Mineral Technologies (MT) has introduced mtOne, a real-time spiral automation platform designed to enhance the efficiency and consistency of gravity separation processes in mineral processing plants. Unlike previous generations of spiral systems, which often operated as “set-and-forget assets”—meaning they were configured once and left to run with minimal adjustment—mtOne enables continuous monitoring and adjustment, aiming to reduce mineral loss and improve overall plant performance.
In a recent pilot installation at a South African chrome plant, implementation of mtOne resulted in a 4.6% increase in chrome recovery and a 7% reduction in tailings volume over a three-month period. Plant operators reported that real-time insights allowed for immediate corrective actions, minimising downtime and variability. A process engineer from the site commented, “The dashboard’s live KPIs gave us a level of control and confidence we hadn’t experienced before. We could see exactly where performance dropped and respond within minutes, not hours.”
A splitter refers to a device within the spiral that divides the flow of slurry, separating valuable minerals from waste. Accurate splitter positioning is crucial for optimal recovery. Set-and-forget assets are equipment or processes that, once configured, are typically left to operate without ongoing adjustments, potentially leading to inefficiencies over time. Re-pulping techniques involve re-mixing separated mineral streams with water to improve grade (the concentration of valuable minerals) and recovery rates.
Compared to traditional spiral systems, which rely heavily on manual inspection and adjustment, mtOne introduces automated splitter control powered by adaptive sensors and artificial intelligence. This system provides a centralised, intuitive dashboard for plant operators, giving real-time visibility into each spiral’s performance. In legacy setups, up to 5% of valuable minerals could be lost daily due to splitter misalignment—a challenge mtOne directly addresses by enabling precise, automated adjustments and instant feedback.
mtOne Spiral Automation Platform: Measurable Impact and Industry Accessibility
mtOne supports various operating modes, including automatic, manual, and override, to accommodate different operational preferences. The platform’s ongoing support includes remote monitoring, regular software updates, and proactive diagnostics, ensuring sustained optimisation. Customers have noted improved consistency across circuits and a reduction in manual intervention, with one operator stating, “Having all splitters aligned to the same precision cut-point has streamlined our workflow significantly.”
mtOne provides a measurable improvement over traditional spiral technology by offering real-time control, increased recovery rates, and enhanced operational transparency, while remaining accessible to both industry experts and newcomers through its user-friendly interface and comprehensive support.
