By Erin Matthews

Sensor-based sorting (SBS) technologies and testwork are evolving, offering the mining industry another tool in the mineral processing toolbox. SBS is a collection of technologies that use sensors to separate ore from waste, either on a particle basis (particle sorting) or “parcel”-of-ore basis (bulk sorting).

Using different sensor techniques — such as X-ray transmission (XRT), near infra-red (NIR), colour and laser scattering — the Saskatchewan Research Council (SRC) provides SBS testing solutions that help industry clients select the most ideal sorting technologies and applications to upgrade their ore and reduce waste.

Used for decades in the recycling and food industry, as well as in the diamond industry, SBS technologies have begun to rapidly expand into other mining sectors in recent years due in part to the increased speed and accuracy at which sensor data can be processed. This has enabled sensor-based measurements to be applied to ore processing streams and downstream separation mechanisms in near real-time.

Sorting can potentially remove waste or provide valuable upgrading possibilities for the potash industry. Knowing mineral properties in near real-time can enable effective and efficient preconcentration or separation of ores before expensive grinding, beneficiation, and hydrometallurgy.

How do you know if sorting is for you?

SRC has developed a testing regime to assist industry clients with choosing the right sensor-based sorting technology for their needs. This regime has evolved over the years through SRC’s work with industry clients, helping to select, adopt and test effective sensor-based sorting applications. Using a data driven approach, SRC’s testing regime helps to maximize early decision-making. It also helps to minimize the sample required and streamlines the metallurgical testwork needed for design and adoption.

SRC’s testing stages for potash sorting starts with sensor-based mineralogical characterization, which assesses the type of sensor technology and the amenability of the ore — based on specific sensor responses and mineralogical characteristics. Using this data, target minerals can be identified and the potential for upgrading or waste removal is determined.

SRC uses a mineralogical sample preparation method for potash that was developed in-house and is proprietary. SRC also tests sensor responses for all commercially available sensors, including XRT, XRF, NIR, colour, laser scattering, radiometric, electromagnetic, and more. 

Understanding insolubles

Understanding the individual minerals within the waste (called “insolubles”) is one of the important factors in applying sensor-based sorting to potash. This includes the proportion of potassium-bearing minerals to other soluble salts. Sensor-based sorting targets minerals (such as clays) within wastes differently and is important for understanding the types of insolubles and how they present within the ore.

In the second stage, targeting (selecting the target mineral, particle size and corresponding sorting technology) and modelling help potash clients decide on a desirable sorting strategy – upgrading or waste removal. Before deciding on a pilot testwork strategy, SRC develops a sorting model from sensor response data. Clients can then use this valuable modelling tool to test out various scenarios — including sizes, grades, and sorter parameters — while designing their final flowsheet.

Finally, SRC’s pilot testing stage allows industry clients to obtain real-world sorting performance data and an understanding of sorting yields and recoveries under these conditions, as well as general performance of the full circuit. This phase is important in determining the feasibility and capital costs of a sorting project. SRC currently possesses two XRT sorters for these purposes and is evaluating options for introducing other sorting sensor technologies.

Why is testing so important for potash?

Through our testing regime, SRC’s sorting team plays a key role in the optimum application of SBS technologies for potash. We help the potash industry to identify, integrate and optimize the right sorting solution for their operation in the most cost-effective and streamlined way. Using a unique combination of mineralogical work, sensor testing and data, SRC helps navigate the application of sorting technologies.