Advanced separation technologies for pre-concentration of metal ores and the additional process control

A new sensor based sorting system has been developed at Comex, based on complex image analysis. The sorting system employs different images generated by visible light and X-ray to provide maximal information about processed particles. Application of X-ray makes it possible to analyse the internal structure of the particles, which provides a 2D image with the valuable information. The advanced system for the texture and the pattern recognition is applied to analyse these images simultaneously, to provide the required identification of the particles for efficient separation. The paper describes a number of tests during sorting of Cu-Zn-Sn ores with high separation efficiency. As an example, the Cu content is enriched from 0.4% to 1.25% and the Zn content is increased from 0.83% to 2.24%. In addition, the performance of the X-ray sorting system is described for enrichment of Zn-Pb ore and compared with the heavy media separation technology. Simplifying the pre- concentration through the use of the sorting technology can significantly reduce the cost of these operations. Finally, the operating data from the sorting system have been analysed regarding a potential use for controlling the plant operation. This can bring the new tools for control strategies for the complex processing plants.