Breakthrough in Sustainable Lithium Extraction with TOMRA’s Technology
Pilbara Minerals has set a new industry benchmark with its state-of-the-art Pilgangoora operation in Western Australia. As part of its ambitious P680 Expansion Project, the company successfully commissioned the world’s largest lithium ore sorting plant. This facility, equipped with TOMRA Mining’s cutting-edge sensor-based sorting technology, represents a significant leap forward in sustainable mining practices.
At the heart of this breakthrough lies a strong collaboration between Pilbara Minerals, TOMRA Mining, and several key partners. Together, they have showcased how advanced technology and coordinated teamwork can drive remarkable results in the mining sector.
The groundbreaking technology transforming lithium processing
The core process of Pilbara Minerals’ success is TOMRA Mining’s advanced sensor-based sorting technology. This innovative solution revolutionizes traditional lithium processing by enabling the precise separation of valuable spodumene ore from barren host rock. The new sorting facility operates with an impressive capacity of over 1,000 tonnes per hour, making it the largest of its kind in the world.
TOMRA’s technology incorporates a series of 10 specialized sorters, tailored to handle different particle sizes: four XRT COM TER sorters for fines, three XRT COM2.0 sorters for mid-sized particles, and three PRO Primary Color sorters for coarse materials. These systems work in harmony to optimize ore recovery and ensure consistent feed quality for downstream processing.
The benefits extend beyond improved recovery rates. By removing waste material upstream, the facility reduces the energy and resources required in later stages of processing. This efficiency not only enhances the plant’s productivity but also significantly lowers its environmental footprint.
“This technology ensures that only valuable ore reaches the processing plant,” explains Gavin Rech, Area Sales and Technical Manager at TOMRA Mining. “By avoiding the processing of barren material, we save energy, water, and reagents, while also boosting downstream efficiency and recovery rates.”
Achieving energy and environmental goals with advanced sorting
The Pilgangoora operation has set a new standard in energy efficiency and environmental stewardship, thanks to TOMRA Mining’s advanced ore-sorting technology. By removing barren material early in the process, the sorting facility reduces the energy demand for subsequent processing stages, saving an estimated 8–15 GWh annually.
The impact is not limited to energy savings. The elimination of waste upstream minimizes water and reagent usage in the wet processing plant, further enhancing resource efficiency. This approach also prevents contamination of downstream operations, ensuring higher recovery rates and improved product consistency.
The sustainability gains align closely with the broader industry goal of reducing carbon footprints and minimizing environmental impact. Pilbara Minerals’ adoption of TOMRA’s sorting technology highlights how innovation can reconcile economic objectives with environmental responsibility.
“The resource utilization improvements we’re seeing here are transformative,” says Rech. “By processing only valuable material, we’re not only enhancing efficiency but also supporting more sustainable mining practices.”
Overcoming challenges in spodumene ore sorting
Lithium mining, particularly hard-rock lithium extraction, presents unique challenges. Spodumene ore, the primary source of lithium, is often embedded within barren host rock. Some of these materials have densities similar to lithium-bearing ore, complicating traditional processing methods and reducing downstream efficiency.
TOMRA Mining tackled this challenge head-on with its sensor-based sorting solutions. Each of the 10 sorters installed at Pilgangoora is designed to identify and separate specific types of materials based on particle size and density.
The success of this sorting process has tangible results. By reducing the amount of non-lithium-bearing material processed in the wet plant, TOMRA’s technology has significantly lowered energy and reagent consumption. Moreover, the high precision of the sorters ensures a consistent, high-quality product that meets market demands.
Collaboration at the heart of the P680 project’s success
The success of Pilbara Minerals’ P680 Expansion Project can be attributed to the robust collaboration between TOMRA Mining, Pilbara Minerals, and key engineering and logistical partners. This cooperative effort began in 2017 with comprehensive geological assessments and bulk test work conducted at TOMRA’s Sydney Test Center.
A key aspect of this collaborative approach was TOMRA’s commitment to ongoing support. With a 24-month service contract in place, the TOMRA team provides on-site assistance 365 days a year, ensuring optimal sorter performance and addressing operational challenges as they arise.
“This project exemplifies the importance of teamwork and adaptability in achieving large-scale success,” notes Rech. “It’s a demonstration of what’s possible when stakeholders align toward a shared goal.”
With the scalability and effectiveness of TOMRA’s sensor-based sorting technology, the process sets a new benchmark for sustainable and efficient ore processing.
This success opens the door for wider adoption of similar technologies in other mining operations around the world. As industries increasingly align with global sustainability goals, projects like the P680 Expansion offer a roadmap for integrating innovation into resource extraction.
To keep up-to-date with our latest mining and minerals news, subscribe to our newsletter today.