Is Misrouted Ore Costing You Recovery? Fix the Flow

Are You Feeding the Wrong Stockpile? How Misdirected Ore Destroys Recovery Value

At NTWIST, we often see it happen in the field: a truck hauls valuable ore - only for it to be dumped on the wrong stockpile. Whether it's the result of blast misalignment, routing miscommunication, or static classification, the outcome is the same: value, literally, in the wrong place.

This isn’t just a logistics problem. It’s a recovery problem. Every time high-grade ore ends up in a low-grade or marginal pile, you’re not just introducing inefficiency - you’re permanently compromising mill performance. In this article, we’ll explore how ore misallocation occurs, the real cost it imposes on recovery, and how intelligent routing can reclaim that lost value.

How Ore Gets Misallocated

Ore misallocation happens when material ends up in a stockpile that doesn’t reflect its true grade, metallurgical characteristics, or intended destination. There are many reasons for this:

• Uncorrected blast movement: Shifted material boundaries post-blast lead to digging in the wrong zone.
• Overgeneralized dig blocks: Wide classification bins don’t account for in-situ variability.
• Static routing rules: Dispatch logic based on outdated models or inconsistent field input.

Research from copper operations shows that failing to account for blast-induced movement can result in up to 20% ore misclassification - leading to grade dilution and misrouted material (ResearchGate, 2018).

Why This Kills Recovery

Once ore is misclassified and routed to the wrong stockpile, that error travels downstream. It impacts blending, flotation, energy efficiency, and ultimately - recovery rates. According to AusIMM, poor ore classification and stockpile variability can reduce recovery efficiency by up to 10%, especially in metallurgically sensitive processes (AusIMM, 2021).

When high-grade material is routed into a marginal pile, it may never make it back into the mill. Even if it does, it’s no longer in the context of a controlled blend. You’ve turned feed optimization into feed variability. And that inconsistency doesn’t just reduce yield - it increases rehandling, consumes more energy, and disrupts downstream processes like thickening and tailings.

A Realistic Example

Let’s say a truck is flagged as carrying material from Block 42 - a 0.85% Cu zone. But due to blast movement, that truck actually contains a 1.05% Cu section displaced from Block 43. Because the blast shift wasn’t modeled, and the block was overgeneralized, the truck gets routed to the marginal ore pile.

Weeks later, that stockpile is reclaimed as part of a low-priority blend. The ore is processed under lower energy input, with minimal flotation recovery. The result? You’ve lost the opportunity to maximize recovery from that material - and you’ve distorted your reconciliation data in the process.

How to Stop the Value Drain

Fixing this doesn’t require perfect data - it requires better integration. Here’s how we’ve helped clients improve routing decisions and protect ore value:

• Model blast movement: Use vector offsets or AI models to dynamically adjust dig boundaries.
• Upgrade classification logic: Incorporate real-time sensor data, not just drill logs.
• Connect systems: Ensure dispatch, ore control, and reconciliation tools share grade updates.
• Build feedback loops: Use mill performance to recalibrate upstream routing decisions.

When these changes are made, we’ve seen recovery rates rise, stockpile blends stabilize, and trust in the plan return across technical teams.

3 Strategic Takeaways

1. Ore routing is a value decision. Treat it like a cost center and manage it with precision.
2. Misallocation compounds. One wrong dump can mislead multiple downstream models.
3. Integration wins. You don’t need new equipment - you need your systems to talk.

Conclusion: You Can’t Afford to Guess

Ore misallocation isn’t just a missed opportunity - it’s a structural failure that undermines throughput, recovery, and decision confidence. If your current stockpile routing is based on outdated assumptions or siloed data, it’s time to rethink the way you move material.

At NTWIST, we help mines close the loop - connecting geology, dispatch, and metallurgy with intelligent tools that make every truck count. Because when every tonne matters, there’s no room for the wrong stockpile.

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