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Home > Archives > Vol. 8 No. 4(Publishing) > Original Research Article
ACE-5791

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2025-11-24

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Vol. 8 No. 4(Publishing)

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Original Research Article

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Copyright (c) 2025 Ramdas Biradar, Babaso A. Shinde, Milind Manikrao Darade, Tushar Gaikwad, Seeram Srinivasa Rao, Aarti Puri, Ashwini G. Thokal, Govindrajan Mural, Anant Sidhappa Kurhade

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Ramdas Biradar, Babaso A. Shinde, Milind Manikrao Darade, Tushar Gaikwad, Seeram Srinivasa Rao, Aarti Puri, … Anant Sidhappa Kurhade. (2025). AI Applications in Smart Mineral Processing: Ore Characterization, Sorting, and Efficiency. Applied Chemical Engineering, 8(4), ACE-5791. https://doi.org/10.59429/ace.v8i4.5791
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AI Applications in Smart Mineral Processing: Ore Characterization, Sorting, and Efficiency

Ramdas Biradar

School of Engineering and Technology, PCET’s Pimpri Chinchwad University, Pune - 412106, Maharashtra, India

Babaso A. Shinde

Department of Artificial Intelligence and Data Science, Marathwada Mitramandal’s Institute of Technology, Lohgaon, Pune - 411047, Affiliated to Savitribai Phule Pune University, Maharashtra, India

Milind Manikrao Darade

Department of Civil Engineering, Dr. D. Y. Patil College of Engineering, Akurdi, Pune – 411044, Maharashtra, India

Tushar Gaikwad

Department of Engineering Chemistry, PCET’s Pimpri Chinchwad College of Engineering and Research, Ravet, Pune - 412101, Maharashtra, India

Seeram Srinivasa Rao

Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields, Vaddeswaram, Guntur (Dt) - 522502, Andhra Pradesh, India

Aarti Puri

Department of First Year Engineering (Engineering Chemistry), Dr. D. Y. Patil Institute of Technology, Pimpri – 411018, Pune, Maharashtra, India;Dnyaan Prasad Global University (DPGU), School of Technology and Research - Dr. D. Y. Patil Unitech Society, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India

Ashwini G. Thokal

Department of Chemical Engineering, Bharati Vidyapeeth College of Engineering, Navi Mumbai – 400614, Maharashtra, India

Govindrajan Murali

Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fields, Vaddeswaram, Guntur (Dt) - 522502, Andhra Pradesh, India

Anant Sidhappa Kurhade

Department of Mechanical Engineering, Dr. D. Y. Patil Institute of Technology, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India ; Dnyaan Prasad Global University (DPGU), School of Technology and Research - Dr. D. Y. Patil Unitech Society, Sant Tukaram Nagar, Pimpri, Pune, 411018, Maharashtra, India


DOI: https://doi.org/10.59429/ace.v8i4.5791


Keywords: Artificial Intelligence (AI), Mineral Processing, Ore Characterization, Intelligent Ore Sorting, Predictive Maintenance, Digital Twin Technology.


Abstract

Artificial intelligence (AI) is increasingly vital in modern mineral processing, where it addresses critical challenges such as falling ore grades, rising energy costs, and the demand for sustainable operations. Despite notable progress, most existing studies focus on individual applications like ore sorting or predictive maintenance and lack a holistic view of AI-enabled mineral processing systems. This review aims to bridge that gap by examining how AI tools can be integrated into a unified workflow that spans ore characterization, sorting, and real-time process optimization. Using a structured review of research articles, industrial case studies, and technical reports from 2015 to 2025, the study evaluates key AI techniques including machine learning, computer vision, digital twins, and predictive modelling. Findings indicate that AI has improved ore recovery by up to 30% in smart sorting systems and reduced equipment downtime by as much as 50% through predictive maintenance. These results demonstrate AI’s ability to enhance both productivity and resource efficiency, though challenges related to data quality, system compatibility, and model interpretability persist. The review highlights the need for explainable AI, scalable digital twin architectures, and targeted workforce development to support wider adoption. Overall, the paper emphasizes the potential of AI to accelerate the transition toward intelligent, sustainable mining under the Mining 4.0 paradigm.


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[93]. Corrigan CC, Ikonnikova S. A review of the use of AI in the mining industry: Insights and ethical considerations for multi-objective optimization. The Extractive Industries and Society [Internet]. Elsevier BV; 2024 Mar 1 [cited 2025 Jun];17:101440. Available from: https://doi.org/10.1016/j.exis.2024.101440

[94]. Kurhade A, Talele V, Rao TV, Chandak A, Mathew VK. Computational study of PCM cooling for electronic circuit of smart-phone. Materials Today: Proceedings. 2021 Jan 1;47:3171-6.

[95]. Kurhade AS, Amruth E, Joshi PS, Kondhalkar GE, Jadhav PA, Murali G, Mahajan RG, Waware SY. Enhancing Flat-Plate Solar Collector Efficiency: A Numerical Study. jmmf [Internet]. 2025 Apr. 16 [cited 2025 Apr. 28];73(4):1065-76.

[96]. Kurhade AS, Murali G. Thermal control of IC chips using phase change material: A CFD investigation. International Journal of Modern Physics C. 2022 Dec 28;33(12):2250159.

[97]. Kurhade AS, Murali G, Rao TV. CFD approach for thermal management to enhance the reliability of IC chips. Int J Eng Trends Technol. 2022;71(3):65-72.

[98]. Waware SY, Kore SS, Kurhade AS, Suhas Prakashrao Patil. Innovative Heat Transfer Enhancement in Tubular Heat Exchanger: An Experimental Investigation with Minijet Impingement. J. Adv. Res. Fluid Mech. Therm. Sc. [Internet]. 2024 Apr. 30 [cited 2025 Jun. 7];116(2):51-8.

[99]. Kurhade AS, Biradar R, Yadav RS, Patil P, Kardekar NB, Waware SY, Munde KH, Nimbalkar AG, Murali G. Predictive placement of IC chips using ANN-GA approach for efficient thermal cooling. J Adv Res Fluid Mech Therm Sc. 2024;118(2):137-4.

[100]. Waware SY, Chougule SM, Yadav RS, Biradar R, Patil P, Munde KH, Kardekar NB, Nimbalkar AG, Kurhade AS, Murali G, Kore SS. A comprehensive evaluation of recent studies investigating nanofluids utilization in heat exchangers. J Adv Res Fluid Mech Therm Sci. 2024;119(2):160-72.

[101]. Upadhe SN, Mhamane SC, Kurhade AS, Bapat PV, Dhavale DB, Kore LJ. Water saving and hygienic faucet for public places in developing countries. InTechno-Societal 2018: Proceedings of the 2nd International Conference on Advanced Technologies for Societal Applications-Volume 1 2020 (pp. 617-624). Springer International Publishing.

[102]. Sidhappa KA, Hande MS, Patil MS, Mask MV. Heat Transfer Enhancement by using Twisted Tape Inserts with circular holes in forced convection. International journal of innovations in engineering research and technology. 2016 Mar;3(3):1-7.

[103]. Kurhade AS, Kardekar NB, Bhambare PS, Waware SY, Yadav RS, Pawar P, Kirpekar S. A comprehensive review of electronic cooling technologies in harsh field environments: obstacles, progress, and prospects. J Mines Met Fuels. 2024; 72 (6): 557-79 [Internet].

[104]. Kurhade AS, Waware SY, Bhambare PS, Biradar R, Yadav RS, Patil VN. A comprehensive study on Calophyllum inophyllum biodiesel and dimethyl carbonate blends: Performance optimization and emission control in diesel engines. J Mines Met Fuels. 2024; 72 (5): 499-507.

[105]. Kurhade AS, Waware SY, Munde KH, Biradar R, Yadav RS, Patil P, Patil VN, Dalvi SA. Performance of solar collector using recycled aluminium cans for drying. J Mines Met Fuels. 2024; 72 (5): 455-61.

[106]. Kurhade AS, Siraskar GD, Bhambare PS, Dixit SM, Waware SY. Numerical investigation on the influence of substrate board thermal conductivity on electronic component temperature regulation. J Adv Res Numer Heat Trans. 2024;23(1):28-37.

[107]. Kurhade AS, Siraskar GD, Kondhalkar GE, Darade MM, Yadav RS, Biradar R, Waware SY, Charwad GA. Optimizing aerofoil design: A comprehensive analysis of aerodynamic efficiency through CFD simulations and wind tunnel experiments. Journal of Mines, Metals and Fuels. 2024 Sep 17:713-24.

[108]. Kurhade AS, Siraskar GD, Darade MM, Dhumal JR, Kardile CS, Biradar R, Patil SP, Waware SY. Predicting heat transfer enhancement with twisted tape inserts using fuzzy logic techniques in heat exchangers. Journal of Mines, Metals and Fuels. 2024 Sep 17:743-50.

[109]. Kurhade AS, Kadam AA, Biradar R, Bhambare PS, Gadekar T, Patil P, Yadav RS, Waware SY. Experimental investigation of heat transfer from symmetric and asymmetric IC Chips mounted on the SMPS board with and without PCM. J Adv Res Fluid Mech Therm Sc. 2024;121(1):137-4.

[110]. Patil P, Kardekar N, Yadav R, Kurhade A, Kamble D. Nanofluids: An Experimental Study for MQL Grinding. Journal of Mines, Metals and Fuels. 2023;71(12):2751-6.

[111]. Patil P, Kardekar N, Yadav R, Kurhade A, Kamble D. Al2O3 nanofluids: An experimental study for MQL grinding. J Mines Met Fuels. 2023; 2751-6.

[112]. Kurhade AS, Bhambare PS, Desai VP, Murali G, Yadav RS, Patil P, Gadekar T, Biradar R, Kirpekar S, Charwad GA, Waware SY. Investigating the effect of heat transfer influenced by applying wavy corrugated twisted tape inserts in double pipe heat exchangers. J Adv Res Fluid Mech Therm Sc.[Internet]. 2024;122(2):146-55.

[113]. Kurhade AS, Murali G, Jadhav PA, Bhambare PS, Waware SY, Gadekar T, Yadav RS, Biradar R, Patil P. Performance analysis of corrugated twisted tape inserts for heat transfer augmentation. J Adv Res Fluid Mech Therm Sci. 2024;121(2):192-200.

[114]. Kurhade MA, Dange MM, Nalawade DB. Effect of wavy (Corrugated) twisted tape inserts on heat transfer in a double pipe heat exchanger. International journal of innovations in engineering research and technology. 2015;2(1):1-8.

[115]. Kurhade AS, Gadekar T, Siraskar GD, Jawalkar SS, Biradar R, Kadam AA, Yadav RS, Dalvi SA, Waware SY, Mali CN. Thermal Performance Analysis of Electronic Components on Different Substrate Materials. Journal of Mines, Metals and Fuels. 2024 Oct 30:1093-8.

[116]. Kurhade AS, Siraskar GD, Jawalkar SS, Gadekar T, Bhambare PS, Biradar R, Yadav RS, Waware SY, Mali CN. The impact of circular holes in twisted tape inserts on forced convection heat transfer. J Mines Met Fuels. 2024; 72 (9): 1005–12 [Internet].

[117]. Kurhade AS, Darade MM, Siraskar GD, Biradar R, Mahajan RG, Kardile CS, Waware SY, Yadav RS. State-of-the-Art Cooling Solutions for Electronic Devices Operating in Harsh Conditions. Journal of Mines, Metals and Fuels. 2024 Sep 27:843-61.

[118]. Kurhade AS, Warke P, Maniyar K, Bhambare PS, Waware SY, Deshpande S, Harsur S, Ingle M, Kolhe P, Patil PA, Jadhav P. The wind rose analysis of temperature variation with sensor implantation technique for a wind turbine. J Adv Res Fluid Mech Therm Sci. 2024;122(1):1-8.

[119]. Kurhade AS, Siraskar GD, Bhambare PS, Keloth D, Kaithari SM, Waware SY. Enhancing Smartphone Circuit Cooling: A Computational Study of PCM Integration. J. Adv. Res. Numer. Heat Trans. 2024 Nov 30;27(1):132-45.

[120]. Yadav RS, Gadekar T, Gundage V, Patil P, Patil A, Patil P, Patil A, Sutar R, Kurhade AS. Numerical and Experimental Investigation of the Effect of Overlapping Angle on Strength and Deformation of Curved Plate Joined Using Arc Welding Process. Journal of Mines, Metals and Fuels. 2024 Oct 30:1059-66.

[121]. Yadav RS, Nimbalkar A, Gadekar T, Patil P, Patil VN, Gholap AB, Kurhade AS, Dhumal JR, Waware SY. Comparison of Experimental and Numerical Investigation of Mono-Composite and Metal Leaf Spring. Journal of Mines, Metals and Fuels. 2024 Sep 27:815-27.

[122]. Deshpande SV, Pawar RS, Keche AJ, Kurhade A. Absolute time surface finish measurement of stepped holding shaft by automatic system. Journal of Advanced Manufacturing Systems. 2025 Jan 17.

[123]. Kurhade AS, Siraskar GD, Bhambare PS, Murali G, Deshpande SV, Warke PS, Waware SY. Simulation and Analysis of Heat Transfer in Counter-Flow Helical Double-Pipe Heat Exchangers Using CFD. International Journal of Modern Physics C. 2025 Jan 10.

[124]. Parkar A, Yadav RS, Chopade R, Dhavase N, Dhumal JR, Mankar SP, Patil S, Ghuge K, Giri B, Kurhade AS. Automating the Two-Dimensional Design of Heating, Ventilation, Air Conditioning, and Refrigeration (HVACR) Ducts using Computer Programming Language: An Algorithmic Approach. Journal of Mines, Metals and Fuels. 2025 Jan 7:211-20.

[125]. Kurhade AS, Siraskar GD, Darade MM, Murali G, Katkar TR, Patil SP, Charwad GA, Waware SY, Yadav RS. Enhancement in Heat Transfer with Nanofluids in Double-Pipe Heat Exchangers. Journal of Mines, Metals and Fuels. 2025 Jan 7:165-72.

[126]. Kurhade AS, Chougule SM, Kharat PV, Kondhalkar GE, Murali G, Raut PN, Charwad GA, Waware SY, Yadav RS. Integrated Approach to Enhance Vehicle Safety: A Novel Bumper Design with Energy-Absorbing Mechanisms. Journal of Mines, Metals and Fuels. 2025 Jan 7:27-35.

[127]. Raut PN, Dolas AS, Chougule SM, Darade MM, Murali G, Waware SY, Kurhade AS. Green Adsorbents for Heavy Metal Removal: A Study on Zinc Ion Uptake by Tinospora cordifolia Biocarbon. Journal of Mines, Metals and Fuels. 2025 Jan 7:21-5.

[128]. Yadav R, Nimbalkar A, Kirpekar S, Patil PJ, Dalvi SA, Jadhav PA, Kurhade AS, Wakchaure GN. Effect of Transformed-Induced Plasticity Steel Plate Thickness on Ultimate Tensile Strength of Butt Welded Joint using Nd: YAG Laser. International Journal of Vehicle Structures and Systems. 2024 Dec 31;16(6).

[129]. Yadav RS, Gandhi P, Veeranjaneyulu K, Gaji R, Kirpekar S, Pawar D, Khairnar YS, Patil S, Kurhade AS, Patil SP. Influence of Plate Thickness on the Mechanical Behaviour of Mild Steel Curved Plates: An Experimental Study. Journal of Mines, Metals and Fuels. 2024 Dec 11:1319-27.

[130]. Kurhade AS, Bhambare PS, Siraskar GD, Mukesh S, Dixit PS, Waware SY. Computational Study on Thermal Management of IC Chips with Phase Change Materials.

[131]. Kurhade MA, Dange MM, Nalawade DB. Fuzzy Logic Modeling of Heat Transfer in a Double Pipe Heat Exchanger with Wavy (Corrugated) Twisted Tape Inserts. International Journal of Innovations in Engineering Research and Technology.;2(1):1-8.

[132]. Kurhade AS, Siraskar GD, Raut PN, Dolas AS, Murali G, Dalvi SA, Waware SY, Yadav RS. Investigating the Impact of Oxygenated Additives on Exhaust Emissions from Unleaded Gasoline Vehicles. jmmf. 2025 Feb. 24;73(2):333-44

[133]. Purandare P, Yadav RS, Nema AA, Kulkarni A, Kirpekar S, Giri B, Patil PA, Jagdale M, Kurhade AS. Comparative Study of Helical Coil, Spiral Coil and Conical Coil (90O) Heat Exchanger for Single Phase Fluid Flow. jmmf. 2025 Feb. 24 ;73(2):377-84.

[134]. Kurhade AS, Siraskar GD, Dalvi SA, Kharat PV, Jadhav NA, Shelkande VD, Murali G, Waware SY, Yadav RS. Passive Cooling of EV Batteries Using Phase Change Material: A Simulation Study. jmmf . 2025 Feb. 24 ;73(2):447-54.

[135]. Kurhade AS, Kharat PV, Chougule SM, Darade MM, Karad MM, Murali G, Charwad GA, Waware SY, Yadav RS. Harnessing the Power of Plastic Waste: A Sustainable Approach to Fuel Production. jmmf . 2025 Feb. 24;73(2):467-73.

[136]. Kurhade AS, Siraskar GD, Deshmukh MT, Patil PA, Chaudhari SS, Kadam AA, Dolas AS, Mahajan RG, Waware SY, Yadav RS. Impact of PCM on Heat Dissipation from IC Chips. Journal of Mines, Metals & Fuels. 2025 Mar 1;73(3).

[137]. Ramani P, Reji V, Sathish Kumar V, Murali G, Kurhade AS. Deep Learning-Based Detection and Classification of Moss and Crack Damage in Rock Structures for Geo-Mechanical Preservation. Journal of Mines, Metals & Fuels. 2025 Mar 1;73(3).

[138]. Chippalkatti S, Chekuri RB, Ohol SS, Shinde NM, Barmavatu P, Shelkande VD, Murali G, Kurhade AS. Enhancing Heat Transfer in Micro-Channel Heat Sinks through Geometrical Optimization. Journal of Mines, Metals & Fuels. 2025 Mar 1;73(3).

[139]. Kurhade AS, Siraskar GD, Chekuri RB, Murali G, Pawar P, Patil AR, Waware SY, Yadav RS. Biodiesel Blends: A Sustainable Solution for Diesel Engine Performance Improvement. Journal of Mines, Metals & Fuels. 2025 Mar 1;73(3).

[140]. Kurhade AS, Bhavani P, Patil SA, Kolhalkar NR, Chalapathi KS, Patil PA, Waware SY. Mitigating Environmental Impact: A Study on the Performance and Emissions of a Diesel Engine Fueled with Biodiesel Blend. jmmf [Internet]. 2025 Apr. 16 [cited 2025 Apr. 28];73(4):981-9.

[141]. Wakchaure GN, Vijayarao P, Jadhav TA, Bhamare YM, Jagtap A, Gaji R, Chavan Patil AS, Kamble SD, Jagtap SV, Yadav RS, Kurhade AS. Performance Evaluation of Trapezoidal Ducts with Delta Wing Vortex Generators: An Experimental Investigation. jmmf [Internet]. 2025 Apr. 16 [cited 2025 Apr. 28];73(4):991-1003.

[142]. Wakchaure GN, Jagtap SV, Gandhi P, Chavan Patil AS, Kandharkar S, Kokare NN, Bhamare YM, Kamble SD, Jadhav A, Yadav RS, Kurhade AS. Heat Transfer Characteristics of Trapezoidal Duct using Delta Wing Vortex Generators. jmmf [Internet]. 2025 Apr. 17 [cited 2025 Apr. 28];73(4):1053-6.

[143]. Chougule SM, Murali G, Kurhade AS. Failure Investigation of the Driving Shaft in an Industrial Paddle Mixer. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1247-56.

[144]. Kurhade AS, Sugumaran S, Kolhalkar NR, Karad MM, Mahajan RG, Shinde NM, Dalvi SA, Waware SY. Thermal Management of Mobile Devices via PCM. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1313-20.

[145]. Chougule SM, Murali G, Kurhade AS. Finite Element Analysis and Design Optimization of a Paddle Mixer Shaft. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1343-54.

[146]. Waware SY, Ahire PP, Napate K, Biradar R, Patil SP, Kore SS, Kurhade AS. Advancements in Heat Transfer Enhancement using Perforated Twisted Tapes: A Comprehensive Review. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1355-63.

[147]. Patil Y, Tatiya M, Dharmadhikari DD, Shahakar M, Patil SK, Mahajan RG, Kurhade AS. The Role of AI in Reducing Environmental Impact in the Mining Sector. jmmf [Internet]. 2025 May 9 [cited 2025 May 12];73(5):1365-78.

[148]. Chougule SM, Murali G, Kurhade AS. Dynamic simulation and performance evaluation of vibratory bowl feeders integrated with paddle shaft mechanisms. Advances in Science and Technology Research Journal. 2025;19(7):179-96.

[149]. Rao SS, Sugumaran S, Ameresh H, Amruth E, Thamke VP, Waware SY, Patil PA, Kurhade AS. Impact of Regularly Spaced Cut Sections on the Heat Transfer Efficiency of Helical Strip Inserts in Circular Pipes. jmmf [Internet]. 2025 Jun. 4 [cited 2025 Jun. 6];73(6):1517-25

[150]. Sanadi A, Shinde S, Burgute G, Purandare P, Ramtirthkar C, Jadhav Sachin Z, Awati SS, Yadav R, Kurhade A. Assessing the Impact of Exhaust Gas Recirculation on the Emission Profile of a Diesel Engine Operating on Mohua Oil: An Experimental Study. jmmf [Internet]. 2025 Jun. 4 [cited 2025 Jun. 6];73(6):1535-42.

[151]. Chaudhari SS, Shahakar M, Gholap P, Dhamdhere PB, Agrawal SS, Mahajan RG, Kurhade AS, Waware SY. Enhancing Energy Efficiency in Metallurgical Operations Using AI: A State of the Art Review. jmmf [Internet]. 2025 Jun. 4 [cited 2025 Jun. 6];73(6):1595-616.

[152]. Waware SY, Ahire PP, Ghutepatil PR, Biradar R, Kadam AA, Kore SS, Kurhade AS, Ghunake KB. Enhancing Heat Transfer in Tubular Heat Exchanger Using Minijet Technology. jmmf [Internet]. 2025 Jun. 4 [cited 2025 Jun. 6];73(6):1699-706.

[153]. Kharat PV, Darade MM, Dhamdhere PB, Shinde BA, Patil Y, Mahajan RG, Kurhade AS, Waware SY. Smart Hydrology: The Role of Artificial Intelligence in Sustainable Soil and Water Resource Management. jmmf [Internet]. 2025 Jul. 5 [cited 2025 Jul. 7];73(7):2035-50.

[154]. Waware SY, Bote MA, Biradar R, Ahire PP, Kadam AA, Patil SP, Ghunake KB, Kore SS, Kurhade AS. Experimental Investigation of Heat Transfer Improvement Using Perforated Helical Twisted Tapes in a Tube-In-Tube Heat Exchanger. jmmf [Internet]. 2025 Jul. 5 [cited 2025 Jul. 7];73(7):2083-9.

[155]. Pavan A, Murali G, Masthan Vali PSN, Kurhade AS. Enhancing Lithium-Ion Battery Cooling with Composite Phase Change Materials: A Numerical Approach. jmmf [Internet]. 2025 Jul. 5 [cited 2025 Jul. 7];73(7):2109-25.



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