TOMRA Mining technology delivers transformative impact at the world's largest lithium sorting plant

A year after Pilbara Minerals commissioned the world’s largest lithium ore sorting plant, TOMRA Mining’s sensor-based sorting technology is delivering measurable value at the Pilgangoora Operation in Western Australia, contributing to the strongest quarterly production of FY25, significantly reduced costs, and enhanced resource utilisation.

Dale Henderson, the CEO of Pilbara Minerals, explained the benefits of the TOMRA Mining sorting solutions at the recent Diggers and Dealers conference in Australia. Dale said "The ore sorter helps us get more of the ore from the ore body and helps clean it to further improve recoveries," adding that "it really is the secret sauce."

Powered by TOMRA Mining’s advanced sensor-based sorting technology, the Pilgangoora Operation has achieved impressive results, boosting production, reducing costs, and unlocking value from previously uneconomical ore. In its June Quarter FY25 results, Pilbara Minerals reported a 77% increase in production volume and a 10% reduction in unit operating costs (FOB) compared to the previous quarter. These gains stem from the ramp-up of the P1000 expansion and the integration of TOMRA Mining’s cutting-edge sorting technology.

Commissioned in August 2024 as part of the P680 Expansion Project, the crushing and sorting plant is the largest lithium ore sorting facility in the world, with a capacity of more than 1000 tph. TOMRA Mining’s sensor-based technology enables early waste rejection, significantly improving lithium recovery and final product quality while reducing energy consumption and environmental impact.

“The June Quarter marked the strongest performance of the year, clearly demonstrating the impact that TOMRA’s technology can deliver at scale,” said Gavin Rech, Area Sales and Technical Manager Australia at TOMRA Mining. “By unlocking value from lower-grade contact ore previously considered uneconomical, the operation now accesses more lithia units from the pit, enhancing resource utilisation and mine flexibility.”

The sorting plant successfully addresses a key challenge in lithium mining: managing spodumene ore within barren host rock. It includes 10 high-precision TOMRA sorters – 4 TOMRA COM Tertiary XRT for fines, 3 TOMRA COM XRT 2.0 for mid-sized particles, and 3 TOMRA PRO Primary Color for coarse-sized particles. By removing barren material upstream, the plant enhances the efficiency of downstream processes, reduces energy use by 8 – 15 GWh annually, and ensures consistent product quality.

This success is the result of several years of collaboration between TOMRA Mining, Pilbara Minerals and engineering partner DRA Global. The project was delivered on time and on budget, following extensive testwork at TOMRA’s Sydney Test Center that demonstrated the technology’s capability to deliver high lithium recovery and effective waste separation across varied ore domains.

This strategic choice supports Pilbara Minerals’ long-term goals of cost optimisation and sustainable growth. The ore sorting facility boosts Pilgangoora’s production capacity and lays the foundation for future expansions under the P2000 project. As the lithium market evolves, the company is well-positioned to lead through innovation and resilience.

With the P1000 expansion now complete and the P2000 feasibility study underway, TOMRA Mining’s proven technology and industry-leading expertise continue to support Pilbara Minerals’ long-term strategy for scalable, cost-efficient and responsible lithium production.

Read the article online at: https://www.globalminingreview.com/mining/06082025/tomra-mining-technology-delivers-transformative-impact-at-the-worlds-largest-lithium-sorting-plant/