How sensor-based sorting is extending the life of critical mineral deposits

Global demand for lithium, copper, rare earth elements, tin, tungsten, nickel, and cobalt is accelerating, driven toward clean energy and electrification. At the same time, mining operators face mounting pressures from declining ore grades, rising costs for energy, water, chemicals and labour, alongside increasing scrutiny of their environmental performance. Against this backdrop, sensor-based sorting is emerging as a transformative approach, enabling more efficient recovery of minerals while reducing environmental impact.

Maximising recovery from previously discarded ore

Sensor-based sorting is redefining efficiency in mineral processing by addressing one of the industry’s long-standing challenges: how to extract more metal from every ton of ore while using fewer resources.

By separating barren material early in the process, miners can significantly reduce energy, water and chemicals required for downstream treatment, unlocking value from ore that was previously uneconomic. This shift enables operations to recover more from what they already mine, turning lower-grade and marginal deposits into viable resources.

As ore grades continue to decline and operational costs rise, it has become increasingly important for mining companies to extract maximum value from every tonne of material. TOMRA Mining applies cutting-edge x-ray transmission (XRT), near-infrared (NIR), and laser sorting technologies to selectively separate valuable minerals from waste rock before processing. This early intervention reduces the need to crush, mill, and chemically treat all mined material, lowering the use of energy and inputs, increasing recovery rates, and substantially reducing tailings volumes. The result is a more efficient, sustainable, and economically resilient operation.

“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,” explains Rasoul Rezai, Global Segment Manager Metals at TOMRA Mining. “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 delivered tangible results in mines across the world. At Eloro Resources’ Iska Iska Polymetallic project in southern Bolivia, TOMRA’s XRT ore sorting tests demonstrated the potential to reject significant quantities of sub-cut-off-grade waste, which dramatically reduces the capital and operating costs, permitting lower-grade ore blocks to be processed.

In Europe, TOMRA Mining is contributing its expertise to the EU-funded Li4Life project, which aims to develop technologies that enable access to lithium from existing mining deposits and tailings, reducing pressure on primary supply. This collaboration highlights the growing recognition of sensor-based sorting as a vital technology for ensuring the long-term security of critical minerals supply chains.

Technology that redefines resource recovery

With decades of pioneering innovation of sensor-based sorting, TOMRA Mining is redefining how the industry approaches mineral recovery. Its XRT, NIR and Laser sorting technologies enable operators to identify and separate valuable minerals with precision, even in complex or lower-grade deposits.

Recent Ai-powered advancements have expanded the capabilities of TOMRA’s XRT sorters. OBTAIN™ can double sorting capacity without changing the machine’s size and mechanical design, while CONTAIN™ detects inclusion-type ores such as tin, tungsten, nickel, copper, and sulphides, revealing even the smallest inclusions. Together, they form what Rezai describes as “a new set of wings” for XRT technology.

Field trials at Wolfram Bergbau in Mittersill, Austria, demonstrated the transformative potential of these innovations. OBTAIN increased revenue by 12% with the same product quality while reducing water consumption by 40%, with no change in annual tonnage. “It immediately changed the way we think about sorting and processing,” said David Comtesse, Production Manager. “This isn’t just an upgrade – it's a completely new level of performance."

Another breakthrough, the TS100 precision ejection system, reduces air consumption by up to 70%, lowering operational costs and increasing recovery even further. TOMRA’s portfolio of technologies allows operators to tailor solutions to the specific characteristics of each ore and deposit.

Beyond the technology, TOMRA takes a collaborative approach to ensure that every solution is optimised for the unique needs of a customer’s mine and business case. Testing is conducted at TOMRA’s global network of test centres in Germany, Australia, and South Africa, and the company’s experts work closely with operators on site to fine-tune performance and maximise efficiency.

Extending mine life and unlocking marginal deposits

TOMRA Mining’s sensor-based sorting is also helping operators unlock value from ore that was previously considered uneconomic. By removing waste early in the process, blocks once classified as marginal can be incorporated into mine plans, expanding recoverable ore and extending mine life without requiring additional capital-intensive infrastructure. “Sensor-based sorting doesn’t just improve processing, it reshapes mining strategy,” explains Rezai. “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.”

Facilitating access to financing for advanced sorting technologies

TOMRA also works closely with customers to tailor financial arrangements to individual situations. Through partnerships with banks, leasing institutions and grant programs, TOMRA assists customers in securing financing and grants, preparing technical documentation and optimising project economics. This support ensures that investment in advanced sorting technologies is economically feasible, helping operators realise the full value of recovered resources.

Supporting ESG goals and a circular mining economy

Sensor-based sorting is not only economically transformative; it directly advances mining companies’ ESG objectives. By removing barren material before energy-intensive processing, TOMRA Mining’s solutions help operators reduce energy use by up to 50%, cut water consumption, and lower greenhouse gas emissions, contributing to decarbonisation and net-zero targets. Tailings volumes are reduced, less land is disturbed, and coarse, untreated waste can often be repurposed in other industries such as aggregates or road construction, supporting circular economy principles.

The technology also improves social outcomes by prolonging the life of mines and safeguards local jobs and economic contributions in a sustainable way. On the governance side, data-rich insights enable operators to quantify environmental benefits and demonstrate responsible sourcing in line with ESG reporting frameworks.

Driving the future of critical mineral supply

The role of sensor-based sorting in critical mineral production is gaining recognition across the mining industry. Pioneering projects such as the Pilbara lithium plant in Australia have consolidated sensor-based sorting as a game changer in critical mineral processing, demonstrating both reliability and measurable economic and environmental benefits.

“Efficiency and recovery are paramount in an era of declining ore grades and rising demand,” Rezai concludes. Through its combination of advanced technology, operational expertise, and collaboration with operators worldwide, TOMRA Mining is helping to shape a more sustainable and strategic future for critical mineral supply.

Read the article online at: https://www.globalminingreview.com/handling-processing/12112025/how-sensor-based-sorting-is-extending-the-life-of-critical-mineral-deposits/