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Chapter 14

Sensor-based Ore Sorting

14.1 INTRODUCTION crushing, after sufficient liberation is achieved. Applica-


tions show that many mines have about 30 wt% barren
The term “sensor-based (ore) sorting” (SBS) is introduced waste liberated in the size range 10 100 mm, which
as an umbrella term for all applications where particles allows material to be discarded without significant loss of
are singularly detected by a sensor technique and ejected value. Pre-concentration by sorting is seen as a method of
by an amplified mechanical, hydraulic, or pneumatic pro- improving the sustainability of mineral processing opera-
cess (Wotruba and Harbeck, 2012). Analogous terms tions by reducing specific materials handling require-
include ore sorting, electronic sorting or automated sort- ments, minimizing energy consumption and water in
ing. A variety of sensor types are available and see use in grinding and concentration, and achieving more benign
the minerals, recycling, and food industries. SBS can be tailings disposal (Cutmore and Ebehardt, 2002; Lessard
implemented at various positions in the mineral proces- et al., 2014). The ultimate goal is to minimize specific
sing flowsheet: investment and processing costs while reducing the envi-
1. Pre-concentration ronmental footprint of an operation. Sensor-based sorting
Pre-concentration is defined as a physical separa- can be applied to a waste rejection stage (e.g., base and
tion stage in mineral beneficiation, where a fraction of precious metals) or concentration (i.e., the production of
high grade coarse particles can be separated from the an intermediate or final product, e.g., industrial minerals,
run-of-mine material to produce a final concentrate, ferrous metals, and gemstones). Sorting has also been
prior to downstream processing of particles below ca. used to upgrade previously mined/processed waste-rock
5 mm. material prior to re-processing (von Ketelhodt, 2009;
2. Waste rejection Wotruba and Harbeck, 2012).
Waste rejection is defined as a beneficiation stage SBS is the automation of hand sorting, which is now
where coarse non-valuable waste particles are sepa- extended by the use of additional sensing/detection tech-
rated from the run-of-mine ore. nologies (i.e., techniques are not limited to optical sen-
3. Concentration sors). Hand sorting is the original mineral concentration
Concentration using SBS is the creation of a final process, having been used by the earliest workers several
marketable product. thousand years ago. The practice was recorded by
4. Ore-type diversion Agricola (1556) (Figure 14.1).
Separation of one or more ore types that are fed alter- Hand sorting involves the visual assessment of indi-
nately as batches into the same plant or parallel into mul- vidual ore particles and the rejection of those particles
tiple plant lines for specialized treatment. that do not warrant further treatment. Figure 14.2 shows
hand sorting in the early days of operation at the Sullivan
Note that SBS is almost always used in diamond pro- Mine (Cominco), British Columbia, Canada, which began
cessing flowsheets where the terminology differs slightly: operation in 1909 (Ednie, 2006).
waste rejection is referred to as “concentration” and con- Hand sorting has declined in importance due to the
centration is referred to as “recovery.” need to treat large quantities of low-grade ore which can
SBS refers to a concentration stage which identifies require extremely fine grinding. Hand sorting of some
certain physical or chemical characteristics of individual kind, however, is still practiced (e.g., the removal of large
rock particles and separates them from the process stream pieces of timber or tramp iron from the run-of-mine ore).
via a physical mechanism (Arvidson, 1987). Ore sorting It is also still applied in countries with low labor pay
is commonly undertaken after primary or secondary rates.

Wills’ Mineral Processing Technology.


© 2016 Elsevier Ltd. All rights reserved. 409
410 Wills’ Mineral Processing Technology

underground or at the mine. The techniques are not cur-


rently employed underground due to the need for complex
water handling and retreatment systems (Hughes and
Cormack, 2008; Murphy et al., 2012). Complete SBS
installations are relatively compact (small volume to
throughput ratio), especially when operated dry. Thus,
SBS is commonly employed using a semi-mobile opera-
tion. About 30% of today’s machines being installed are
containerized systems. This being said, there is great
potential for SBS systems integration underground (near-
to-face sorting) especially where stoping and cut-and-fill
methods are used (Schindler, 2003; Dammers et al., 2013;
Robben, 2014).
SBS was first introduced in the late 1940s, and although
its application is fairly limited, it is an important technique
for the processing of certain minerals (e.g., diamonds, ura-
nium, limestone, magnesite, gemstones) (Sassos, 1985;
Salter and Wyatt, 1991; Sivamohan and Forssberg, 1991;
Collins and Bonney, 1998; Arvidson, 2002). Arvidson
(1987) stated that vein-type, layered, brecciated or pebbly
mineralizations were typically good candidate ores for sort-
FIGURE 14.1 Early reference to hand sorting by Agricola (1556)
ing. There is a general misconception that sorters cannot be
(Used with permission Dover Publications, Inc., New York, 1950).
used in massive ores, but full liberation is not necessarily
required for successful waste elimination (Chapter 1).
Complete liberation may be required in certain instances for
concentration, such as when limestone is required for filler
purposes (Arvidson, 1987).

14.2 SENSOR-BASED SORTING PRINCIPLES


Many mineral properties have been used as the basis of
sensor-based sorting, including reflectance and color in visi-
ble light (magnesite, limestone, base metal and gold ores,
phosphates, talc, coal), ultraviolet (scheelite), natural
gamma radiation (uranium ore), magnetism (iron ore), con-
ductivity (sulfides), X-ray fluorescence (base metals), and
X-ray luminescence (diamonds). Infrared, Raman, micro-
wave attenuation, and other properties have also been
tested. Table 14.1 gives examples of the properties that can
be exploited using commercially-available sensor technolo-
FIGURE 14.2 Hand sorting at Sullivan Mine ca. 1915 (Used with per- gies along with example industrial applications. Reviews on
mission Columbia Basin Image Bank).
historical developments, the various sensor types, and appli-
cations are given elsewhere (Salter and Wyatt, 1991;
Early workers identified ore sorting as a key variable Wotruba, 2006; Wotruba and Harbeck, 2012).
which affected the economics of a mine. Rickard (1905) SBS systems inspect particles to determine the value
in the book “The Economics of Mining” stated “whether of some property using contactless and real-time measure-
to (hand) sort or not, is a question of vital importance to ments that obtain both location and material properties.
the economics of a mine; it may mean the choice between The data are processed and the information (e.g., visible
a small yield of high-grade material or a large output of light reflectance) creates a basis for ejection (or retention)
low-grade, which immediately affects all the operations of those particles which meet some criterion (e.g., light
carried on at the surface, as well as underground. . ..” vs. dark particles). Therefore, a distinct difference in the
SBS is reviewed here, but several other waste elimina- required physical property must exist between the valu-
tion methods exist, which are primarily gravity-based pro- able minerals and the gangue. Either valuables or waste
cesses (Chapters 10 and 11) that could be employed may be selected for ejection. Automated sorters consist of
Sensor-based Ore Sorting Chapter | 14 411

TABLE 14.1 Industrial Sensor Technologies and Applications

Sensor Type Material Property Example Applications


Radiometric Natural gamma radiation Uranium
X-ray Transmission Atomic density Base metals, coal
X-ray Fluorescence Compositional analysis Base/precious metals
X-ray Luminescence Visual fluorescence Diamonds
Color Reflectance, brightness, transparency Base/precious metals
Photometric Monochromatic reflection/absorption Gemstones
Near Infrared Spectrometry Reflectance/absorption Industrial minerals
Thermal Infrared Camera Electromagnetic Differential heating Conductivity Base/precious metals Base metals

Modified From Salter and Wyatt, 1991; Robben et al., 2013

four basic subsystems (Arvidson, 1987; Salter and Wyatt, Various sensing technologies that are available and
1991; von Ketelhodt, 2012; Robben et al., 2013): common industrial sensors are listed in Table 14.1.
Electronic processing involves analysis of the data
1. Particle presentation
acquired by the detector. A wide range of site-specific
2. Sensing (particle examination/detection)
algorithms are used, depending on the sensor type and
3. Electronic processing (data analysis)
ore characteristics. Physical separation is typically
4. Separation
achieved using an array of about 200 high speed air
Robben et al. (2013) include a material conditioning valves. Mechanical ejectors are installed in low through-
stage prior to particle presentation. Most important for put units, for example, single particle XRL (X-ray lumi-
successful operation is the presentation of a carefully nescence) diamond or XRF (X-ray fluorescence) sorters.
selected and screened particle size range that shows both Water jets have been discussed and trialed, but have not
liberation and a minimum amount of fine material which found their way into today’s industrial scale sorters
is detrimental for high availability. For photometric sort- (Fickling, 2011; Robben et al., 2013).
ing, particle surfaces sometimes must be moistened or
washed, so that blurring of the signal by a covering layer
does not occur. The upper size limit is technically
350 mm, but nonetheless liberation of barren waste is
14.3 HISTORICAL DEVELOPMENT
often experienced below 100 mm. The lower size limit is First patents for SBS technology originated in the 1920s
technically 0.5 mm for most detection technologies, but (Sweet, 1928). During the 1950s Kelly and Hunter
as the operating costs are inversely proportional to the (K 1 H) developed the Model 6 (M6) photometric sorter,
average particle size (and weight), the economically fea- which was subsequently installed at the Mary Kathleen
sible lower size limit is often in the range of 10 20 mm. uranium mine in Australia (Salter and Wyatt, 1991;
Separation efficiency decreases when a wide range of Stewart, 1967). In 1966, Gold Fields of South Africa
particle sizes is fed to a single machine, the ratio undertook a joint project with Rio Tinto-Zinc (RTZ)
between maximum and minimum particle size (size (through their subsidiary Ore Sorters) to develop sorting
range coefficient) typically should not exceed three technology for use in South African gold-mining opera-
(Robben et al., 2013). tions (Barton and Peverett, 1980). The project culminated
Particle presentation can be achieved via two system with the installation of a Model 13 prototype photometric
types: chute or belt-type systems (shown in Figure 14.3). sorter at the Doornfontein Gold Mine in 1972 (Keys
The chute system senses the particles as they free-fall et al., 1974; Barton and Peverett, 1980). The sorters were
after being guided on a high-incline chute. For the belt the first to use laser technology and are considered the
system, the sensor is mounted above or below the con- first high tonnage sorters (Salter and Wyatt, 1991). The
veyor belt, which feeds a monolayer of particles. The Gunson’s Sortex MP80 machine was probably the first
ore must be fed in a monolayer, as individual particles sorter to employ microprocessor technology (Anon.,
must be displayed to the sorting device for effective 1980). The sorter handled minerals in the size range
separation. 10 150 mm at feed rates of up to 150 t h21.
412 Wills’ Mineral Processing Technology

FIGURE 14.3 Schematics of (a) Belt-type, and (b) Chute-type sorting systems (NIR is near infra-red) (Courtesy Tomra Sorting Solutions).

Rocks having white or gray quartz pebbles in a darker up to 4,000 times per second, and the reflection analyzed
matrix were accepted, while quartzite ranging from light in less than 0.25 μs by photomultiplier tubes and high
green through olive green to black, were rejected. Most of speed parallel processors. One or more of 120 air ejectors
the gold occurred in rocks which reported to the “accept” are fired to divert the value or waste past a cutter and into
category. Uniform distribution of the ore entering the the accept/reject bins. As the position of the rock is accu-
sorter was achieved by the use of tandem vibrating fee- rately identified, and the ejector firing duration is less
ders and the ore was washed on a second feeder to than 1 ms, the sorter can operate very selectively.
remove slimes which could affect light-reflecting quali- SBS has been employed in diamond recovery since
ties. The successful implementation of the Model 13 the 1960s, initially using simple optical sorters and more
sorter led to the development of the RTZ Ore Sorters recently machines based on the fact that diamonds lumi-
Model 16 photometric sorter, which has been used since nesce when irradiated by X-rays (Anon, 1971; Rylatt and
1976 on a wide range of ore types (e.g., magnesite, wol- Popplewell, 1999a,b; Damjanović and Goode, 2000). X-
framite, gold) (Anon., 1981a; Barton and Peverett, 1980). ray luminescence sorters are used in almost all diamond
A subsequent development to the RTZ Ore Sorters operations for the final stages of recovery after the ore
Model 16 is the Ultrasort UFS120 photometric sorter, has been concentrated by DMS (Chapter 11). They replace
which is used in the processing of magnesite, feldspar, grease separation (Taggart, 1945), which exploits the
limestone, and talc. Ore passes from a vibrating feeder to natural hydrophobicity (oleophilicity) of diamonds and is
high pressure water sprays and counterweight feeder now used only in rare cases where the diamonds luminesce
where water is removed and the rocks are accelerated to weakly or to audit the X-ray sorter tailings. Luminescence
form a monolayer. They drop onto a short conveyor mov- is a more consistent diamond property than oleophilicity,
ing at 2 m s21 where they pass via a high speed 5 m s21 and sorters are more secure than grease belts or tables.
“slinger” conveyor into free fall, now well separated. The Figure 14.4 shows an early dry X-ray sorter, in which
rock layer, 0.8 1.2 m wide, is scanned by a laser beam at the DMS concentrates are exposed to a beam of X-rays in
Sensor-based Ore Sorting Chapter | 14 413

detected and used as the means of sorting. The method is


most applicable in the size range 25 150 mm. Boron
minerals are easy to sort by neutron absorption since
the neutron capture cross section of the boron atom is
very large compared with those of common associated
elements and thus the neutron absorption is almost pro-
portional to the boron content of the particles. The tech-
nique has also been tested on gold ores (Uken et al.,
1966, 1968).
Near infra-red (NIR), which has seen wide use in recy-
cling applications, has recently been investigated for use
in the mining industry. It has been successfully imple-
mented for waste elimination from boron minerals (cole-
manite, ulexite) (Dehler et al., 2012). Development work
FIGURE 14.4 Early diamond sorter. A: X-Ray generator; B:
Photomultiplier tubes; C: Air ejectors; D: Feed belt (Courtesy JKMRC has shown promise in separating talc from carbonate and
and JKTech Pty Ltd). quartz (von Ketelhodt and Bartram, 2009), processing
porphyry copper samples (Dalm et al., 2014), and for
waste rock removal in the diamond industry (von
free fall from a conveyor belt, the luminescence detected Ketelhodt and Bartram, 2014).
by photomultiplier tubes and the diamonds ejected by air Photoneutron separation (gamma activation) is
ejectors. Both dry and wet X-ray machines are now recommended for the sorting of beryllium ores. When a
available, and the process is usually multistage to ensure beryllium isotope in the mineral is exposed to gamma
efficient rejection of waste with very high diamond radiation of a certain energy, a photoneutron is released
recoveries. and this may be detected by scintillation or by a gas
The “Lapointe picker” was probably the earliest radio- counter.
metric sorter, developed in Canada and used in the 1940s The RTZ Ore Sorters Model 19 sorter measured con-
(Lapointe and Wilmot, 1952; Bettens and Lapointe, 1955; ductivity and magnetic properties and had application to a
Salter and Wyatt, 1991). Radiometric sorting has since wide variety of ores including sulfides, oxides, and native
been used to pre-concentrate uranium ore in South Africa metals (Anon., 1981a). The machine treated 25 150 mm
(Anon., 1981b), Namibia, Australia (Bibby, 1982), and rocks at up to 120 t h21. Such systems employ a tuned
Canada (IAEA, 1967, 1980, 1993). A sorter installed at coil under the belt which is influenced by the conductivity
the Rössing Mine in Namibia (Gordon and Heuer, 2000) and/or magnetic susceptibility of the rocks in its proxim-
detected gamma radiation from the higher grade ore ity. Phase shift and amplitude are used to decide on
pieces using scintillation counters comprising NaI crystals acceptance or rejection.
and photomultiplier tubes mounted under the belt. Lead Outokumpu developed the “Precon” sorter which
shielding was used to achieve improved resolution of was installed at the Hammaslahti copper mine (now
detection. A laser-based optical system similar to that closed) (Kennedy, 1985). The Precon sorter used
used in photometric sorters was used to determine rock gamma scattering analysis to evaluate the total metal
position and size for ejection, and could be adapted to content, and had a capacity of 7 t h21 for 35 mm lumps
determine additional optical characteristics of the rocks. rising to 40 t h21 for 150 mm lumps. Primary crushed
Some uranium operations undertake selective mining ore was pre-concentrated, rejecting about 25% as waste
practices, which could be considered ore sorting (IAEA, grading 0.2% copper, compared with an average feed
1980, 1993). Radiometric readings are taken on truck- grade of 1.2%.
loads of ore. Based on the readings, ore is placed in RADOS XRF sorting technology has been used (pri-
high-grade, low-grade, or waste stockpiles. The ore can marily in Russia) over the past two decades at 49 opera-
then be appropriately blended or processed separately tional sites for over 20 commodities (Fickling, 2011;
based on grade. RADOS, 2014). The sensor directly identifies ore elemen-
Several other physical properties of ores and minerals tal composition using X-ray fluorescence technology
have been exploited in a range of sorting machines. (able to detect elements with an atomic number .20) and
Neutron absorption (or activation) separation has been sorts accordingly. Figure 14.5 shows the internal arrange-
used for the sorting of boron minerals (Mokrousov et al., ment of the RADOS XRF chute-type sorter and a row of
1975). The ore is delivered by a conveyor belt between a units operating at a copper/zinc mine in Russia. Particles
slow neutron source and a scintillation neutron detector. free-fall from the chute past an X-ray source and detector.
The neutron flux attenuation by the ore particles is Particles are separated via a mechanical ejector into
414 Wills’ Mineral Processing Technology

FIGURE 14.5 Left: Internals of a RADOS XRF sorter (modified from Fickling, 2011), Right: Rados XRF sorter installation at Ural Mountains
Mining Company’s Svyatogor Cu/Zn Mine (Courtesy RADOS International Technologies).

concentrate and discard streams. Typically, feed grade now benefiting from those developments, with proven
must exceed 0.1 wt% for effective detection, although the detection and data processing being available for applica-
system can also use a matrix of elements as the criteria tion on mining proof machines.
for separation in low grade ore systems (e.g., gold, ura-
nium or PGM) (RADOS, 2014).
Microwave attenuation has been used to sort diamond- 14.4 EXAMPLE FLOWSHEET AND
bearing kimberlite from waste rock (Salter et al., 1989).
The development was notable for the first use of high
ECONOMIC DRIVERS
speed pulsed water ejectors. Equipment to sort asbestos SBS installations typically consist of: crusher, screen,
ore has also been developed (Collier, 1972). The detection sorter, and compressor. Because of the often large parti-
technique was based on the low thermal conductivity of cle sizes and low concentrations of valuables, it is
asbestos fibers and used sequential heating and infrared advised to install mechanical sampling, size reduction
scanning to detect the asbestos seams. The use of micro- and splitting equipment to enable determination of plant
wave heating coupled with infrared-thermography has performance.
been tested on a wide range of minerals (e.g., cop- Figure 14.6 shows an example flowsheet for a multi-
per molybdenum ore, iron ore) for sorting purposes stage, multi-machine stage operation. Machines are com-
(Sivamohan and Forssberg, 1991; van Weert et al., 2009; monly operated in parallel for high throughput opera-
Ghosh et al., 2013). tions. Cascading circuit arrangements enhance
A machine was installed at King Island Scheelite separation efficiency and allow for redundancy and the
in Tasmania, where the scheelite was sensed by its potential for multiple detection technologies to be
fluorescence under ultraviolet radiation. XRT (X-ray combined.
transmission) has proven to be superior to UV fluores- Capital and operating costs are typically roughly half
cence. Mittersill Mine currently operates XRT sorters the costs of dense-media systems. Since SBS is a single
for waste elimination where ca. 25% of the 130 t h21 particle technology, the throughput is inversely propor-
run-of-mine stream grading 0.03% WO3 is rejected tional to the average particle size fed to the machine.
before milling and sold as aggregate (Mosser and Both types of specific costs are thus inversely dependent
Gruber, 2010). upon the average particle size. The upper particle size is
Rapid developments in sensing and computing tech- determined by the liberation characteristics of the ore and
nology have increased the capabilities of today’s SBS the lower particle size limit by the economically viable
machines significantly. In addition, industrial food proces- specific costs per ton of product.
sing and recycling industries have openly adopted the Typically, the highest economic benefit is obtained
technology and tens of thousands of sorters are installed when eliminating deleterious waste that hinders down-
for numerous separation tasks. The mining industry is stream processes. In such cases, the overall recovery
Sensor-based Ore Sorting Chapter | 14 415

conductivity, atomic density). Today’s mining machines


integrate state of the art technology into mechanical
designs. Increased pressure to decrease processing costs
and environmental impact will undoubtedly further the
use of SBS in the mining industry.

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