Sensor-based ore sorting is taking on a larger role in mine development as operators look to remove waste before material reaches energy-intensive grinding and beneficiation circuits. A key development came from TOMRA Mining, which was selected to supply 22 X-ray transmission sorters for the proposed P2000 expansion at Pilgangoora in Western Australia.
The lithium operation already has 10 sorters installed, with the existing system capable of processing more than 1,000 tonnes per hour. The planned expansion would further integrate sorting into the operation’s processing strategy rather than using it solely as a supplementary pre-concentration stage.
Processing and Energy Savings
Removing waste before milling can reduce the amount of material requiring grinding, flotation, reagents and tailings storage. At Pilgangoora, the existing sorting system has been associated with estimated electricity savings of approximately 8–15 GWh annually.
The potential value of these savings increases as ore grades decline. Conventional mine expansions can require operators to process greater quantities of rock to sustain metal production, while pre-concentration provides an alternative by improving feed quality before material enters the processing plant. Lithium pegmatites can provide suitable contrasts between spodumene-bearing ore and barren material, supporting the application of sensor-based sorting in lithium operations.
Wider Application Across Mining
The technology is also being tested across copper, tungsten, tin, gold and polymetallic operations, extending its potential beyond lithium processing. Its effectiveness, however, remains dependent on geological conditions and the ability of sensors to consistently distinguish ore from waste at industrial throughput rates. Representative bulk testing therefore remains an important part of evaluating sorting performance.
The Pilgangoora expansion illustrates how ore sorting is increasingly being considered as part of the broader processing design. Its role is shifting beyond an environmental application toward reducing the quantity of material that must enter the processing plant. This could affect the scale of processing infrastructure required for mine developments, as well as the volume of rock that needs to be processed to achieve production targets.
