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• The potential of bulk ore sorting application at a block cave mine was investigated. • The grade heterogeneity and sortability was evaluated for different mining zones. • The relationship between ore grade heterogeneity and sortability was discussed. A block cave mine operation was investigated in terms of ore grade heterogeneity and the potential of bulk ore sorting application. The grade heterogeneity within the caved material was measured for different draw points and mining zones, in terms of Distribution Heterogeneity and Fractal Dimension. The potential of bulk ore sorting was assessed by comparing the Net Smelter Return before and after a hypothetical bulk ore sorting system was implemented. Results showed that the potential of applying bulk ore sorting was influenced greatly by the heterogeneity within the mined material. A certain level of heterogeneity was necessary in considering the mine production as 'sortable'. The sortability would also vary for different mining areas depending on heterogeneity level of the production. Peripheral zones of the orebody were considered with the highest level of heterogeneity and the most significant potential of bulk ore sorting application. [ABSTRACT FROM AUTHOR]

• A bulk ore sorting model was developed for sortability assessment. • Metal distribution within ore deposits was recognized as a fractal structure. • The optimum cut-off grade was determined based on model calculations. Bulk ore sorting (BOS) has the potential to reduce processing costs and improve mine economics. A factor that impedes its acceptance is the lack of a method to assess ore amenability to sorting. In this study, a fractal model of metal distribution was used to assess an ore's bulk sortability. A BOS model was developed where metal distribution properties were characterised, optimum cut-off grade for sorter operation was determined, and economic potential of BOS was evaluated. For the developed model, the metal distribution within the ore deposits was recognised as a fractal structure. Two parameters were introduced, namely the grade factor and fractal dimension, to quantitatively characterise ore properties in terms of grade magnitude and heterogeneity. The mass balance of the sorter operation was modelled as a function of the characterised ore properties and the optimum cut-off grade was determined based on model calculations. The economic potential of BOS was evaluated in terms of the net smelter return and compared with that when no BOS was implemented. Based on the developed model, the bulk ore sortability of different ore properties was assessed with a hypothetical underground copper mine. The developed BOS model provided a powerful tool for ore sortability assessment and is expected to encourage academic research and industrial practices of BOS. [ABSTRACT FROM AUTHOR]