TOMRA launches advanced optical sorting tech

One year after commissioning the world’s largest lithium ore sorting facility, Pilbara Minerals is reaping substantial rewards from TOMRA Mining’s advanced sensor-based sorting technology at its Pilgangoora Operation in Western Australia.

The technology has helped deliver the strongest quarterly production figures of FY25, significantly lowered operating costs, and improved overall resource utilisation.

The June Quarter FY25 results underline this transformation. Pilbara Minerals reported a 77% increase in production volumes and a 10% reduction in unit operating costs (FOB) compared with the previous quarter.

These impressive gains are attributed to the ramp-up of the P1000 expansion and the seamless integration of TOMRA Mining’s high-precision sorting systems. By unlocking value from ore that was previously uneconomical to process, the operation is improving both profitability and sustainability.

Commissioned in August 2024 as part of the P680 Expansion Project, the state-of-the-art crushing and sorting plant boasts a capacity exceeding 1,000 tonnes per hour, making it the largest lithium ore sorting facility in the world. At the heart of its success is TOMRA Mining’s sensor-based technology, which enables early waste rejection during processing.

This approach not only enhances lithium recovery rates and final product quality but also reduces energy usage and minimises environmental impact.

The facility addresses one of the core challenges in lithium mining—efficiently managing spodumene ore embedded within barren host rock. It operates with 10 high-precision TOMRA sorters, each tailored to specific particle sizes: four TOMRA COM Tertiary XRT units for fine material, three TOMRA COM XRT 2.0 units for mid-sized particles, and three TOMRA PRO Primary Color sorters for coarse material.

This targeted sorting removes waste material at an early stage, which streamlines downstream processing, cuts annual energy consumption by an estimated 8–15 GWh, and ensures a consistently high-quality lithium product.

The project’s delivery was the result of years of collaboration between TOMRA Mining, Pilbara Minerals, and engineering partner DRA Global. Extensive test work at TOMRA’s Sydney Test Center confirmed the technology’s ability to maintain high lithium recovery and effective waste separation across varying ore types. The facility was completed on time and on budget, demonstrating the strength of the partnership and the operational readiness of the technology.

From a strategic perspective, the sorting facility supports Pilbara Minerals’ long-term objectives of cost optimisation and sustainable growth. It expands the Pilgangoora Operation’s production capacity while establishing the foundation for further growth through the P2000 project, for which feasibility studies are already underway.

With the P1000 expansion fully operational and the next phase of growth in motion, the Pilgangoora Operation stands as a benchmark for innovation in the lithium mining sector.