Sensor-based ore sorting is moving beyond its role as an emerging mining technology, with operators increasingly using it to remove waste before material reaches energy-intensive grinding and beneficiation circuits. A major example came from Western Australia, where TOMRA Mining was selected to supply 22 X-ray transmission sorters for the proposed P2000 expansion at Pilgangoora.
The lithium operation already operates 10 sorters, and its existing sorting system can process more than 1,000 tonnes per hour. The planned expansion would make sorting a more central component of the processing strategy rather than simply an additional pre-concentration stage.
Reducing Processing Costs Before the Plant
The economic case for ore sorting is based on removing waste before it enters the main processing circuit. Material rejected at the sorting stage does not require grinding power, flotation capacity, reagents or additional tailings storage. At Pilgangoora, existing sorting has been linked to estimated electricity savings of approximately 8-15 GWh annually.
The potential benefits become increasingly significant as ore grades decline. Conventional mine expansions can require operators to process progressively greater quantities of rock to maintain production levels. Ore sorting provides an alternative by improving the quality of feed entering the processing plant rather than relying solely on larger processing capacity.
Technology Expands Beyond Lithium
Lithium pegmatites can provide favourable differences between spodumene-bearing ore and barren material, making them suitable candidates for sensor-based sorting. The technology is also being tested across a broader range of commodities, including copper, tungsten, tin, gold and polymetallic ores.
Its application remains dependent on geology and the ability of sensors to consistently distinguish valuable material from waste at commercial processing rates. For that reason, representative bulk ore testing remains an important part of assessing whether sorting can deliver reliable results at industrial scale.
Ore Sorting Enters Mine Planning
The development at Pilgangoora highlights a broader shift in how mining companies view the technology. Ore sorting is increasingly being evaluated not simply as an environmental or waste-reduction measure, but as a way to reduce the volume of material that must be processed through the plant. By rejecting waste earlier, operators can potentially reduce energy consumption and processing requirements while improving plant feed quality. That could give sensor-based ore sorting a much more important role in mine feasibility studies, processing plant design and future mine expansions, particularly as operators face declining grades and rising processing costs.
