HPY AI Sorting Unlocks a DRC Copper Waste Pile’s True Value

HPY’s AI-driven ore sorting technology enables the efficient processing of Comika Mining’s 100,000t waste rock pile, turning waste into value with responsible green solutions.

Unlocking value from low-grade copper ore remains one of the greatest challenges in the mining industry. At the Comika Copper-Cobalt Mine in the Democratic Republic of Congo (DRC), HPY Technology Co., Ltd. has demonstrated how sensor-based ore sorting solutions can play a transformative role – enhancing the utilization of waste rock, reducing environmental risks, and improving overall resource recovery.

Comika Mining is characterized by a variety of complex copper ore types, including oxidized ores, sulfide ores, and low-grade waste rock stockpiles. These variations typically require different processing approaches, contributing to increased operational complexity and cost.

One of the key challenges at the mine involved a large stockpile of low-grade copper sulfide ore, which had been accumulating since 2022. This material could not be processed efficiently using conventional methods. Left unutilized, the stockpile posed environmental concerns – including land degradation, water contamination, soil erosion, and heightened social risks – particularly affecting vulnerable rural communities already facing food insecurity. Additionally, with an unstable power supply, there was a strong need for a more energy-efficient processing solution.

Founded in 2015, HPY Technology is a pioneer in sensor-based ore sorting, specializing in intelligent mineral processing through AI-driven systems. With a mission to enhance operational efficiency and resource recovery, HPY is transforming the mining industry by delivering cost-effective and sustainable solutions to complex beneficiation and land restoration challenges.

At the Comika Copper-Cobalt Mine, HPY introduced a customized XRT ore sorting system designed to unlock additional copper resources. The primary objective was to upgrade low-grade copper sulfide ore by recovering higher-grade material from previously untouched waste rock stockpiles. By removing ore at or below cut-off grade, HPY’s technology enabled the recovery of valuable minerals while contributing to the remediation of the environmentally hazardous waste rock stockpiles.

Following initial test trials, Comika Mining quickly recognized the economic advantages of HPY’s solution. A stockpile of 100,000 tons of low-grade ore, accumulated over several years, was evaluated for processing using HPY’s sorting system. The project aimed to clear the pile within two years.

The mine’s existing processing plant was originally designed for copper ore with grades above 1.5%. However, with HPY’s sensor-based ore sorting technology, it became possible to efficiently recover copper ore with the grades of 0.3% to 0.6%, significantly expanding the economically viable resource base for Comika Mining.

Comika Copper Mine
Ore Type	Copper & Cobalt	Feed Grade	Cu 0.42% Co 0.11%
Particle Size	+10-60 mm	Concentrate Grade	Cu 1.72% Co 0.35%
Processing Capacity	40-60 t/h	Waste Rock Grade	Cu 0.18% Co 0.05%
Rejection Rate	85.6%	Enrichment Ratio	Cu 4.1 Co 3.2
Model: 1 Classic Series HPY-P60-X1400

The results of installing HPY Technology’s Classic Series HPY-P60-X1400 sorting machine were substantial. The sorter was able to process between 40 to 60 tons of +60-10mm material with an initial feed grade of 0.42% copper and 0.11% cobalt. After running through the machine, the concentrate grade increased to 1.72% Cu and 0.353% Co, achieving an effective enrichment ratio of 4.1 and 3.2 for Cu and Co, respectively.

According to HPY’s on-site chief engineer, Mr. ZH Wang, “HPY’s ore sorter achieved an 85.6% waste rejection rate, effectively transforming what was previously considered ‘waste’ into economically viable resources for further processing.” He further noted that the rejected material – waste rock discharged from the sorting machines – “can be repurposed as construction aggregate valued at approximately $50/m³ for sale in the local market and used in road construction.”

Given the region’s unstable power supply, the sorting system’s high efficiency and low energy consumption provided additional operational value. Following the successful results from the initial implementation of the waste rock stockpile, Comika Mining is now considering expanding HPY’s ore sorting solution to its underground operations.

This case underscores a broader challenge in the mining sector: balancing resource extraction with sustainability. While critical minerals such as copper and cobalt are often scrutinized for their environmental footprint, they remain essential to achieving global Sustainable Development Goals (SDGs). HPY’s ore sorting solutions offer a win-win approach, helping reduce unnecessary mining activity while contributing to land restoration.

A notable example of this approach is HPY’s contribution to what was once Asia’s largest lead-zinc mine. By deploying three ore sorters for desulfurization sorting, sulfur-bearing waste rock was converted into valuable construction aggregate, creating a new revenue stream from previously discarded material. The remaining sorted waste was repurposed as backfill, enabling the mine to shut down its tailings pond located near a scenic area on schedule, in full compliance with national environmental regulations.

In addition, economically viable lead-zinc ore recovered during the sorting process was redirected to the processing plant, ensuring maximum resource utilization. This enabled the mine to generate profits not only from legacy waste rock, but also from real-time ore sorting within the processing plant and material directly from the excavation site – creating a comprehensive circular economy model across its operations.

Moreover, HPY’s resource utilization plans have found successful application in gangue sorting, promoting greener mining practices in Inner Mongolia’s coal sector. In addition to reducing environmental impact, these efforts have enabled the recovery of valuable industrial minerals such as kaolin and white sandstone.

The Comika Mining case study in the DRC serves as a compelling example of the transformative potential of sensor-based ore sorting. By recovering high-grade ore from within low-grade waste stockpiles, mining companies can maximize resource utilization, reduce environmental impact, and enhance economic returns.

As the global mining industry moves toward more sustainable and cost-effective practices, HPY Technology remains at the forefront – delivering AI-powered sorting systems that help companies unlock value from challenging materials and complex ore bodies.

For mining companies seeking to extract greater value from waste rock stockpiles or low-grade ore resources, HPY Technology offers a proven pathway to improved productivity, profitability, and environmental responsibility.

For further inquiries, please contact info@hpysorting.com.

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