Geometallurgical models are commonly built by combining explanatory variables to obtain the response that requires prediction. This study presented a phosphate plant with three concentration steps: magnetic separation, desliming and flotation, where the yields and recoveries corresponding to each process unit were predicted. These output variables depended on the ore composition and the collector concentration utilized. This paper proposed a solution based on feature engineering to select the best set of explanatory variables and a subset of them able to keep the model as simple as possible but with enough precision and accuracy. After choosing the input variables, two neural network models were developed to simultaneously forecast the seven geometallurgical variables under study: the first, using the best set of variables; and the second, using the reduced set of inputs. The forecasts obtained in both scenarios were compared, and the results showed that the mean squared error and the root mean squared error increase in all output variables evaluated in the test set was smaller than 2.6% when the reduced set was used. The trade-off between simplicity and the quality of the model needs to be addressed when choosing the final neural network to be used in a 3D-block model.

Knowing the quantity and the quality of products and tailings generated by a beneficiation plant, even before ore processing, can make the mining operations more sustainable, more profitable, and safer. To forecast these values, it is necessary to submit samples to batch tests which mimic the processing workflow used on an industrial scale. Then, the results need to be analysed with the aim of finding a statistical model able to comprehend how Run of Mine (ROM) characteristics impact the performance at the beneficiation. After developing a model, it is possible to apply it to blocks where the ROM characteristics are known, but the metallurgical information is not, making it possible to estimate these. With this goal, a geometallurgical model was developed with a neural network technique using 37 samples collected at two Brazilian gold mines. The Au and S grades in ROM, and the mine from where the sample was collected, were used as input variables. The model was able to forecast the following variables with a Pearson correlation coefficient on the cross validation test set equal to the value in parenthesis: mass (0.55) and metallurgical (0.54) recovery in the gravimetric concentrate, mass (0.80) and metallurgical (0.12) recovery in the flotation tailings, mass (0.77) and metallurgical (0.11) recovery in the leaching tailings, mass recovery (0.84) of gas sent to the sulphuric acid plant, and metallurgical recovery (0.65) in the leaching concentrate. The results obtained with neural networks were superior to the ones obtained when three alternative techniques were tested.

Alkaline carbonatite complexes are formed by magmatic, hydrothermal, and weathering geological events, which modify the minerals present in the rocks, resulting in ores with varied metallurgical behavior. To better spatially distinguish ores with distinct plant responses, creating a 3D geometallurgical block model was necessary. To establish the clusters, four different algorithms were tested: K-Means, Hierarchical Agglomerative Clustering, dual-space clustering (DSC), and clustering by autocorrelation statistics. The chosen method was DSC, which can consider the multivariate and spatial aspects of data simultaneously. To better understand each cluster’s mineralogy, an XRD analysis was conducted, shedding light on why each cluster performs differently in the plant: cluster 0 contains high magnetite content, explaining its strong magnetic yield; cluster 3 has low pyrochlore, resulting in reduced flotation yield; cluster 2 shows high pyrochlore and low gangue minerals, leading to the best overall performance; cluster 1 contains significant quartz and monazite, indicating relevance for rare earth elements. A hierarchical indicator kriging workflow incorporating a stochastic partial differential equation (SPDE) trend model was applied to spatially map these domains. This improved the deposit’s circular geometry reproduction and better represented the lithological distribution. The elaborated model allowed the identification of four geometallurgical zones with distinct mineralogical profiles and processing behaviors, leading to a more robust model for operational decision-making.

The past decade has seen a renewed possibility of using machine learning algorithms to solve a large collection of problems in several fields. Data acquisition for mining operations has increased with the growth in sensor-based technologies, and therefore the amount of information available for mining applications has dramatically increased. Ore sorting equipment is available for separating ore from waste based on differences in physical properties detected by a real-time analyser. The separation efficiency depends on the contrast in these properties. In this study we investigate the application of machine learning models trained using data from the output of a dual-energy X-ray ore sorting apparatus at a gold mine. The particles were first hand-sorted into ore and gangue classes based on their mineralogical composition. Classification models were then used to help decide the balance between the number of true and false positives for ore in the concentrate, with a view to economic parameters, using their receiver operator characteristic (ROC) curves. The results showed AUC (area under the ROC curve) scores of up to 0.85 for the classification models and a maximum reward condition Fpr/Tpr around 0.5/0.9 for a simplified economic model.