XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 549
of water, highlighting the urgent need for more efficient
practices.
A lot has been suggested in the path for a more sus-
tainable mining industry, one promising area is pre-
concentration and alternative processing routes using
sensor-based-sorting (SBS) technology. Beneficiation of
run-of-mine (ROM) ore before the milling and mineral
extraction can significantly reduce water and energy con-
sumption. SBS utilizing a variety of different sensors has
proven to be effective in waste removal before energy inten-
sive milling and further processing such as flotation or
leaching.
By implementing dry pre-concentration techniques,
SBS can reduce water usage by up to 40% per tonne of
processed material and decrease specific energy consump-
tion by approximately 30% (Esteves, et al., 2023). This
technology not only reduces environmental risks but also
enhances operational efficiency and cost-effectiveness and
can be implemented in various stages of the mining pro-
cess, including:
• Run-of-Mine Pre-concentration: This involves early-
stage separation of waste material, reducing the load
on downstream processes and conserving energy and
water (see Figure 1).Final Concentration: Applied
particularly in diamond processing, this technique
can also be adapted for other minerals, providing
high-purity concentrates.
• Haulage Efficiency: By minimizing the amount of
material transported from mining sites to processing
plants, SBS reduces energy consumption and opera-
tional costs.
• Secondary Mining: This involves re-processing
stockpiles of previously discarded material, poten-
tially uncovering additional valuable resources.
• Low-Grade Reserves: SBS can make it economically
viable to process low-grade ore bodies, thus maximiz-
ing resource utilization.
Figure 1 flowchart illustrates a pre-concentration pro-
cess for mineral ores using SBS technology. Material is
extracted from either an open pit or an underground mine
and undergoes crushing to break it into smaller pieces
which is then screened to separate it into different size frac-
tions, ensuring that it is within the optimal size range for
efficient processing. The screened material is divided into
Figure 1. ROM preconcentration flowhseet
of water, highlighting the urgent need for more efficient
practices.
A lot has been suggested in the path for a more sus-
tainable mining industry, one promising area is pre-
concentration and alternative processing routes using
sensor-based-sorting (SBS) technology. Beneficiation of
run-of-mine (ROM) ore before the milling and mineral
extraction can significantly reduce water and energy con-
sumption. SBS utilizing a variety of different sensors has
proven to be effective in waste removal before energy inten-
sive milling and further processing such as flotation or
leaching.
By implementing dry pre-concentration techniques,
SBS can reduce water usage by up to 40% per tonne of
processed material and decrease specific energy consump-
tion by approximately 30% (Esteves, et al., 2023). This
technology not only reduces environmental risks but also
enhances operational efficiency and cost-effectiveness and
can be implemented in various stages of the mining pro-
cess, including:
• Run-of-Mine Pre-concentration: This involves early-
stage separation of waste material, reducing the load
on downstream processes and conserving energy and
water (see Figure 1).Final Concentration: Applied
particularly in diamond processing, this technique
can also be adapted for other minerals, providing
high-purity concentrates.
• Haulage Efficiency: By minimizing the amount of
material transported from mining sites to processing
plants, SBS reduces energy consumption and opera-
tional costs.
• Secondary Mining: This involves re-processing
stockpiles of previously discarded material, poten-
tially uncovering additional valuable resources.
• Low-Grade Reserves: SBS can make it economically
viable to process low-grade ore bodies, thus maximiz-
ing resource utilization.
Figure 1 flowchart illustrates a pre-concentration pro-
cess for mineral ores using SBS technology. Material is
extracted from either an open pit or an underground mine
and undergoes crushing to break it into smaller pieces
which is then screened to separate it into different size frac-
tions, ensuring that it is within the optimal size range for
efficient processing. The screened material is divided into
Figure 1. ROM preconcentration flowhseet