects since 2011, TOMRA says. Based on this experience, the company turned to TOMRA once again for the Mt Carbine mine, with test work conducted at TOMRA’s Test Center in Wedel, Germany, confirming its XRT technology would provide the solution for the project.

“We were confident it would work, but we sent a small sample for testing to make sure,” Kevin MacNeill, CEO of Mt Carbine mine, EQ Resources, said. “The advantage of TOMRA’s sorters compared to others is in the image resolution: it is able to resolve the finer inclusions in the tungsten. This high resolution gives us better recovery and more control over the sorting process.”

Mt Carbine is currently mining the 12 Mt of low-grade historical stockpiles. The ore is crushed and screened at 6 mm and 40 mm. Two TOMRA XRT sorters are used to pre-concentrate the feed in the 6-40-mm-size range before processing in the wet plant. Approximately 10% of the sorters’ feed mass is ejected as product with a recovery of tungsten of well over 90%. This means only 10% of the mass is processed in the wet plant, dramatically cutting running costs, reducing the required size of the wet plant, as well as saving water and energy, TOMRA says.

“We let the technology do the work for us and take out all the rubbish and we’re left with just the pure tungsten to send to the processing plant – and we do that very cheaply using the sorters,” MacNeill says. “One of the best things about the TOMRA XRT is the cost savings to the operation. It costs approximately A$1.5/t ($1.02/t) to sort and then it costs A$14/t for wet processing: as we take out 90% of the sortable fraction mass, we only have to process 10% of the higher grade concentrate and natural -6 mm material while maintaining recovery, so our cost benefit is obvious.

“We couldn’t afford to run this waste dump if we had to crush everything to 6mm and process it through the wet plant, it would be too low grade and costly.”

EQ Resources is also taking advantage of the TOMRA XRT sorters to create an additional revenue stream from the waste material.

MacNeil explained: “Normally you would grind the waste down to 6 mm and put it through the jigs, but, by putting it through the TOMRA sorters, we are able to keep a whole range of aggregates on the coarser size fractions. The sorters remove any material containing acid-forming sulphides and the waste rock that comes out is incredibly clean. We are, therefore, able to use it in making all kinds of different quarry products – from road bases to concrete aggregates. It’s a perfect example of a circular economy.”

“Selling these green aggregates adds a significant portion to our business – about A$5 million a year – and that’s all because of the TOMRA sorters. In fact, we’ve probably paid for each machine from this revenue five times over.”

The TOMRA XRT sorters are delivering both environmental and business benefits to the Mt Carbine operation, to the satisfaction of MacNeill: “They’re dry, they create no water usage, they require very little power compared to what we use in the processing plant, so it’s a real advantage to us to have these, and we’re looking at purchasing a third one in the near future.

“From an environmental point of view, I think the TOMRA sorters will play a huge role in the future because of their capability of removing sulphides. If you remove sulphide before stockpiling waste rock, you will have the benefit of no acid creation and drainage – and it would reduce your footprint in your closure plans.”

Metso Outotec aims for higher capacities as ore sorting offering develops

Base metals, Bulk handling, Environmental, Mineral processing, Mining equipment, Mining services, Precious metals, Steel and iron ore, Sustainable mining, Water management, , , , , , , , , , , , , , , , , , , , , ,

The entry of Metso Outotec into the bulk ore sorting space arguably heralds the beginning of a new stage of market adoption – one that is focused on significant throughputs across multiple commodities.

In May, the mining OEM announced a collaboration agreement with Malvern Panalytical, a company that has been using Pulsed Fast Thermal Neutron Activation (PFTNA) technology onboard its cross-belt analysers to analyse and help divert ore and waste streams with improved accuracy.

Up until that announcement, Metso Outotec had mooted the benefits of bulk ore sorting in several industry articles. On the smaller scale, it had also renewed its ongoing agreement with particle ore sorting major player, TOMRA.

The company said its agreement with Malvern Panalytical, which has previously worked on bulk sorting projects with Anglo American among others, brought together its expertise in crushing and bulk material handling solutions with Malvern Panalytical’s ore analysis nous to offer an industry-leading portfolio of solutions for bulk ore sorting.

Rashmi Kasat, Vice President, Digital technologies at Metso Outotec, said in the press release that the pact with Malvern Panalytical would allow the company to meet the industry’s increasing sustainability and resource efficiency needs in an enhanced way in the early comminution stage.

“Sensor-based bulk ore sorting and data-driven analysis upgrades low grade or waste stockpiles, making them economical and far less energy-intensive to treat,” she said.

There are obvious positive benefits up- and down-stream of sensor-based sorting too, with the ability to carry out a low-cost mining method (upstream), as well as reduced capital investments in downstream equipment already shown with early-adopter projects.

That is before considering the relative energy and water reduction requirements that come with applying the technology.

Kasat later told IM that the company’s existing portfolio of material handling modules, crushing stations or mobile crushing equipment, as well as bulk material handling solutions, already “complement” the concept of bulk sorting.

“The addition of the bulk sensor is easily achieved,” she clarified. “The diversion mechanism will be included as well to be able to offer the whole plant out of one hand.”

With crushing stations – at least in the in-pit crushing and conveying (IPCC) space – that can go up to 15,000 t/h (see the company’s Foresight™ semi-mobile primary gyratory station), the prospect of Metso Outotec making a concerted effort to get into the bulk ore sorting space bodes well for the rising throughputs of projects.

NextOre recently claimed it had commissioned the world’s largest bulk ore sorting system at First Quantum Minerals’ Kansanshi copper mine in Zambia. This installation, which uses the company’s magnetic resonance technology, comes in at a 2,800 t/h-rated capacity.

Scantech, meanwhile, recently confirmed it has a GEOSCAN GOLD installation using prompt gamma neutron activation analysis technology for bulk sensing/sorting up and running that uses a diversion system at conveyed flow rates of more than 6,000 t/h.

Kasat, without naming a range, confirmed Metso Outotec was targeting “higher capacities” in line with the sensors available on the market. She also clarified that the agreement with Malvern Panalytical was “non-exclusive”.

“We will choose all our sensor/analyser partners strategically,” she explained. “Malvern Panalytical has a leading position and history in this field with proven technology for ore sensing. We will leverage our and their Tier 1 position in the industry for our bulk ore sorting offering.”

Malvern Panalytical uses Pulsed Fast Thermal Neutron Activation technology onboard its cross-belt analysers to analyse and help divert ore and waste streams with improved accuracy

As the type of sensor to be employed varies based on several factors including mineralogy, plant capacity, application of bulk ore sorting, etc, Metso Outotec will identify the right partners for the right need, she explained.

The major constraints for these sensors are often measurement times and sensor penetration, according to Kasat.

“There are very few sensors out there that can do sensing of a 500-mm-deep bed of rock on a conveyor belt, moving at 5-6 m/s,” she said. “But our current and future prospective partners are working on developing the technologies to reduce measurement times without compromising the accuracy of measurement.”

The mining OEM is looking to, in most cases, provide ‘plug and play’ flowsheets for bulk ore sorting and then carry out the required customisation per sensor.

This plan reinforces Kasat’s assertion that there is no ‘one-size-fits-all’ concept in bulk ore sorting applications.

For new projects, the process could see the company start with metallurgical testing, progress to mobile/fixed pilot plants in the “backyard” to test the accuracy of the sensors for the given application, and then find the right solution for the customer’s use case.

Renato Verdejo, Business Development Lead for Bulk Ore Sorting at Metso Outotec, added: “For existing plants, we will install the sensor over the belt conveyor and analyse the results after selecting the right sensor for this sorting application.”

Metso Outotec intends to focus on major commodities like copper, iron, nickel and gold, among others, with applications such as waste/ore sorting, low grade re-crushing and beneficiation process optimisation.

Within this wide remit – and in line with its non-exclusive agreements with Malvern Panalytical and TOMRA – the company is also considering the combination of both bulk and particle sorting in flowsheet designs.

Metso Outotec, in 2021, renewed its ongoing agreement with particle ore sorting major player, TOMRA

“The combination of the superior throughput of a bulk application with the selectivity of particle sorting in a rougher-scavenger setup is something that can bring sorting to high volume mines in the future,” Kasat said.

“Plant concepts and flowsheets have already been conceptualised and we expect the first deliveries to be in pilot stations to test the sensors on site,” she added, saying that the tonnage requirements for bulk ore sorting sensor validation meant a bulk sensor would have to be piloted in the field to get statistically meaningful data about the properties of the deposit.

Metso Outotec’s crushing system offering will form the “base” for these solutions, with ore sorting optionality available to all customers, she said.

This sensor-based optionality also overlaps with another in-demand part of Metso Outotec’s business: IPCC.

The company’s dedicated team in Germany are responsible for this area, developing projects backed by comprehensive studies.

They – like most of the industry – are aware of the potential application for sensor-based ore sorting in IPCC projects.

Markus Dammers, Senior Engineer of Mine Planning for Metso Outotec and one of the team members in Germany, said there were applications for both bulk and particle sorting in IPCC applications, with the former likely integrated after primary crushing and the latter after secondary/tertiary crushing.

“Bulk ore sorting in an IPCC application should be integrated after primary crushing in order to recover marginal material determined as waste in the block model, or reject waste from the ore stream,” he said.

Bulk ore sorting in an IPCC application should be integrated after primary crushing in order to recover marginal material determined as waste in the block model, or reject waste from the ore stream, according to Markus Dammers

If integrated after secondary or tertiary crushing, it becomes less effective, with the ore’s heterogeneity decreasing every time the ore is rehandled, transferred, crushed, blended, etc.

“In this manner one can take advantage of the natural variability in the deposit, rather than blending it out, with bulk ore sorting,” he said.

After secondary and tertiary crushing, particle sorting may be applied as a “standalone or subsequent ‘cleaner’ process step”, he added.

With Metso Outotec open to the inclusion of ore sorting in fully-mobile, semi-mobile and stationary crushing stations within an IPCC context, the company has many potential customers – existing and new – out there.

And that is just in IPCC applications.

The company also has hundreds of crushing stations on fixed plant installations that could represent potential sorting opportunities.

Metso Outotec, on top of this massive install base, has a few advantages over traditional ore sorting vendors in that it understands the plant that goes around the analysis and diversion process associated with ore sorting; knows how important uptime is to its customers; and, through sophisticated modelling, realises what impact changes in the flowsheet will have up- and down-stream of such equipment.

“The key point here is to have all the equipment to handle and process the ore to feed the sorter and, later, having the technology to divert the material and retain the availability of the plant without changes,” Kasat said.

Energised by its Planet Positive aims of responding to the sustainability requirements of its customers in the fields of energy or water efficiency, emissions, circularity and safety, the company is now ready to flex its processing plant muscles to increase the industry’s adoption of bulk and particle sorting technology.

TOMRA Mining to demonstrate Final Recovery diamond sorter at Electra Mining 2022

Diamond mining, Mineral processing, Mining events, Mining services, Mining software, , , , , , , , , , , , , , ,

TOMRA Mining will showcase its sensor-based sorting solutions at the Electra Mining 2022 exhibition, in Johannesburg, South Africa, in September, showcasing, for the first time, live demonstrations of its COM XRT 300 /FR Final Recovery sorter for diamond operations.

Representatives from its Sales and Field Service teams will also present TOMRA’s offering of advanced digital products and services, such as the TOMRA Insight cloud-based platform and its latest generation TOMRA ACT PC-based system, as well as its portfolio of sorting solutions for the diamonds, metals and industrial minerals industry at the show, which runs from September 5-9.

Corné de Jager, Diamond Segment Manager TOMRA Mining, said: “The Electra Mining Show is the perfect platform for us to showcase TOMRA’s advanced mining solutions. This important exhibition attracts a wide audience – from operators and metallurgists – interested in smart solutions that are simple to operate and maintain, to decision makers who need to be up to date with the latest value-adding technologies. At the event we will have the opportunity to meet them face-to-face and discuss their requirements, giving them a taste or TOMRA’s collaborative approach, product expertise and after-sales support.”

TOMRA will demonstrate the Final Recovery sorter with fine kimberlitic or alluvial ore together with diamond powdered tracers in a Final Recovery and Sort House application. Visitors will be able to experience first-hand the sorter’s capability to produce an ultra-high diamond-by-weight concentrate with an exceptionally low yield by using TOMRA’s proprietary ultra-high-resolution sensor, advanced new image processing and high-precision ejector valve system, the company says. The sorter offers 100% diamond detection within the specified size fraction and > 99% guaranteed diamond recovery with appropriate feed material preparation.

“We are very excited to demonstrate the TOMRA COM XRT 300 /FR sorter,” de Jager says. “It completes our unique partnered diamond recovery ecosystem, which covers the entire process. We are now able to offer our customers a full XRT solution to sort +2-100 mm particles: +4-100 mm particles with our bulk concentration sorters, and +2-32 mm particles with the COM XRT 300 /FR in its Final Recovery, Sort House or small-capacity exploration applications. The sorter offers higher efficiency, better grade, simplified security requirements with fewer sorting stages and a smaller footprint. It reduces complexity and operational costs, and unlocks the potential for previously deemed non-profitable projects and marginal deposits to be economically viable. ”

The COM XRT 300 /FR sorter can also add value to existing kimberlitic and alluvial operations that use conventional bulk-concentration methods like rotary pans, dense medium separation or X-ray luminescence, if installed in a Final Recovery and/or Sort House function after these existing processes. With a contained capital expense, operations can benefit from a quick, simple and significant revenue gain, TOMRA says.

The TOMRA team at the exhibition will explain the full benefits of its complete partnered diamond recovery ecosystem consisting of XRT technology covering the entire process – from Bulk Concentration to Final Recovery and Sort House applications – as well as its advanced digital products and services. These include the newly refreshed TOMRA ACT PC-based system interface and TOMRA Insight cloud-based subscription solution.

TOMRA Mining has 190 sorter installations operating around the world, of which more than 60 are in Africa. It offers installation opportunities in Africa in the metals industry, for example in applications such as lithium, chromite, platinum, manganese and gold.

Tungsten West breaks ground at Hemerdon for TOMRA XRT ore sorters

Comminution of minerals, Energy minerals, Mine operation news, Mineral project development, Mining equipment, Precious metals, , , , , , , ,

Tungsten West says it has broken ground at its Hemerdon tungsten-tin mine in Devon, England, with the first sod turned for the installation of the TOMRA X-ray Transmission (XRT) sensor-based ore sorters.

This event, the company says, marks another major step in the company’s upgrade and refurbishment plans for the project’s processing plant.

Hemerdon is, Tungsten West says, the third largest tungsten resource globally, as well as being a previously producing mine that was operational from 2015-2018. Tungsten West purchased the Hemerdon Mine in 2019, and has since completed a bankable feasibility study that demonstrated an extensive reserve of approximately 63.3 Mt at 0.18% W and 0.03% Sn, as well as 37.4 Mt of saleable aggregate material. The company estimates that the life of mine is currently 18.5 years with the opportunity to extend this through future investment.

As announced earlier this month, the company took receipt of important long-lead equipment items, including the seven XRT ore sorters, which will make up part of the upgraded equipment the company plans to install into the front end of the processing plant. The XRT ore sorter will substantially improve and streamline operations once production restarts, minimising plant downtime, increasing recovery as well as a host of ESG benefits, it said.

After significant test work, Tungsten West engaged TOMRA to supply the seven units that are required to treat the run of mine throughput. This consists of six duty units and one standby unit. Orders and deposits for these units were placed in 2021 and the units have now been delivered to the UK and await final transfer to Hemerdon where they will be installed in the front end of the processing plant.

Additionally, the company is pleased to announce the appointment of James McFarlane as Managing Director of Tungsten West. McFarlane previously held the position of Technical & Operations Director of the company.

Max Denning, Tungsten West CEO, said: “We are extremely excited to have broken ground at Hemerdon this week, marking an important milestone in the project’s restart. Ensuring the UK and the western hemisphere have got access to two key critical minerals has never been more profound. We are also delighted to announce James as our new Managing Director; his extensive experience will prove invaluable in the company’s development as we move closer to first production at Hemerdon.”

Tungsten West makes EPCM progress at Hemerdon as TOMRA XRT ore sorters hit the road

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Tungsten West has named Fairport Engineering Limited as its engineering, procurement and construction management (EPCM) contractor at the Hemerdon tungsten-tin project, in the UK, as well as confirmed it was soon expecting to receive seven X-ray Transmission (XRT) sensor-based ore sorters from TOMRA.

Since successfully listing on the AIM Market of the London Stock Exchange, Tungsten West has been advancing the development of Hemerdon, which is one of the most advanced mining projects in England and is expected to be a key future global supplier of tungsten and tin.

Hemerdon is, Tungsten West says, the third largest tungsten resource globally, as well as being a previously producing mine that was operational from 2015-2018. Tungsten West purchased the Hemerdon Mine in 2019, and has since completed a bankable feasibility study that demonstrated an extensive reserve of approximately 63.3 Mt at 0.18% W and 0.03% Sn, as well as 37.4 Mt of saleable aggregate material. The company estimates that the life of mine is currently 18.5 years with the opportunity to extend this through future investment.

On top of the ore sorters, Tungsten West said the rest of the long-lead items had been ordered and were scheduled for delivery within the company’s timetable. It plans to recommence mining this year.

The upgrade and refurbishment of the existing processing plant at Hemerdon is centred around the optimisation of the existing concentrator circuit as well as the introduction of a new crushing and screening circuit that will then feed into a new XRT ore sorting stage. These upgrades will streamline processing, minimise plant downtime and improve recovery rates, according to the company.

After significant test work, Tungsten West engaged TOMRA to supply the seven units that are required to treat the run of mine throughput. This consists of six duty and one standby units. Orders and deposits for these units were placed in 2021 and the units have now been delivered to the UK and await final transfer to Hemerdon where they will be installed in the front end of the processing plant.

On top of this, six new screens and 11 vibrating pan feeders have been ordered from Vibramech of South Africa at fixed prices. These will replace the existing large screens, which caused the low frequency issues, and were a key contributor to plant downtime under Wolf Minerals – the previous owner of Hemerdon. Delivery is expected in the June quarter of 2022.

Max Denning, Tungsten West CEO, said: “We are extremely pleased with progress at site, particularly the onboarding of Fairport Engineering to undertake the detailed design and construction of the project. We are looking forward to working with Fairport as we move towards restarting full production at Hemerdon, with a substantially improved processing route, through the introduction of XRT ore sorting and upgraded processing equipment. The company has assembled a strong projects and operations team, and we remain confident in our progress.”

TOMRA’s XRT solution creates value from waste at Mina Esperanza de Caravelí in Peru

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The integration of TOMRA’s ore sorting technology at the Mina Esperanza de Caravelí mine in Peru has helped the polymetallic miner produce more metal as well as clean up its legacy tailing operations.

The close collaboration between two companies emphasises a shared philosophy, that of making the most of natural resources and embracing a circular economy.

Mina Esperanza de Caravelí, owned by MTP and operated by Minera Croacia, is a polymetallic vein deposit with a mining rate of 150 t/d. It is located in the district of Atico, in the Nazca-Ocoña geological gold belt in the southern part of Peru, and contains narrow veins with a rosary formation, of which over 30 have been discovered so far. The mineralisation is located in vein fill fractures of hydrothermal origin and are mesothermal in appearance.

In 2019, Minera Croacia contacted TOMRA to explore a solution to extract value from low-grade material previously deemed uneconomical, and to address the environmental issue of metals left in the dumps.

Marco Fernandez Concha, Senior Geologist to Minera Croacia, said: “Mining operations need to find ways to optimise the use of natural resources while reducing waste and their impact on the environment as much as possible. With TOMRA’s ore sorting technologies, this is possible.”

A sensor-based ore sorter represents a significant investment for a mine the size of Minera Croacia, according to Emilio Uribe, Senior Metallurgical Advisor at Minera Croacia.

“When we purchase important equipment, we need to analyse the solution in great detail because we can’t afford to make mistakes,” he said. “We need it to work and deliver the results we want from the start. TOMRA has adapted to our needs as a small business with limited resources. They have been an important advisor, giving us all the support we needed with highly qualified and knowledgeable staff. They have really committed to the project and found the solution that meets our operational needs and is financially viable for us.”

The teams from TOMRA and Minera Croacia worked closely to precisely analyse the requirements and identify the best solution. TOMRA’s Test Center in Wedel, Germany, conducted three series of tests on samples from the mine to narrow down the requirements. A technical team from Minera Croacia attended the final session, which gave them a better understanding of what TOMRA’s XRT technology could do for their operation.

Christian Korsten, who at the time was the Test Center’s Manager, said: “This project stands out for presenting different types of ores from different locations. Usually we test one or two different ores for a customer, but, with Minera Croacia, we had different metallogenic veins. They were all a little bit different in mineralogy, sensor response and in the customer’s objectives for each.”

Strong communication between the two companies’ teams was crucial to the successful outcome – especially since COVID-19 travel restrictions limited the opportunities for face-to-face meetings.

Mathilde Robben, TOMRA Key Account Manager, said the company ensured Minera Croacia received the support and advice they needed throughout the process.

“We did it all through online meetings,” she said. “The management team and staff at Minera Croacia were always to the point and friendly, and together we completed this fast-track project.”

Korsten agreed: “Minera Croacia had very clear objectives. All our questions were answered in a perfect, fast and professional manner, and the same applies to the discussion of the test results. This project was one of my favourites in almost 10 years in the Test Center.”

Following the detailed analysis of the test results and Minera Croacia’s requirements, Robben proposed the use of a TOMRA COM Tertiary XRT sorter as the solution: a machine suited to the particle size range of the dump material (-25 mm/+ 10 mm and -40 mm/+ 25 mm) and an investment that fitted Minera Croacia’s budget.

The test results made a clear business case for the sorter, showing that out of 1,300 t of run of mine material containing gold and copper, 21% are fines (-10 mm) and screened out. This results into a concentration of gold and copper in the fines and, therefore, this material does not need to be sorted. Of the rest of the material, 34% is enriched, going from a grade of 2.7 g/t gold-equivalent to 5.12 g/t gold-equivalent – almost double.

This leaves 45% of the material discarded as waste with very low metal content, 0.41 g/t gold-equivalent, which addresses the environmental issue, as it contains virtually no contaminants. This also shows that maximum value has been extracted from the material, as there is virtually no gold left, TOMRA said.

Uribe said: “The test has shown that TOMRA’s sorter can create value from material that would have gone to the waste dump, from 33% of the run of mine that is too low-grade for processing to be financially viable.”

The TOMRA COM Tertiary XRT sorter is now installed and has been operating since December 2021 re-processing the mine’s 800,000 t of historic dumps. It is delivering on all counts for Minera Croacia: now able to increase the grade of the dump material that was not considered economic, it has reduced freight costs of the operation as it is now transporting less low-grade material to its processing plant, and it has successfully addressed the environmental impact of its waste materials.

Uribe concluded: “All the calculations we made when we evaluated this investment are being fulfilled. The sorter’s performance is perfectly consistent with the test results, and we expect it to pay for itself as planned within two years – including the other components and infrastructure of the circuit.”

The company’s management is so impressed with the results achieved that it is considering investing in further sorters for low grade run of mine ore with the aim of extracting value from mineral that is currently considered marginal, according to TOMRA.