Tomra Mining’s sensor-based sorting technologies are transforming how minerals are recovered
Tomra Mining's sensor-based sorting technologies are transforming how minerals are recovered, turning once-discarded materials into a valuable resource, extending mine life, and reinforcing supply security for the energy transition
The global demand for copper, lithium, tin, rare earth elements, cobalt, tungsten, and nickel is growing due to the push toward clean energy and electrification. Mining operators are dealing with rising pressure from declining ore grades, mounting costs for energy, water, chemicals and labour, as well as increased scrutiny of their environmental performance. As a result, sensor-based sorting is becoming a transformative approach to enable more efficient recovery of minerals and reduce the environmental impact.
Maximising recovery
Sensor-based sorting is enhancing efficiency in mineral processing by addressing the challenge of extracting more metal from every tonne of ore while using fewer resources. Miners can reduce energy, water, and chemicals needed for downstream treatment by separating barren material early in the process. This change allows operations to recover more from what they already mine, turning lower-grade and marginal deposits into viable resources.
Ore grades are continuing to decline, and operational costs are increasing, making it more important for mining companies to extract maximum value from every tonne of material. Tomra Mining applies X-Ray Transmission (XRT), Near-infrared (NIR) and Laser sorting technologies to separate valuable minerals from waste rock before processing begins.
This early intervention reduces the need to crush, mill, and chemically treat all mined material, decreasing energy and input use, increasing recovery rates, and lowering tailings volumes.
Rasoul Rezai, global segment manager metals at Tomra Mining, said, “At its core, sensor-based sorting addresses one of mining’s greatest inefficiencies: we are able to recover more metal from the same amount of material. By rejecting waste early, operators feed higher-grade material into their mills, reduce operational expenditure, and improve overall efficiency. This is particularly crucial for critical minerals, where supply tensions are increasing worldwide.”
This approach has produced tangible results in mines worldwide. At Eloro Resources' Iska Iska Polymetallic project in southern Bolivia, Tomra's XRT ore sorting tests demonstrated the potential to reject significant quantities of subcut-off-grade waste, reducing capital and operating costs and enabling lower-grade ore blocks to be processed.
In Europe, Tomra Mining is providing its expertise to the EU-funded Li4Life project, which is developing technologies to enable access to lithium from existing mining deposits and tailings, thereby lessening pressure on primary supply.
Redefining resource recovery
Tomra Mining's XRT, NIR, and Laser sorting technologies allow operators to identify and separate valuable minerals with precision.
Recent AI-powered advancements have broadened the capabilities of Tomra's XRT sorters. Obtain can double its sorting capacity without changing the machine's size or mechanical design, while Contain detects inclusion-type ores such as tin, nickel, copper, tungsten, and sulfides.
David Comtesse, production manager, said, “It immediately changed the way we think about sorting and processing. This isn’t just an upgrade – it's a completely new level of performance."
The TS100 precision ejection system reduces air consumption by up to 70%, decreasing operational costs and further increasing recovery. Tomra's portfolio of technologies enables operators to tailor solutions to the specific characteristics of each ore and deposit.
Extending mine life
Tomra Mining's sensor-based sorting can also help operators unlock value from previously uneconomic ore. Removing waste early in the process enables blocks that were once classified as marginal to be incorporated into mine plans, expanding recoverable ore and prolonging mine life.
Rezai said, “Sensor-based sorting doesn’t just improve processing, it reshapes mining strategy. By increasing the grade of feed to the mill and rejecting waste early, operators can extract more value from the same deposit, increasing both the size and longevity of the mine.”
Supporting ESG goals
Sensor-based sorting is economically transformative and directly advances mining companies' ESG objectives. Tomra Mining's solutions can help operators to reduce energy use by around 50%, decrease water consumption, and minimise greenhouse gas emissions by removing any barren material before processing.
The technology also has the means to improve social outcomes by extending the life of mines and safeguarding local jobs and economic contributions in a sustainable way. Data-rich insights also allow operators to quantify environmental benefits and demonstrate responsible sourcing in line with ESG reporting frameworks.
