STEINERT AI Ore Sorting Line Deployed at Navachab Gold Mine in Namibia

Industry Milestone: AI-Powered Ore Sorting Arrives at Navachab

The Navachab Gold Mine in Namibia has become the first large-scale operation in the country to deploy an AI-powered X-ray ore sorting system, marking a significant advancement in African mining technology. The mine, operated by QKR Namibia, has installed the latest generation of STEINERT KSS EVO 6.0 multi-sensor sorters, building on a partnership with STEINERT that began in 2016 with the installation of XSS T sorters. Over the past decade, these earlier machines preconcentrated more than 10 million tonnes of low-grade stockpiles—material previously considered uneconomical to process. Now, with the EVO 6.0 upgrade, Navachab has taken the next evolutionary step in unlocking value from its orebody. The mine produced approximately 131,000 ounces of gold in 2025 and is pursuing an underground expansion that will extend its operational life. For the crushing and screening industry, this deployment demonstrates how AI-powered pre-concentration is reshaping mineral processing circuits worldwide—reducing the volume of material that must be crushed, ground, and processed. OCP Mechanical Company, with over 40 years of manufacturing experience, supplies high-performance jaw crushers, cone crushers, impact crushers, and complete crushing and screening plants engineered for the demands of modern, pre-concentration-enabled mining operations. Our direct factory model eliminates intermediaries, delivering factory-direct pricing and responsive technical support.

Intelligent.Declustering: Solving the Throughput-Accuracy Trade-Off

The Navachab installation showcases a critical breakthrough in ore sorting data interpretation: STEINERT‘s Intelligent.Declustering software. In traditional particle sorting, higher throughput increases the likelihood that multiple rocks are identified as a single particle—a phenomenon called “clustering.” This leads to costly errors: valuable ore classified as waste, or waste classified as valuable. The Intelligent.Declustering software solves this problem by digitally extracting individual rocks from a cluster, even when particles are very close together, and analysing them separately. As material flows at 2.8 m/s, sensors including X-ray transmission and 3D laser scan the stream and generate detailed images. When particles are clustered, intelligent algorithms virtually separate them into individual objects, enabling accurate sorting decisions even when physical separation is incomplete. The result is that higher throughput and greater accuracy—previously mutually exclusive goals—are now achievable together. For mining operations, this means the sorting system can process higher volumes without sacrificing recovery rates, directly improving the economic performance of the pre-concentration circuit.

Proven Results: Doubling Grade and Cutting OPEX by 75%

The performance data from Navachab demonstrates the transformative impact of AI-powered ore sorting. The dry sorting plant processes 200 tonnes per hour, identifying material that falls below the CIP plant cut-off grade. The result is a doubled gold grade in the pre-concentrated material, which can then be profitably treated by downstream processes. Compared with the previous Dense Media Separation (DMS) process, dry sensor-based sorting now runs at one-quarter of the overall operational costs while doubling throughput. This represents a 75% reduction in OPEX and a 100% increase in processing capacity—a combination that fundamentally changes the economics of low-grade gold processing. The technology requires a minimum of water, making it exceptionally environmentally friendly and suitable for arid regions like Namibia, where water conservation is a critical operational priority. As Hildebrand Wilhelm, Project Manager at Navachab, noted, “The more of a holistic view you have, the better you can decide what technologies can work, as long as you understand these technologies.”

Reducing the Load on Crushing and Grinding Circuits

The deployment of AI-powered ore sorting at Navachab has direct implications for crushing and grinding circuit design. By rejecting waste material before it enters the milling circuit, the sorting plant reduces the volume of material that must be crushed and ground—the most energy-intensive stages of mineral processing. Industry analysis confirms that pre-concentration at crushing sizes—typically 10–100 mm—can reject a high quantity of non-valuable material before it enters the grinding circuit, delivering reduced comminution energy consumption, extended equipment lifespan, and lower grinding media usage. The Navachab experience validates this principle: material that would previously have been milled at significant cost is now pre-concentrated, with only higher-grade material advancing to the downstream CIP circuit. For operators of jaw crushers, cone crushers, and impact crushers, this trend means that crushing circuits are increasingly being designed with pre-concentration in mind—with sorting equipment positioned after primary or secondary crushing to remove waste before it reaches the tertiary and grinding stages. This reduces the load on tertiary crushers, lowers liner wear, and improves the grade of material entering downstream processing.

Namibia‘s Mining Sector: A Strategic Context for Innovation

The Navachab deployment comes at a time of significant strategic importance for Namibia’s mining sector. In March 2026, the Bank of Namibia signed a gold purchase agreement with QKR Namibia Navachab Gold Mine as part of efforts to strengthen the country‘s foreign reserves, targeting gold holdings of around 3% of Namibia’s net foreign exchange reserves. The mine is also advancing an underground expansion, with the first blast for the current phase carried out in December 2025 and exploration drilling expected to commence in the third quarter of 2026. The mine has partnered with underground mining contractor Byrnecut, employing 58 nationals, and has welcomed 28 apprentices as part of its skills development programme. These developments position Navachab as a strategically important operation for Namibia—and its investment in AI-powered ore sorting demonstrates how technology can extend mine life, reduce environmental impact, and improve economic returns.

Global Momentum: AI Sorting Expands Across the Mining Industry

The Navachab deployment is part of a broader global trend toward AI-powered sensor-based ore sorting. The global sensor-based ore sorting market was valued at approximately USD 327 million in 2025 and is projected to reach USD 836 million by 2036, growing at a compound annual growth rate of 8.9%. The X-ray Transmission (XRT) mining sorters segment alone was estimated at USD 166 million in 2025 and is forecast to reach USD 325 million by 2032 at a CAGR of 10.1%. In China, the sensor-based ore sorting market is forecast to grow from approximately USD 320–380 million in 2026 to USD 680–820 million by 2035 at 8–10% CAGR, with Chinese equipment manufacturers developing AI classification algorithms capable of sorting over 40 mineral types including gold, copper, tungsten, and tin. The technology is being deployed across gold, potash, tungsten, and polymetallic operations worldwide, driven by declining ore grades, rising energy costs, and the imperative to reduce environmental impact.

OCP Mechanical Company: Factory-Direct Crushing Solutions for the Pre-Concentration Era

With over 40 years of manufacturing experience and exports to more than 180 countries and regions worldwide, OCP Mechanical Company brings proven expertise to mining operations adopting pre-concentration technologies. Our product range includes jaw crushers, cone crushers, impact crushers, VSI crushers, vibrating screens, feeders, and complete crushing and screening plants—all brand-new and built to rigorous quality standards. We understand that the integration of AI-powered sorting into mining flowsheets requires crushing equipment that delivers consistent, well-graded product to the sorting stage, and that can operate reliably in demanding conditions. Our cone crushers feature hydraulic adjustment systems for precise CSS control and high-manganese steel liners in Mn13Cr2, Mn18Cr2, and Mn22Cr2 grades for extended wear life. Our vibrating screens deliver efficient classification across multiple product fractions, ensuring that sorting equipment receives the narrow feed size range it requires for optimal performance. As a direct factory manufacturer, we eliminate distributor margins, passing the savings directly to you—a significant advantage when every dollar of capital expenditure must be justified. All price information provided is for reference only; final quotes depend on equipment configuration, shipping terms, optional features, and current exchange rates. Our engineering team works closely with each customer to design custom crushing plants that match specific site conditions, feed characteristics, and production targets. Product specifications are continuously updated; please consult our online customer service for the latest technical parameters tailored to your application.

Complete Crushing Solutions and After-Sales Support

A crushing plant is most effective when integrated into a complete processing line designed for efficiency and reliability. OCP Mechanical Company supplies complete crushing and screening plants that include vibrating feeders, primary jaw crushers, secondary cone crushers or impact crushers, and vibrating screens for classification. Every component is matched to your capacity requirements, preventing bottlenecks and ensuring smooth continuous operation across multiple shifts. Our after-sales support includes remote diagnostics, spare parts delivery, and wear-part prediction services to minimise downtime and extend equipment life. With the global sensor-based ore sorting market projected to reach USD 836 million by 2036, ensuring your crushing plant is designed for compatibility with modern pre-concentration technologies is essential to long-term competitiveness. Our team is available to assist with installation supervision, commissioning, and ongoing operational questions.

Your Next Step: Get a Custom Quote for Your Pre-Concentration-Enabled Crushing Circuit

The successful deployment of AI-powered ore sorting at Navachab Gold Mine demonstrates that the technology is ready for industrial-scale application, delivering measurable reductions in energy consumption, operating costs, and environmental impact. For mining companies evaluating pre-concentration strategies, the crushing circuit is the foundation—and selecting the right equipment partner is critical to success. OCP Mechanical Company offers factory-direct, high-quality crushing and screening solutions engineered for durability, energy efficiency, and compatibility with modern sorting technologies—all at competitive prices. Our online customer service is available 24 hours a day, seven days a week, to provide free consultations, updated price references, and equipment selection guidance. Click the chat button now to discuss your project with a specialist—we are ready to help you build a more efficient and profitable processing operation.