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  • https://doi.org/10.59429/ace.v8i4.5791Copy DOI Icon

AI Applications in Smart Mineral Processing: Ore Characterization, Sorting, and Efficiency

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Abstract

Artificial intelligence (AI) is increasingly vital in modern mineral processing, where it addresses critical challenges such as falling ore grades, rising energy costs, and the demand for sustainable operations. Despite notable progress, most existing studies focus on individual applications like ore sorting or predictive maintenance and lack a holistic view of AI-enabled mineral processing systems. This review aims to bridge that gap by examining how AI tools can be integrated into a unified workflow that spans ore characterization, sorting, and real-time process optimization. Using a structured review of research articles, industrial case studies, and technical reports from 2015 to 2025, the study evaluates key AI techniques including machine learning, computer vision, digital twins, and predictive modelling. Findings indicate that AI has improved ore recovery by up to 30% in smart sorting systems and reduced equipment downtime by as much as 50% through predictive maintenance. These results demonstrate AI’s ability to enhance both productivity and resource efficiency, though challenges related to data quality, system compatibility, and model interpretability persist. The review highlights the need for explainable AI, scalable digital twin architectures, and targeted workforce development to support wider adoption. Overall, the paper emphasizes the potential of AI to accelerate the transition toward intelligent, sustainable mining under the Mining 4.0 paradigm.

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