TOMRA Mining’s global network of Test Centers provides mining companies with a vital resource to make informed decisions about sensor-based ore sorting. By testing material samples under real-world conditions, mining operations can determine whether sorting is a viable solution for their mine and identify the most effective technology for their specific ore.

In the highly competitive mining industry, efficiency, sustainability and profitability hinge on optimizing every stage of mineral processing. TOMRA Mining’s Test Centers, located in Wedel (Germany) and Sydney (Australia), allow mining companies to conduct performance tests under real-world conditions that closely replicate site-specific circumstances and operational capacities at their operation. This provides a clear understanding of how sorting technology will function once implemented, offering deeper insights into the ore’s sortability. It helps to identify the most suitable sorting solution – X-Ray Transmission (XRT), Laser, Color, Near-Infrared (NIR) or Electromagnetic – and simulates the outcomes that can be achieved on-site under actual operational conditions. A third Test Center in Johannesburg (South Africa) is able to provide support with initial testing on samples to assess the sortability of the rocks.

For example, the Sydney Test Center played a key role in the development of the world’s largest lithium ore sorting plant at Pilbara Mineral’s Pilgangoora Operation in Western Australia. The collaboration began in 2017, when it conducted geological assessments and bulk test work, validating the sorting equipment’s performance under operational conditions. These insights became the foundation for the sorting plant’s design.

“Mining operations across a broad spectrum of sectors – such as base metals to industrial minerals and gemstones – gain significant benefits from the specialized services offered by TOMRA Test Centers,” explains Alina Shibistova, Test Center Manager Germany. “Any operation seeking to enhance ore quality, maximize recovery, and drive profitability while minimizing waste and operational costs will find immense value in these solutions. Moreover, sensor-based sorting plays a crucial role in advancing environmental sustainability, shrinking the ecological footprint of mining activities.”

Why TOMRA’s Test Centers? A tailored approach to ore sorting

Sensor-based sorting is not a one-size-fits-all solution. Each ore deposit has unique characteristics, and different sorting technologies perform better depending on mineral composition and processing conditions. TOMRA’s Test Centers follow a structured approach to evaluate sorting potential, beginning with initial static testing, which includes a first inspection to identify the most efficient sorting technology and assess detectability. determine whether the material can be effectively sorted. A rock-by-rock analysis compares each TOMRA sensor with the mineralogical data at the individual rock level in order to ascertain sortability and quantify the efficiency of the sorting process as well as identify the appropriate sorter for the subsequent testing stages.

If results are promising, dynamic testing simulates real operational conditions, assessing throughput, estimating separation efficiency, encompassing recovery rates and possible upgrades. The sortability test studies the sorting behavior of the feed material in more detail by identifying the results that can be achieved using different sensitivities. Finally, the performance test involves feeding a large mass of the expected final sorter feed through a full-scale TOMRA sorter at rated capacity in order to test the process flow and establish the expected sorter performance and throughput. For some projects, pilot plant testing may be conducted to further validate performance before full-scale production implementation.

This systematic approach enables mining companies to understand how sorting can be integrated into their process flow and ensures that the selected solution delivers maximum efficiency.

TOMRA’s Wedel Test Center provided vital insights to Spanish quartz producer Ferroglobe when they faced the complex challenge of separating quartz ore from contaminants of the same color. Optical sorting methods had proven ineffective, but testing at the Center demonstrated that TOMRA’s Laser technology could differentiate high-quality white quartz from impurities, convincing Ferroglobe that it was the solution they were looking for. “Operations will definitely improve,” said Thierry Alary, VP Purchasing & Supply Chain at Ferroglobe, when he reviewed the results. “By solving that specific problem, sorting becomes more accurate, impacting recovery rate, avoiding contamination, and reducing further processing.”

Confidence in investment: the added value of TOMRA Test Centers’ services

Beyond technical insights, TOMRA’s Test Centers provide mining companies with hands-on experience, enabling them to make data-driven decisions with confidence. Customers witness their material being processed on TOMRA’s equipment, gaining first-hand insight into sorting performance, and receive comprehensive test reports that detail machine efficiency, throughput and recovery rates. This process helps mitigate risk by assessing the economic and technical feasibility of sensor-based sorting before committing to full-scale implementation.

“Our Test Centers offer performance tests where our customers can observe the testing process, which is conducted under conditions that closely replicate their site and operational capacities,” explains Alina Shibistova. “The results provide a clear indication of the outcomes that can be expected during actual operations. This hands-on experience, where customers are directly involved in the testing, is one of the most valuable aspects of the service.”

Lucara Diamonds experienced this when evaluating TOMRA’s XRT technology for the Karowe diamond mine in Botswana. Visiting TOMRA’s Wedel Test Center played a pivotal role in their decision-making process. “We gained a lot of confidence in the people at TOMRA, in the technology that they were presenting to us, and the possible solution that it provided to the Karowe mine,” said John Armstrong, VP Mineral Resources at Lucara Diamonds. “We could also see that they had already gone down the road of the next step in XRT technology, so they were not just focused on one particular module to present to us, but they were working on different modules. That helped alleviate some of our concerns about the robustness of the platform and the technology itself, which ultimately led us to use TOMRA as the solution.” Since integrating TOMRA’s XRT technology at the Karowe mine, Lucara has recovered some of the largest diamonds in history.

Experience TOMRA’s Test Centers first-hand

By offering a structured testing process, expert guidance and real-world validation, TOMRA’s Test Centers provide mining companies with the data-driven information they need to invest in sensor-based sorting with confidence. Testing allows them to assess feasibility, optimize performance, and ultimately enhance resource recovery while reducing operational costs and environmental impact.

TOMRA Mining invites mining companies to experience the benefits of its Test Centers first-hand. By putting sensor-based sorting to the test, operations can unlock new efficiencies and gain a competitive advantage in mineral processing.

“Along with all the advantages of ore sorting, customers who come to our Test Centers also have the chance to see the process in action, interact with our friendly and highly motivated team, and have fun while doing it! Our test center gives you that authentic ‘dusty, down-to-business’ mining atmosphere – hard hats and shoveling activities are included!” concludes Alina Shibistova.