Coal sorting solutions using DRX intelligent mineral sorting equipment include: Solution of removing gangue from raw coal, Solution of selecting high-quality clean coal, Solution of coal recycle from gangue.

Solution of removing gangue from raw coal

I. Solution background

As coal mining intensifies, the gangue content in raw coal increases. Traditional hand sorting or heavy media sorting methods face challenges such as low efficiency, high energy consumption, and significant environmental pressures. To achieve efficient, accurate, and environmentally friendly intelligent coal sorting, Softfox Technology Co., Ltd. has developed the DRX series X-ray intelligent mineral sorter, which demonstrates significant advantages in the raw coal and gangue removal process.

II. Solution overview

Goals:
• Achieve efficient and automated removal of gangue from coal mines
• Improve clean coal recycle and product quality
• Reduce pressure and costs on subsequent washing systems
• Enable intelligent, unmanned, and continuous operations

III. Process design

📍1. Raw coal preparation
• Material specification requirements: Raw coal particle size must be controlled between 20mm and 350mm (A multi-stage sorting system can be configured as needed. Particles exceeding 350mm require a pre-crusher. A drum screen is recommended to remove small particles. If the material is wet and sticky with pulverized coal, use a roller screen to peel and remove small particles)
• Feeding equipment: A loader and belt conveyor feed the vibrating feeder attached to the sorting machine to ensure uniform material distribution
📍 2. DRX intelligent sorting equipment
• Equipment type: DRX
• Core functions:
(1) High-energy and low-energy X-ray dual-energy imaging technology
(2) AI identifies the physical property differences between coal and gangue
(3) Precisely controls the air jet system to eliminate target objects
📍 3. Sorting process
• Raw coal enters the sorting chamber through the conveying system
• X-ray scanning device obtains the transmission characteristics of mineral particles
• The system identifies coal and gangue and automatically marks the gangue discharge target
• High-speed air valve array achieves precise elimination
• After sorting, the materials enter the "clean coal" and "gangue" collection areas respectively

IV. System advantages

• Accurate sorting: Utilizing high-resolution dual-energy X-rays and a deep learning algorithm, the system achieves an accuracy rate exceeding 95%.
• High efficiency: A single unit can process up to 200 tons/hour, suitable for continuous operation.
• Low energy Consumption: Over 90% more energy efficient than dense medium systems, eliminating the need for water or chemicals.
• Intelligent control: Fully automatic intelligent control using AI, machine vision, and FPGA.
• Environmentally Friendly and Safe: A dry process prevents water pollution and dust spillage.
• Modular design: Flexible configuration of single or multi-unit systems tailored to mine or coal preparation plant scale.

V. Application scenarios

• Pre-processing of raw coal at the mine entrance (direct gangue discharge, reducing the burden on the coal preparation plant)
• Removal of gangue before feeding into the coal washing plant (improving product purity)
• Unmanned intelligent operation scenarios in coal mines

VI. Implementation suggestions

• Research and evaluation: On-site sampling, particle size analysis, and waste rock feature identification.
• System selection: Configure the DRX model based on processing capacity and particle size range.
• Equipment installation: Complete foundation construction, electrical connections, and system commissioning.
• Interconnection testing: Integration and commissioning with conveying, loading, and control systems.
• Training and delivery: Operational training and integration with the remote monitoring platform.
• After-sales service: 24/7 technical response and periodic maintenance services.

VII. Actual cases

Inner Mongolia Donglaiwang Co. removing gangue, sorting clean coal
• Daily processing capacity: 2,000 tons
• Actual removal rate of gangue: 99%
• Annual Cost Savings: Approximately RMB 2.5 million
• Labor positions reduced from 30 to 4

VIII. Conclusion

Softfox Technology Co., Ltd.'s DRX series of intelligent mineral sorting equipment has been successfully deployed in numerous coal mines, significantly improving sorting efficiency and resource utilization. This system represents the forefront of intelligent, green, and unmanned coal sorting, and is a powerful complement, upgrade and alternative to traditional coal preparation processes.

Solution of selecting high-quality clean coal

I. Solution background

In the processing of raw coal and washed coal, the clean coal recycle rate and gangue removal rate directly impact economic benefits and resource utilization efficiency. Traditional heavy media and water washing methods suffer from high investment, high water consumption, and unstable efficiency. Softfox Technology Co., Ltd.'s DRX intelligent mineral sorting equipment, based on dual-energy X-ray imaging and artificial intelligence recognition technology, enables efficient, dry, and environmentally friendly clean coal intelligent sorting.

II. Technical features of the equipment

• Identification technology: X-ray Dual Energy + AI Image Recognition
• Sorting method: Dry, high-speed sorting based on density and elemental signature differences
• Processing capacity: Up to 200 tons/hour
• Sorting accuracy: > 95%
• Applicable particle size range: 20 - 350 mm
• Control system: PLC + Industrial computer, supporting remote operation and data monitoring

III. Application 1: Clean coal sorting from raw coal

📍1. Raw coal sorting objectives
• Objective: Remove gangue and low-quality coal from raw coal with a high gangue content, extracting high-calorific-value clean coal.
• Raw coal particle size: 20 - 350 mm (Particles larger than 350mm require a pre-crusher)
📍2. Sorting process flowchart
Raw coal stockpile → Feeder → Belt conveyor → DRX Intelligent Sorting Equipment →
├─ Clean coal output → Clean coal silo
└─ Rejected material (Gangue + Low-quality coal) → Waste conveyor → Transport or backfill
📍3. Key implementation steps
• If necessary, a magnetic separator and drum screen can be installed at the front end to remove impurities and small-sized materials (a roller screen can be used to remove sticky pulverized coal and small particles from wet materials)
• DRX sortor performs X-ray scanning and identification + Separation of clean coal and gangue
• Clean coal calorific value can be increased by 20 - 30%, with a gangue removal rate of >95%.

IV. Application 2: Further quality improvement and sorting of washed coal

📍1. Scenario description
• Washed coal still contains some gangue or low-calorific-value medium coal
• DRX equipment is used to further purify clean coal and improve the quality of commercial coal
📍2. Sorting flowchart
Washed coal storage yard → Conveying system → DRX sorting equipment →
├─ High-quality clean coal → Finished product warehouse
└─ Impurities + inferior coal → Secondary processing or blending
📍3. Performance evaluation
• Further reduction of clean coal ash content by 2 - 5%
• Calorific value-graded products can be produced (e.g., separate sales of coal above 6000 kcal and below 5000 kcal)
• Reduced overall water washing system load and tailwater treatment costs

V. Economic and environmental benefits

• Investment cost: Low (dry sorting)
• Operating energy consumption: Low (dry sorting), no water required
• Clean coal reciclaje: High
• Sorting efficiency: Stable and accurate
• Environmentally friendly emissions: Zero drainage, low dust, no tailwater, and no sludge

VI. Implementation suggestions

1. Site preparation: A dust-proof, enclosed operating area with hardened flooring is required.
2. Production line integration: Seamless integration with existing conveyor systems.
3. Sorting strategy: Flexible adjustment based on calorific value and ash content thresholds.
4. Maintenance and operation: Softfox Technology remote monitoring ensures stable and efficient equipment operation.

VII. Actual cases

Inner Mongolia Donglaiwang Co. removing gangue, sorting clean coal
• Daily Processing Capacity: 2,000 tons
• Gangue Removal Rate: 99%
• Annual Cost Savings: Approximately RMB 2.5 million
• Labor Positions Reduced from 30 to 4

VIII. Conclusion

Softfox Technology Co., Ltd.'s DRX series of intelligent mineral sorting equipment has been successfully deployed in numerous coal mines, significantly improving sorting efficiency and resource utilization. This system represents the forefront of intelligent, green, and unmanned coal sorting, offering a powerful supplement, upgrade, and alternative to traditional coal preparation processes.

Solution of coal recycle from gangue

I. Solution background

As coal mining intensifies, the gangue content in raw coal ore increases. Traditional hand sorting or heavy media sorting methods face challenges such as low efficiency, high energy consumption, and significant environmental pressures. To achieve efficient, accurate, and environmentally friendly intelligent coal sorting, Softfox Technology Co., Ltd. has developed the DRX series X-ray intelligent mineral sorter, which demonstrates significant advantages in the raw coal and gangue removal process.

II. Characteristics of sorted materials

Main composition and characteristics of the source
• Gangue heaps contain unselected clean coal lumps and a large amount of gangue with large particle size, high impurity content, and uneven distribution
• Gangue removed from heavy media or jigs in water-washed gangue piles is more uniform, has a concentrated particle size, and low water content

III. Overall goals

• Efficiently identify and recover residual coal (clean coal/medium coal) from gangue
• Improve resource utilization by ≥10%
• Reduce gangue pile volume, environmental footprint, and pollution

IV. Process for coal recycle from guangue pile

📍1. Processing particle size range: 20 - 350 mm (Particles larger than 350mm require a pre-crusher)
📍2. Recommended configuration process

Gangue pile → Loading by loader → Drum screen (Small particle removal) → Conveyor → DRX Intelligent Sorting Equipment
├─ Combustible coal (Clean coal/Medium coal) → Finished product silo → Return to furnace or blending
└─ Real waste rock → Closure compaction/Construction fill/Ecological restoration
📍3. Sorting performance targets
• Coal recycle rate: 10 - 25% (Depending on the coal content of the original waste gangue)
• Accuracy sorting: false picking rate <5%
• Combustible ash reduction: 3 - 6%
• Annual processing capacity: 500,000 Tons/Line

V. Process for coal recovery from washed guangue pile

📍1. Processing particle size range: 20 - 350 mm
📍2. Recommended configuration process
Gangue Pile → Bucket Feeder → Drum screen (Impurity removal) → Conveyor → DRX Intelligent Sorting Equipment →
├─ Combustible coal (Can be used as secondary commercial coal) → Clean coal silo
└─ Real waste rock → Stockpile or secondary recycling
📍3. Advantages and results
• Effectively recovers "missed" coal particles in waste rock
• Can be sorted and reused according to metrics such as calorific value and ash content
• Replaces some newly mined coal, reducing raw coal mining costs

VI. Technical advantages

• Sorting accuracy based on X-ray + AI for precise identification of coal and gangue
• Particle size adaptability supports a wide range of material sizes from 20–350mm
• Dry operation requires no water source and eliminates the pressure of tailwater treatment
• Environmentally friendly, no secondary pollution, and suitable for field operations
• Modular operation and maintenance, remote monitoring, and easy maintenance

VII. Economic and environmental benefit analysis

Estimated annual benefits for a single project line (Indicative)
• Annual processing capacity: 500,000 tons of gangue
• 10% coal recycle, or approximately 50,000 tons of coal
• Average market coal price: 300 yuan/ton (reference)
• Annual incremental benefits: ≥ 15 million yuan/year
• Reduced landfill costs: Gangue compression costs reduced by 10–20 yuan per ton
Additionally, the project can:
• Reduced stockpile footprint
• Reduced green mine remediation costs
• Support for ESG environmental indicators and green financing

VIII. Implementation recommendations

• Equipment layout: It is recommended to set up a mobile or semi-fixed sorting station near the gangue pile.
• Sorting parameter adjustment: Adjust the AI recognition model based on the coal content of the gangue.
• Safety and environmental protection: Configure a dust control system to prevent dust from screening.
• Subsequent utilization: Recovered coal can be used for blending, fuel for medium- and low-calorific value boilers, etc.

IX. Case reference

Yongtai Energy Sendayuan Coal Washing Plant Coal recycle from guangue rock
• Bid awarded
• Contract signed
• Production expected to begin in October 2025

X. Optional services

Softfox Technology offers:
• Sorting testing services
• Custom project design and installation
• Solutions for managing the operation and maintenance of sorting equipment
• Remote device management

XI. Conclusion

Softfox Technology Co., Ltd.'s DRX series intelligent mineral sorting equipment has been successfully deployed in numerous coal mines, significantly improving sorting efficiency and resource utilization. This system represents the forefront of intelligent, green, and unmanned coal sorting, offering a powerful supplement, upgrade, and alternative to traditional coal sorting processes. It is particularly effective in recovering low-coal content coal from gangue, achieving tasks that traditional processes could not accomplish.

Utilize DRX intelligent mineral sorting equipment, DRXV intelligent mineral sorting equipment to sort kaolinite raw materials and coal calcined kaolinite include: Sorting for kaolinite raw materials, Sorting for calcined kaolin finished products.

Sorting for kaolinite raw materials

I. Key prerequisites

1. Mineralogical differences: Kaolinite and associated non-kaolinite materials such as quartz and sandstone do not differ significantly in chemical composition and density (density is similar). Using density to distinguish kaolinite from non-kaolinite sandstone or quartz-rich gangue can allow for the selection of kaolinite, but accuracy often falls short of requirements
2. Identification strategy: Utilize DRX X-ray imaging to separate materials by high, medium, and low density (removing high/low density materials while retaining medium-density kaolinite). If DRX sortor accuracy fails to meet requirements, use DRXV X-ray imaging combined with industrial camera imaging to combine material density and color texture for differentiation (removing high/low density materials and non-kaolinite in the medium-density range)
3. Sample testing: Since the gangue from different coal mines is different, it is necessary to conduct specific sample testing. After data collection and modeling sorting tests, the decision on whether to proceed with the project can be made based on the test results

II. Using X-ray image sorting logic

1. Data acquisition • X-ray Imaging: Detects the X-ray attenuation characteristics of the material. Used to distinguish clearly low-density materials (coal, interbedded coal, and black rock) from clearly high-density materials (sandstone and high-density gangue)
2. Computational identification
• High-density identification: Ignores sandstone, and high-density gangue
• Low-density identification: Ignores coal, interbedded coal, and black rock
• Medium-density Identification: Marks kaolinite
3. Separation execution
• High-pressure gas is used to eject the marked kaolinite for sorting.

III. Using X-ray + industrial camera image sorting logic

1. Data acquisition • X-ray imaging: Detects the X-ray attenuation characteristics of the material. Used to distinguish clearly low-density materials (coal, interbedded coal, black rock) from clearly high-density materials (sandstone, high-density gangue). • Industrial camera imaging: Identifies the surface spectral characteristics of kaolinite, assisting in distinguishing kaolinite from non-kaolinite. 2. Computational identification • High-density identification using X-ray imaging: Ignores sandstone, and high-density gangue. • Low-density identification using X-ray imaging: Ignores coal, black rock, and interbedded coal. • Further identification of medium-density materials using industrial camera imaging: Ignores non-kaolinite and marks kaolinite. 3. Separation execution • High-pressure gas ejects the marked kaolinite for sorting.

IV. Project preparation

1. Sample preparation: 200-500 kg of kaolinite-containing coal gangue sample
2. Data Acquisition: First, classify the sample to separate kaolinite and non-kaolinite samples, then acquire X-ray images and industrial camera images
3. Sorting modeling: Develop a sorting model using X-ray images and a sorting model using X-ray image + industrial camera image fusion
4. Sorting tests: Conduct multiple sorting tests and refine the model and parameters based on the sorting results. Finally, generate sorting results samples, including X-ray image sorting and X-ray image + industrial camera image fusion sorting (including kaolinite and non-kaolinite samples, respectively)
5. Sorting verification: Test samples from various sorting results to determine the chemical composition of the sorted kaolinite and non-kaolinite. Use the test results to verify the sorting performance. Based on the test results, determine whether the sorting model parameters can be improved. If so, conduct further sorting tests and retest. Only after the final test results confirm a favorable sorting performance will the project be considered for advancement
6. Process flow determination: Based on the sorting performance, select a sorting process flow: DRX X-ray imaging sorting, DRXV X-ray + camera imaging sorting

V. Sorting process using DRX equipment

Raw materials → (particles larger than 350mm require a pre-crusher + vibrating screen) → particle size 20-350mm → X-ray image recognition → high-pressure gas injection to select kaolinite

VI. Sorting process using DRXV equipment

Raw materials (particles larger than 350mm require a pre-crusher + vibrating screen, and cleaning and dehumidification are required) → particle size 20-350mm → X-ray imaging + industrial camera image recognition → high-pressure gas injection to select kaolinite

VII. Conclusion

DRX sorting equipment uses X-ray imaging to sort kaolinite. Sorting accuracy varies among coal mines, with some mines achieving high kaolinite sorting accuracy from gangue, while others experience lower accuracy. DRXV utilizes a fusion of X-ray imaging and industrial camera image recognition to select high-purity kaolinite and eliminate non-kaolinite. However, industrial camera imaging requires a relatively clean surface for the raw materials, potentially requiring additional cleaning and dehumidification equipment.
Because gangue from different coal mines varies, specific sample data collection and modeling and sorting tests are necessary. Based on the test results, a cost-benefit analysis is conducted before a decision is made on whether to proceed with the project. If it is necessary to recover the coal and gangue contained in the raw materials, it is recommended to first remove the high-density sandstone and gangue to select kaolinite, black stone, coal, and gangue, then select the kaolinite, and finally select the coal and gangue from the remaining materials.

Sorting for calcined kaolin finished products

I. Solution background

Because coal-bearing kaolinite raw materials are impure, calcined kaolinite can contain mixed rocks of high and low density, gangue (white on the outside but with mixed colors inside), and low-quality kaolinite with low whiteness. To obtain kaolinite products with relatively high whiteness or products graded by whiteness, the calcined kaolinite requires further sorting. Manual sorting is inefficient, costly, and poses safety risks, especially for materials with a white surface but non-white interiors. The DRXV intelligent mineral sorting equipment, which utilizes X-rays and industrial camera image recognition, can efficiently, cost-effectively, safely, and reliably sort kaolinite products with high whiteness or graded by whiteness.

II. Using X-ray + Industrial camera image sorting logic

1. Data acquisition
• X-ray Imaging: Using X-ray penetration imaging of the material, distinguish high-density debris and gangue with a white exterior and mixed colors inside
• Industrial camera imaging: Using kaolinite camera imaging, distinguish non-white raw materials
2. Computational identification
• Using X-ray Imaging to Identify High and Low Density: Ignore high- and low-density debris, especially non-kaolinite with a white exterior and mixed colors inside
• Using industrial camera image color identification: Ignore non-white, low-whiteness kaolinite and mark high-whiteness kaolinite; or classify by whiteness to mark kaolinite with a desired whiteness level
3. Separation execution
• Using high-pressure gas to eject: Marked high-whiteness kaolinite, or marked kaolinite with a desired whiteness grade

III. Test using DRXV equipment

1. Sample preparation: 50-200 kg of calcined kaolinite
2. Data collection: First, classify the sample to separate white kaolinite and non-white mixed stone samples. Samples with white exterior and mixed stone inside are identified by breaking the particles apart. Then, obtain X-ray images and industrial camera images
2. Sorting modeling: Develop a sorting model using X-ray imaging and a sorting model using X-ray imaging + industrial camera image fusion
3. Sorting tests: Conduct multiple sorting tests and refine the model and parameters based on the sorting results. Finally, generate sorting results samples, including X-ray image sorting and X-ray image + industrial camera image fusion sorting (including white kaolinite and non-white mixed stone, respectively)
4. Sorting verification: All sorted samples are broken open and inspected again to verify the sorting results. This will determine whether the sorting model parameters can be improved. If so, further sorting tests and verification are conducted to finalize the model parameters
Also, if sorting by whiteness grade is required, samples are selected at different whiteness grades, images are acquired, and sorting parameters are proposed. Sorting tests are then conducted to finalize the model parameters for sorting by whiteness grade.

IV. Sorting process using DRXV equipment

1. High whiteness kaolinite sorting
Calcination (particles over 350mm require a pre-crusher and vibrating screen) → Particle size 20-350mm → X-ray imaging + industrial camera image recognition → High-pressure gas injection to select high-whiteness kaolinite
2. Sorting by whiteness grade
White kaolinite → X-ray imaging + industrial camera image recognition → High-pressure gas injection to select kaolinite of the required whiteness grade

V. Test case reference

Datong Jinyuan Kaolin Co., Ltd.
• Remove impurities and select white kaolinite
• Select kaolinite of different whiteness grades by grade

VI. Conclusion

DRXV intelligent mineral sorting equipment uses X-ray + industrial camera image fusion recognition technology to remove the debris in the calcined kaolinite, especially the gangue that is white on the outside and mixed on the inside, and sort out the high-whiteness kaolinite. It can also be graded according to the whiteness. If necessary, it can use DRXV intelligent mineral sorting equipment to sort for coal kaolinite raw materials before calcination, remove high-density and low-density miscellaneous stones and non-kaolinite materials, improve the purity of kaolinite raw materials, reduce the calcination task and the sorting workload after calcination, so as to reduce costs and improve production efficiency and benefits.

Use DRXV intelligent mineral sorting equipment 's X-ray image and industrial camera image fusion recognition technology is used to sort fluorite ore according to product grade from the fluorite source ore, removing impurities such as potassium feldspar, barite, dolomite and quartz.

I. Product target grades

Typical product grades (Example, subject to adjustment based on company standards)
• Acidspar (AGS): CaF₂ ≥ 97%
• Ceramic (CGS): CaF₂ 85–95%
• Metallurgical (MGS): CaF₂ 60–85%
Ore Characteristics (common): CaF₂ intergrows with calcite/dolomite (carbonates), intercalated with quartz/feldspar (silicates), and minor amounts of potassium feldspar and barite. Colors vary (red/purple/green/colorless).

II. Technical features of the equipment

• Identification Technology: X-ray dual-energy imaging + industrial camera imaging + intelligent image recognition
• Sorting Method: Dry high-speed sorting based on density and elemental characteristics, as well as surface color and texture characteristics
• Processing Capacity: Up to 200 tons/hour
• Identification Accuracy: > 98%
• Applicable Particle Size Range: 20–350 mm
• Control System: PLC + industrial computer, supporting remote operation and data monitoring

III. Sorting logic using X-ray + industrial camera images

1. Data acquisition
• X-ray Imaging: Detects the X-ray attenuation characteristics of the material. Used to distinguish significantly low-density calcite/dolomite (carbonates) and quartz/feldspar (silicates) from significantly high-density potassium feldspar and barite.
• Industrial Camera Imaging: Utilizes the spectral characteristics of the material surface to further distinguish non-fluorite impurities.
2. Computational Identification
• Low-density identification using X-ray imaging: Ignore calcite/dolomite (carbonates) and quartz/feldspar (silicates).
• High-density identification using X-ray imaging: Distinguish significantly high-density potassium feldspar and barite.
3. Separation and Execution
• Using high-pressure gas to eject the marked fluorite for sorting

IV. Sorting process using DRXV equipment

Raw materials (particles larger than 350mm require a pre-crusher + vibrating screen) → particle size 20-350mm → X-ray imaging + industrial camera image recognition → high-pressure gas injection to select fluorite ore

V. Conclusion

The DRXV intelligent mineral sorting equipment utilizes X-ray imaging combined with industrial camera image fusion and recognition technology to remove high-density and low-density impurities and miscellaneous colors from the source ore, resulting in high-purity fluorite products. To achieve product grading, multiple sorting cycles or multiple equipment stages can be used. If fluorite waste materials still contain small amounts of fluorite before project implementation, the DRXV sorting equipment can also be used to sort fluorite that meets product grade requirements, maximizing resource utilization.

The main components of aluminum ore are aluminum oxide and silicon oxide. The content of these two components determines the quality of aluminum ore. Aluminum and silicon have adjacent atomic numbers, so it is very challenging to use X-ray image recognition technology to sort aluminum ore. DRX intelligent mineral sorting equipment can remove non-aluminum ore debris from the aluminum ore raw materials and sort different grades of concentrated aluminum ore, and can also select good ore that meets the aluminum ore grade requirements from the aluminum ore waste.

I. Aluminum ore raw material composition

Aluminum components: Aluminum oxide, including gibbsite (Al2O3·3H2O), boehmite (Al2O3·H2O), and diaspore.
Byproduct components: Silicon dioxide (Si2O2) and ferric oxide (Fe2O3), including quartz, feldspar, pyrite, hematite, and goethite.

II. Sorting target and equitment

• Desiliconization: Reduces SiO₂ (quartz, etc.) entering the clinker/dissolution system, improving the Al₂O₃/SiO₂ ratio.
• Iron Control: Limits Fe₂O₃ (hematite/goethite) content.
• Targets: Remove impurities, increase concentrate Al₂O₃ grade, and reduce SiO₂.
• Equipment: DRX intelligent mineral sorting equipment.

III. Technical features of the equipment

• Identification technology: X-ray Dual-Energy imaging + Intelligent image recognition
• Sorting method: Dry, high-speed sorting based on material density and elemental characteristics
• Processing capacity: Up to 200 tons/hour
• Sorting belt width: 1000mm
• Sorting belt speed: 2.75m/s
• Applicable particle size range: 20–350mm
• Control system: PLC + Industrial Computer, supporting remote operation and data monitoring

IV. Using X-ray image sorting logic

1. Data acquisition
• X-ray Imaging: Acquire X-ray attenuation characteristic images of the aluminum ore raw material
2. Computational identification
• High-density identification: Ignore high-density materials containing iron, manganese, and other substances
• Medium-density identification: Ignore medium-density materials with high silicon content as required
• Low-Density Identification: Identify and mark low-density materials with high aluminum content as required
3. Separation execution
• Use high-pressure gas to eject the marked aluminum ore concentrate for sorting

V. Sorting process using DRX equipment

Aluminum ore raw materials (particles larger than 350mm require a pre-crusher + vibrating screen) → particle size 20-350mm → X-ray image recognition → high-pressure gas injection to select the concentrated aluminum ore

VI. Conclusion

Softfox Technology's DRX intelligent mineral sorting equipment utilizes artificial intelligence (AI) recognition technology based on X-ray imaging to remove high-density non-aluminum debris from raw aluminum ore and sort it into aluminum concentrate. Sorting by grade requires multiple runs on one device or multiple stages across multiple devices. If a small amount of usable aluminum ore remains in the tailings, the DRX sorting equipment can be used to sort the ore that meets the grade requirements, further improving the utilization of aluminum resources.

Use DRX intelligent mineral sorting equipment to sort metal ores such as manganese ore, iron ore, copper ore, antimony ore, lead and zinc ore, etc., to remove impurities from metal ore raw materials and sort out metal ore products of different grades. It is also possible to select good ores that meet the metal ore grade requirements from previous metal mine tailings.

I. Metal ore raw material composition

The metals in metal ores usually exist in the form of metal oxides and metal sulfides, accompanied by carbonates, silicates and small amounts of other metal compounds.

II. Application Scenarios and Objectives

1. Applicable minerals: Manganese, iron, copper, antimony, lead, zinc, etc.
2. Processing targets: Mineral disposal, grade sorting, and metal ore recycle from tailings
3. Core objectives: Crushed and screened particles are then sorted for disposal or grade sorting using the DRX intelligent sorting equipment's dual-energy X-ray transmission imaging technology to achieve:
• Reduced mill feed, energy savings, and reduced chemical consumption
• Improved metal recycle, efficient resource utilization
• Environmentally friendly and safe alternative to heavy media sorting and manual sorting

III. Technical features of DRX equipment

• Identification technology: X-ray Dual-energy imaging + Intelligent image recognition
• Sorting method: Dry, high-speed sorting based on material density and elemental signature differences
• Processing capacity: Up to 200 tons/hour
• Identification accuracy: > 95%
• Applicable particle size range: 20–350 mm
• Control system: PLC + Industrial computer, supporting remote operation and data monitoring

IV. Process route

Plan A: Raw ore disposal
1. Stope → Crushing (150 mm)
2. Dry screening: Less than 20mm conventional grinding; 20mm～150mm enter DRX sorting DRX
3. DRX intelligent sorting: Select middlings; remove tailings

Plan B: Low-grade Stockpile Recycle
1. Stockpile → Crushing (150 mm)
2. Dry screening: Less than 20mm is discharged into real tailings; 20mm～150mm enter DRX sorting
3. DRX intelligent sorting: Eliminate true tailings; select middlings

Plan C: Middling classification
1. Middling → Crushing (80 mm)
2. Dry screening: Less than 20mm conventional grinding; 20mm-80 mm enter DRX sorting
3. DRX intelligent sorting: Separate into high-grade concentrate and low-grade ore

V. Case reference

Antimony ore sorting test conducted by a Central American antimony mining company in three grades.
High-grade antimony ore: Sb > 50%
Medium-grade antimony ore: Sb > 30%
Low-grade antimony ore: Sb > 20%

VI. Conclusion

Softfox Technology's DRX intelligent mineral sorting equipment utilizes artificial intelligence (AI) recognition technology based on X-ray imaging to remove tailings from raw metal ore, sorting metal ore products by grade, and recovering high-quality ore that meets metal grade requirements from former tailings dumps. During the sorting process, particles are crushed to 150mm and then re-crushed to 80mm to improve sorting accuracy and increase metal ore recycle.

When sorting coal using an existing X-ray dry sorter, if the coal contains a lot of gangue, the calorific value of the clean coal is reduced. If the gangue contains a lot of coal, good coal resources are wasted. If the coal is not clearly distinguished from the gangue, it is impossible to safely retain or exclude the interbedded coal. In this case, the existing X-ray dry sorter software can be upgraded to Softfox Technology's DRX intelligent mineral sorting software to enhance the sorter's mineral recognition capabilities and improve the accuracy of mineral identification and sorting. Similarly, Softfox Technology's DRV and DRXV intelligent mineral sorting software can be used to replace the software of color sorters and X-ray + color sorters to improve the accuracy of mineral identification and sorting.

I. Hardware adaptation check

Check the original dry separator's X-ray imaging and industrial camera image acquisition hardware, and maximize the use of the original image acquisition hardware system to reduce costs. If there are any problems with the overfitting, the corresponding hardware upgrade is required.

II. Software installation and operation

Install Softfox Technology's DRX, DRV or DRXV intelligent mineral sorting system and debug the software operation.

III. Sorting test verification

Utilizing Softfox Technology’s intelligent sorting software, from mineral image data acquisition, to data processing and identification, and then to sorting control signal output, the minerals are sorted and tested to verify sorting accuracy.

IV. Sorting production operation

After multiple sorting test verifications, actual mineral sorting production operations can be carried out.

V. Conclusion

While improving the sorting accuracy of the original dry sorter through software upgrades, if the sorting speed of the original dry sorter is 1.6-1.8m/s, the sorting belt speed of the sorter can be increased, and the newly upgraded Softfox Technology Intelligent Mineral Sorting System software can be used to increase the processing capacity of the original dry sorter per unit time.

If the original coal preparation plant has limited space for an X-ray dry sorter, and can only install a dry sorter with a 1-meter or 1.2-meter wide sorting belt, and the dry sorter's processing capacity is too low to meet the requirements, the original X-ray dry sorter software can be upgraded to Softfox Technology's DRX intelligent mineral sorting software to increase the sorting speed and processing capacity per unit time. Of course, Softfox Technology's DRV or DRXV intelligent mineral sorting software can also be used to replace the color sorter and X-ray + color sorter software to increase the mineral sorting speed.

I. Hardware adaptation check

The original dry sorter's X-ray imaging and industrial camera image acquisition hardware were inspected, and the original image acquisition hardware system was reused as much as possible to reduce costs. The motor and motor control inverter that drive the sorting belt of the original dry sorter were inspected to confirm that the motor and inverter can drive the sorting belt at a speed of 3.1 m/s. If there are any problems with the adaptation, the corresponding hardware upgrade is required.

II. Software installation and operation

Install SoftFox Technology's DRX, DRV or DRXV intelligent mineral sorting system and debug the software operation.

III. Sorting test verification

The speed of the dry sorting machine's sorting belt was increased to 2.75-3.1 m/s. Softfox Technology's intelligent sorting software was used to conduct sorting tests on the minerals from mineral image data acquisition, data processing and identification, to sorting control signal output to verify sorting accuracy.

IV. Sorting production operation

After multiple sorting test verifications, actual mineral sorting production operations can be carried out.

V. Conclusion

By upgrading the software to Softfox Technology's intelligent mineral sorting system software, the original dry sorting machine's mineral sorting processing capacity per unit time is increased, and in fact, the original dry sorting machine's accuracy in mineral sorting is also improved.

If the original solenoid valve in a dry sorting machine, even if it's a MAC brand, begins to break after just a few months, or even just three or four months, the cause isn't a quality issue with the solenoid valve itself, but rather flaws in the nozzle box design and solenoid valve installation process. Softfox Technology can upgrade the original nozzle solenoid valve box to one with a more optimized solenoid valve installation process and structure. This will extend the durability of the dry sorting machine's nozzle solenoid valve, reduce the hardware cost and downtime associated with solenoid valve replacement, ensure long-term continuous operation, and increase equipment throughput.

Donglaiwang Clean Energy Co., Ltd. uses Softfox Technology's DRX intelligent mineral sorting equipment, which has been in continuous production for nearly two years since it was put into operation. No solenoid valve has had any problems, which has effectively ensured the long-term, continuous and stable production of the sorting machine.

If the original X-ray detector card in a dry sorter breaks down within a few months, even if it uses DeeTee products, the cause is often not a quality issue with the detector card itself, but rather a problem with the X-ray receiver box design and detector card installation process. Softfox Technology can upgrade the original X-ray receiver box to one with a more optimized detector card installation process and structure, making it more durable. This saves the cost of detector card hardware replacement and reduces downtime, ensuring long-term continuous production and increasing equipment throughput.

The Softfox Technology DRX intelligent mineral sorting equipment used by Donglaiwang Clean Energy Co., Ltd. has been in continuous production for nearly two years since it was put into operation. No X-ray detection card has had any problems, which has effectively ensured the long-term, continuous and stable production of the sorting machine.

Before implementation, conduct sample sorting tests. Contact SoftFox Technology for a shipping address, send raw minerals to SoftFox Technology, and then personally participate in the sorting test on site. Further testing of the test samples will be conducted. Once the test results are obtained, the mineral sorting implementation plan will be determined.

I. Contact Softfox Technology

Send an email to Softfox Technology to obtain the shipping address and testing address. softfox@yeah.net

II. Send mineral samples

Send 50-200 kg of mineral raw materials to Softfox Technology and wait for arrival message.

III. Mineral raw material sorting

Softfox Technology will notify you upon receipt of the sample. Please attend the on-site sorting test in person to witness the sorting process and the resulting samples. If the raw material is virgin ore, the test will include discarding the waste and selecting the concentrate. If the raw material is concentrate, the test will include sorting by grade. If the raw material is waste, the test will include selecting the fine ore from the waste.

IV. Sorting sample testing

After getting the sorted samples, you can send them for testing and get the test results.

V. Determine the sorting plan

After obtaining the test results of the sorted samples, we will jointly discuss the specific implementation plan for mineral sorting.

To use intelligent mineral sorting equipment for mineral sorting production, you need to purchase SoftFox Technology's intelligent sorting equipment (the equipment comes with the corresponding intelligent sorting system software), and you also need to purchase or customize supporting auxiliary equipment.

I. Intelligent mineral sorting equipment provided by Softfox Technology

(Recommended purchase based on customer material and sorting requirements)
1. DRX Intelligent Mineral Sorting Equipment (X-ray Dry Separator)
2. DRV Intelligent Mineral Sorting Equipment (Color Dry Separator)
3. DRXV Intelligent Mineral Sorting Equipment (X-ray + Color Dry Separator)
Each set of equipment includes a dry separator and a vibrating feeder (including the corresponding SoftFox Technology intelligent mineral sorting system software), and is responsible for equipment transportation, installation guidance, and operation commissioning.

II. Required supporting auxiliary equipment

(Customers are advised to purchase or customize the recommended brands and models.)
• Non-Mobile
1. Power control cabinet (1)
2. Air compressor (1)
3. Dust collector (1)
4. Loading conveyor (1)
5. Discharge conveyors (2)
6. Vibrating feed hopper (1)
7. Discharge hopper (1)
• Mobile
1. Containers (2)
2. Air compressor (1)
3. Dust collector (1)
4. Loading conveyor (1)
5. Discharge conveyors (2)
6. Vibrating feed hopper (1)
7. Discharge hopper (1)

III. Warranty period of intelligent sorting equipment

The warranty period is 1 year, and an extended warranty can be purchased. After the warranty period expires, the customer is responsible for the cost of spare parts and maintenance.

Based on the client's ore material and sorting requirements, we recommend the purchase of the most appropriate intelligent sorting equipment hardware (excluding the intelligent mineral sorting software system). The client will also need to purchase supporting auxiliary equipment. The intelligent mineral sorting system software can be subscribed on a monthly or annual basis, helping clients reduce initial one-time investment costs and alleviate financial pressure.

I. Intelligent mineral sorting equipment hardware provided by Softfox Technology

(Recommended purchase based on customer material and sorting requirements)
1. DRX Intelligent Mineral Sorting Equipment (X-ray Dry Sorting) Hardware
2. DRV Intelligent Mineral Sorting Equipment (Color Dry Sorting) Hardware
3. DRXV Intelligent Mineral Sorting Equipment (X-ray + Color Dry Sorting) Hardware
Each set of equipment includes a dry separator hardware and a vibrating feeder (SoftFox Technology's intelligent mineral sorting system software requires subscription), and is responsible for equipment transportation, installation guidance and operation debugging.

II. Required supporting auxiliary equipment

(Customers are advised to purchase or customize the recommended brands and models.)
• Non-Mobile
1. Power control cabinet (1)
2. Air compressor (1)
3. Dust collector (1)
4. Loading conveyor (1)
5. Discharge conveyors (2)
6. Vibrating feed hopper (1)
7. Discharge hopper (1)
• Mobile
1. Containers (2)
2. Air compressor (1)
3. Dust collector (1)
4. Loading conveyor (1)
5. Discharge conveyors (2)
6. Vibrating feed hopper (1)
7. Discharge hopper (1)

III. Warranty period of intelligent sorting equipment

The warranty period is 1 year, and an extended warranty can be purchased. After the warranty period expires, the customer is responsible for the cost of spare parts and maintenance.

Softfox Technology provides intelligent sorting equipment and supporting auxiliary equipment. Customers pay monthly rent. At the end of the lease, Softfox Technology will transfer the ownership of the entire set of equipment to the customer.

I. Basic requirements

The customer's mineral sorting input volume is more than 300,000 tons/year

II. Responsibilities of both parties

Softfox Technology:
• Provides intelligent sorting equipment and supporting auxiliary equipment tailored to customer sorting requirements
1. Intelligent mineral sorting equipment (1)
2. Power control cabinet (1)
3. Air compressor (1)
4. Dust collector (1)
5. Loading conveyor (1)
6. Discharge conveyors (2)
7. Vibrating feed hopper (1)
8. Discharge hopper (1)
• Provides equipment transportation, installation guidance, and commissioning
• Provides a one-year warranty
Customer:
• Customer pays a 10% deposit of the total equipment price, and provides power and communication network for equipment operation
• Covers production costs and monthly rental payments
• Covers equipment maintenance costs after one year

III. Rent calculation

The rental price is calculated by taking the unit cost of the mineral washing process, subtracting the production cost of the intelligent sorting equipment, and using half of the cost savings as the unit price.
For example, if the current cost of coal sorting with water washing equipment is 13-25 yuan/ton, taking the lower of 13 yuan/ton, and the DRX intelligent sorting equipment sorting costs 1 yuan/ton, the rental price is: (13-1)/2 = 6 yuan/ton. If 300,000 tons are sorted annually, or 25,000 tons per month, the total monthly rental is: 25,000*6 = 150,000 yuan. If the sorting production volume in a given month is less than 25,000 tons, it will be calculated as 25,000 tons. If the production volume is greater than 25,000 tons, the rental price is calculated based on the actual sorting volume.

IV. Lease term

The lease term is generally 3 years, with a minimum of 2 years. When the lease expires after 3 years or the total rent paid by the customer reaches 1.5 times the total price of the intelligent sorting equipment and ancillary equipment, SoftFox Technology will transfer all ownership of the intelligent sorting equipment and ancillary equipment to the customer.

V. Conclusion

In the leasing and sales program, a full set of intelligent sorting equipment is provided by Soft Fox Technology. Customers do not need to invest in equipment in advance, and can use the intelligent sorting equipment for sorting production. After generating benefits, they can pay the equipment rental. After the lease period ends, customers own the entire set of intelligent sorting equipment and continue to carry out mineral sorting production.