Segmented Mined Material Sorting for Grade Dilution
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Solution Overview
Problem
Existing methods for sorting mined materials, such as wet concentration and dry sorting plant flowsheets, are costly and inefficient, particularly for low-grade iron ore, leading to significant economic losses due to dilution and variability in feed grade.
Innovation Solution
A method and apparatus that assess the grade of successive segments of mined material and separate them into categories based on grade thresholds, followed by dry sorting of selected segments to produce upgraded material, offering a cost-effective and efficient approach to sorting large volumes of mined material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wet concentration and dry sorting plant flowsheets are used to sort mined materials, then sorting capability is achieved, but processing costs increase significantly
Solution Approach 1:
The invention segments the sorting process into two distinct stages: bulk sorting of large segments followed by particle sorting of selected segments. This segmentation allows the expensive particle sorting technology to be applied only to a fraction of the total material volume, thereby reducing overall processing costs while maintaining sorting capability.
Solution Approach 2:
The invention applies particle-based sorting only partially - specifically to selected segments that require finer discrimination after bulk sorting. This partial action approach avoids the excessive cost of applying particle sorting to all material, achieving cost-effective sorting by concentrating advanced sorting capabilities only where necessary.
2Ease of manufacture
If conventional bulk sorting methods are used, then processing costs are reduced, but dilution and variability in feed grade occur
Solution Approach 1:
The dual-stage sorting process segments material handling into bulk sorting for initial separation and particle sorting for precise grade control. This segmentation enables cost-effective bulk handling while maintaining feed grade consistency through the subsequent particle sorting stage that corrects any dilution issues.
Solution Approach 2:
The system incorporates feedback mechanisms where bulk sort output is assessed and fed into particle sorting operations. This feedback loop ensures that any dilution or grade variability introduced during bulk sorting is corrected in the particle sorting stage, maintaining consistent feed grade for downstream processing.
3Measurement precision
If particle-based sorting is applied to all segments, then sorting precision is improved, but processing time and costs increase
Solution Approach 1:
The invention segments the material stream and applies different sorting intensities to different segments. Bulk sorting handles the majority of material with lower precision requirements, while particle sorting is applied only to selected segments requiring higher precision. This segmentation maintains overall processing throughput while achieving necessary sorting precision where critical.
Solution Approach 2:
Particle-based sorting is applied partially rather than universally - only to selected segments that require finer discrimination. This partial application maintains high sorting precision for critical materials while preserving overall processing throughput by avoiding the time and cost penalties of universal particle sorting.
Data Source
AI summary
A method of separating a mined material that comprises assessing the grade of successive segments of the mined material, and separating each segment on the basis of grade into a category that is at or above a grade threshold or a category that is below the grade threshold. An apparatus is also disclosed.