Integrating Screening and Particle Sorting for the Beneficiation of Low-Grade Gold and Nickel Ores

The progressive depletion of high-grade ore bodies has shifted attention toward the exploitation of lower-grade deposits as viable sources of value. In recent years, there has been growing emphasis on mining and processing methods that incorporate sustainability by addressing both environmental and socio-economic considerations. To maximize resource recovery, integrated strategies that combine exploration, grade control drilling, mine planning, and processing are essential. Within this framework, particle sorting has emerged as an effective coarse separation method that can upgrade low-grade feed prior to the more energy-demanding milling and subsequent processing stages. Incorporating screening before particle sorting not only assists in identifying the distribution of metals but also determines the most suitable particle size ranges for sorting performance. This study reports on the applicability of sensor-based sorting technologies to low-grade gold and nickel ores from Australia, with a focus on grade deportment by particle size. The results demonstrate that substantial upgrading of low-grade ores is possible, achieving 70%–80% metal recovery within approximately 30%–40% of the original mass through the use of induction and XRT sensors. Overall, the findings indicate that both induction and XRT sorting methods are broadly effective across ore types, offering enhanced upgrading capability and improved processing efficiency.