Enhancing Mineral Processing Efficiency: A
Feasibility Study on the Detectability of Various
Minerals Using Dual-Energy X-ray Imaging in XRT
Sorting
Markus Firsching1, Roy Spencer2, Johannes Leisner1
1
Fraunhofer EZRT, Flugplatzstr. 75, 90768 Fürth, Germany
2
Gemstone Research Systems Ltd, London, UK
Corresponding author: Markus Firsching
email: [Link]@[Link]
Phone: +49 911 58061-7568
Abstract:
In the context of sensor-based mineral processing, the development of innovative technologies to
address the challenges in the modern mineral processing industry, has become urgent. XRT-sorting as
a pre-concentration tool has the potential to reduce many areas of processing costs. This study
evaluated the feasibility of detecting a wide range of critically important minerals (including columbite,
tantalite, cassiterite, stibnite, chalcopyrite, monazite, magnetite, pyrolusite, amongst others), located
wholly within ROM rocks, using single/dual-energy XRT sorting technologies. The methodologies
included laboratory-scale testing to detect minerals based on their physical characteristics at different
energy levels. In summary, these results show that while high density minerals were detected using a
single energy x-ray spectrum, others showed excellent detectability using a dual-energy method. All of
the studied minerals were detectable within host rocks and on moving belts. The wide range of
minerals responding well to our technologies, suggests that the system will have applicability in many
different mining environments.
Introduction
The modern mineral processing industry faces XRT sorting enhances the overall efficiency of
increasing challenges that demand innovative mineral extraction by reducing the volume of
technological solutions to improve efficiency material subjected to further downstream
and sustainability. One promising approach is X- processing, thereby minimizing resource usage
ray transmission (XRT) based sorting [1, 2], and operational costs [4]. The technology
which offers significant potential as a pre- employs advanced X-ray sensors to detect and
concentration tool in mineral processing [3]. sort a broad spectrum of critically important
This technology leverages the differential X-ray minerals, including columbite, tantalite,
attenuation properties of various minerals, cassiterite, stibnite, chalcopyrite, monazite,
enabling early-stage detection and separation magnetite, pyrolusite, among others.
of valuable minerals.
The use of both single and dual-energy XRT Table 1: Assignment of minerals to the four host rock
sample pieces
sorting techniques allows for the optimization
of configurations tailored to the detection of Rock 1 Rock 2 Rock 3 Rock 4
specific target minerals. This paper builds on (Oxides) (Sulphides)
laboratory-scale testing to evaluate the
Magnetite Chalcopyrite Pentlandite/ Strontium-
feasibility of using XRT sorting technologies to Pyrrhotite apatite
detect minerals based on their physical
characteristics at different energy levels, Cassiterite Pyrite Monazite
demonstrating the wide applicability of this Pyrolusite Stibnite Coltan
system across various mining environments. Tantalite
Columbite
Materials and Methods
The potential application of XRT sorting
technologies for the detection of a broad
spectrum of crucial minerals within Run-of- Ttl
Mine (ROM) rocks was assessed. The image
acquisition was conducted using a moving table Mag
setup, running at a velocity of 0.45 m/s. The 1
setup incorporated a high-power X-ray tube Clb
(Comet MXR 225HP/11) operating at an
acceleration voltage of 160 to 225 kV. The
imaging system featured a custom-designed Cst Pyl
dual-energy X-ray detector with a pixel pitch of
1.2 mm. This detector was specifically
Ccp
engineered to withstand the rigorous 2
conditions of a mining environment while
Sbn
delivering the high image quality required for
dual-energy image processing. The ongoing
experimental work is now being performed at Py
significantly increased velocities (3 m/s) using
our newly developed XRT sorting
demonstrator. These experiments are carried
out with a system configuration that is
3
consistent with those used in prior setups, but
now incorporate a full-scale industrial sorter.
Pn/Pyh
Mineral samples for this study were sourced
from various international mines by GRS,
featuring particles approximately 5 mm in size. 4
The test group comprised a diverse array of Clb/Ttl
minerals, categorized into oxides, sulfides, and Mnz-Ce/Mnz-La
other groups, including rare earth elements.
Additionally, a range of host rocks, measuring
between 1.5 cm and 8 cm, was included to
SrAp
represent different geological environments.
These host rocks consisted of greisens, Figure 1: four host rock sample pieces, numbered 1 to 4
metamorphic varieties such as slates and from top to bottom, with attached minerals (labeled with
IMA symbols) according to Table 1.
schists, as well as lodes and various volcanic
and sedimentary formations.
To assess the detection capabilities of the XRT
sorting system, critical and strategic mineral
samples were selected and affixed to four
distinct host rock pieces for scanning. The
careful selection and placement of these
mineral samples aimed to mimic realistic
mineral occurrences within the host rocks. The
assignment of the mineral samples to the host
rocks is detailed in Table 1.
Results
The outcomes of the XRT sensor-based sorting
experiments were notably promising,
demonstrating effective detection of a range of
minerals. This section delineates the key
findings and provides visual evidence of the
successful detection of various minerals using
both single-energy XRT and dual-energy XRT
(DE-XRT) imaging technologies.
Figure 2 presents the conventional X-ray images
of four host rock samples containing attached
minerals. High-density and high atomic number
minerals such as cassiterite, tantalite,
columbite, stibnite, and monazite are readily
visible and can be detected easily. However,
minerals like magnetite, pyrolusite,
chalcopyrite, pyrite, and pentlandite, while
detectable, could be mistaken for other
structures within the host rock.
Beyond the standard XRT X-ray images, dual
energy (DE-XRT) images were also obtained Figure 2: Conventional X-ray image of the four host rocks
and analysed. The DE-XRT technique highlights with attached minerals
the contrast of materials with high atomic
The successful detection of the targeted
numbers, as evidenced in the following images
minerals within host rocks and on a moving
where these substances are depicted in
setup highlights the technology's potential for
progressively intense shades of green,
extensive applicability across various mining
indicative of their higher concentrations. Figure
operations and extraction scenarios.
3 through Figure 6 display the resultant DE-XRT
Furthermore, the DE-XRT system's ability to
images.
detect parent minerals, such as monazite,
All minerals mentioned in Table 1 were xenotime, galena, and chalcopyrite, which may
successfully detected using this technology. contain exotic elements, underscores its
Both single and dual-energy XRT configurations superior efficiency compared to targeting the
exhibited strong detection capabilities, daughter elements themselves.
depending on the type of mineral.
Conclusion and outlook
The application of dual-energy X-ray
transmission (DE-XRT) sorting technology in
mineral processing presents significant
advantages as a pre-concentration step,
effectively reducing the volume of run-of-mine
(ROM) material that needs to be processed in
conventional plants. By efficiently segregating
waste material from valuable minerals, this
Figure 3: Resulting dual energy image (rock 1)
technology enhances the grade of target
minerals delivered to traditional processing
facilities. DE-XRT achieves this by scanning the
entire ROM load in the dry to isolate critical
minerals, thereby producing a 'super
concentrate' that more closely mirrors the
original geological grade.
This concentrate can be processed with
minimal or no water usage, resulting in a
Figure 4: Resulting dual energy image (rock 2)
reduced plant footprint, lower energy
consumption, and minimized waste through
dry stacking. Moreover, DE-XRT technology
holds promise for the efficient and
environmentally sensitive mining of low-grade
deposits, particularly in remote or
economically underdeveloped regions. The
development of smaller, portable units could
provide substantial benefits in these areas.
Figure 5: Resulting dual energy image (rock3) A full-scale industrial sorter, utilizing
customized components as the detector and
separation unit, is currently being established
at Fraunhofer EZRT. This setup will facilitate
testing of the complete system under realistic
conditions. The laboratory results presented
were conducted under comparable conditions
and have demonstrated the broad
mineralogical effectiveness of DE-XRT sorting
technology, indicating its potential for
Figure 6: Resulting dual energy image (rock 4)
widespread application across the mineral
processing industry.
The high contrast of minerals in dual-energy
systems significantly enhances the fully By incorporating advanced data processing
automatic detection, setting the basis for an techniques, DE-XRT can produce 'super
enhanced sorting efficiency. However, further concentrates' early in the ore processing
research should investigate the applicability of circuit. This not only improves mineral
these results to more complex particle recoveries but also reduces environmental
compositions and real ore samples. impacts and enhances the sustainability of
mining operations. Benefits include reduced
plant footprints, lower energy and water usage,
and safer dry stacking of waste materials,
alongside significant reductions in both capital
and operating expenditures.
In summary, this feasibility study underscores
the extensive applicability of DE-XRT-based
sorting as a pre-concentration method in
mineral processing. The findings suggest that
this technology has the potential to
significantly improve the efficiency and
sustainability of mineral extraction processes.
Acknowledgement
This research has received funding from the
European Union's Horizon Europe research and
innovation programme under grant agreement
No . 101091885.
References
[1] Zhang, Y., Yoon, N., & Holuszko, M. E.
(2021). Assessment of sortability using a
dual-energy X-ray transmission system for
studied sulphide ore. Minerals, 11(5), 490.
[2] Firsching, M., Mühlbauer, J., Mäurer, A.,
Nachtrab, F., & Uhlmann, N. (2013).
Quantitative sorting using dual energy X-
ray transmission imaging. In Proceedings of
the Conference on Optical Characterization
of Materials (OCM’2013) (pp. 259-264).
[3] Manoucheri, H., Mosser, A., & Gaul, F.
(2016, September). Techno-economic
aspect of ore sorting—Is sorting a missing
part in the mining industry—A case study
at Sandvik’s Mittersill tungsten mine.
In Proceedings of the 28th International
Mineral. Processing Conference IMPC,
Montreal, QC, Canada (pp. 11-15).
[4] Lessard, J., de Bakker, J., & McHugh, L.
(2014). Development of ore sorting and its
impact on mineral processing
economics. Minerals Engineering, 65, 88-
97.