Brazilian Rare Earths Limited has unveiled breakthrough ore sorting results at its Monte Alto project, achieving over 95% yield and doubling rare earth grades in a single pass. This advancement promises to lower costs and environmental impact while enhancing project economics.
- Multi-sensor ore sorting upgrades feed grades from 12.4% to ~27% TREO
- Single-pass processing yields over 95% recovery with minimal rare earth loss
- Waste rejection of approximately 25% mass achieved efficiently
- Potential for reduced capital and operating costs with simpler dry beneficiation
- Results validate pathway to direct hydrometallurgical processing of high-grade ore
Exceptional Ore Sorting Breakthrough
Brazilian Rare Earths Limited (ASX – BRE) has reported outstanding results from its recent sensor-based ore sorting test program at the Monte Alto rare earth project in Bahia, Brazil. Using STEINERT’s advanced multi-sensor KSS CLI XT platform, which combines X-ray transmission, 3D laser, and inductive sensors, the company achieved a remarkable grade upgrade, boosting total rare earth oxide (TREO) content from an already high 12.4% to approximately 27% in a single pass.
This represents more than a 100% increase in grade, alongside an impressive yield exceeding 95%, positioning Monte Alto’s mineralisation as exceptionally amenable to physical beneficiation techniques. The process also demonstrated world-class recoveries between 96% and 99%, with efficient waste rejection of about 25% of feed mass, losing less than 0.3% of contained rare earth metals.
Implications for Project Economics and Environment
These results are significant because rare earth projects typically contend with low head grades and complex, costly processing flowsheets. Monte Alto’s coarse-grained mineralisation, featuring dense and paramagnetic minerals, allows the sensor-based sorting technology to distinguish ore from waste effectively without the need for grinding or chemical reagents.
According to CEO Bernardo da Veiga, the technology not only enhances project economics by reducing capital expenditure and operating costs but also lowers the environmental footprint. The dry beneficiation method requires minimal water and no reagents, cutting energy consumption and simplifying downstream processing.
Technical Validation and Next Steps
The test work builds on previous metallurgical programs, including collaboration with the Australian Nuclear Science and Technology Organisation (ANSTO), which demonstrated direct hydrometallurgical processing of Monte Alto’s high-grade mineralisation. The ore sorting results now provide a clear pathway to integrate sensor-based sorting into the beneficiation flowsheet, enabling the production of ultra-high-grade concentrate suitable for direct extraction.
Brazilian Rare Earths plans to advance flowsheet design targeting a multi-sensor system capable of processing 100% of run-of-mine material at yields above 95%. This development could be a game-changer for the Monte Alto project, potentially accelerating its path to commercialisation.
Broader Industry Context
Rare earth elements are critical to emerging technologies, including electric vehicles and renewable energy systems. Innovations that improve the efficiency and sustainability of rare earth extraction are closely watched by investors and industry alike. Brazilian Rare Earths’ success with sensor-based sorting at Monte Alto may set a new benchmark for beneficiation in the sector.
Bottom Line?
Monte Alto’s ore sorting breakthrough could redefine rare earth project economics, but scaling remains the next critical test.
Questions in the middle?
- How will full-scale implementation of multi-sensor ore sorting impact Monte Alto’s overall project timeline and costs?
- What are the potential challenges in integrating sensor-based sorting with downstream hydrometallurgical processing?
- Could this technology be adapted for other rare earth deposits with different mineralogical characteristics?