Ore sorting performance is influenced by a complex interplay of material properties, preparation standards, and operational parameters:
- Particle Size and Distribution: Effective sorting requires particles to be properly liberated and within a suitable size range, typically between 30 and 120 mm. To ensure accurate separation and prevent equipment damage, the largest particles should be no more than three times the size of the smallest. Excessive fines or oversized material lowers sorting efficiency and increases dust generation (Sepro, 2019).
- Feed Liberation and Heterogeneity: The ore particles must be well liberated from the waste rock to allow sensors to accurately identify valuable material for separation. A lack of liberation means sensors cannot distinguish between mixed particles, drastically reducing sorting effectiveness (SMMVIK Machinery, n.d.).
- Particle Surface Conditions and Sensor Accuracy: Clean, dry, or slightly moist particle surfaces are vital for sensor accuracy and better detection. Dust, dirt, or excess moisture, conversely, hinder performance by causing clumping or misdirected particles (Manouchehri, n.d.).
- Ore Variability and Mineralogical Characteristics: Differences in mineral composition, density, shape, and texture significantly impact sensor accuracy and separation performance. Ores containing problematic phases or fine clay materials can specifically hinder sorting effectiveness and complicate downstream processing (Li et al., 2022).
- Operational Conditions: Maintaining efficiency also requires regular equipment upkeep, accurate calibration of sorting parameters, and, when necessary, utilizing multiple sorting stages.
Ore sorting performance depends heavily on the preparation upstream. What operational factor like feed consistency or surface cleanliness do you believe is most manageable and yields the biggest impact on sorting efficiency?
Reference:
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Li, G., Klein, B., Sun, C., & Kou, J. (2022). Investigation on influential factors of bulk ore sortability based on fractal modelling. Minerals Engineering, 177, 107362. https://doi.org/10.1016/j.mineng.2021.107362
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Manouchehri, H. R. (n.d.). Sorting: Possibilities, Limitations and Future.
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Sepro. (2019, September 11). Crushing and Screening for Ore Sorting Success. Sepro Mineral Systems. https://www.seprosystems.com/crushing-and-screening-for-ore-sorting-success/
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Understanding the operation of grinding mills in the mining and mineral processing industry—NEWS – SMMVIK Machinery. (n.d.). Retrieved September 17, 2025, from https://www.millvik.com/news/understanding-the-operation-of-grinding.html
