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Mining & Resources | Technology
2 Feb 2026, by Amy Sarcevic
The mineral sands sector is bracing for a period of technological disruption, after reflux classifiers – an innovation by Professor Kevin Galvin from the University of Newcastle – gain recognition as an alternative to traditional spirals.
According to Damian Connelly, Principal Consulting Engineer at METS Engineering, the classifiers have broad spectrum benefits in the processing of manganese, gold, and various other minerals.
Offering more throughput and less CAPEX than conventional spirals, Mr Connelly predicts they may be widely embraced by the sector.
“The technology is fairly new, but it has the potential to reduce floor space, equipment, and maintenance. So, it’s quite an innovative change,” he said ahead of the Mineral Sands Conference. “It has been tested across a few laboratory pilot scale projects, and certainly the advantages are quite compelling.
“There is better mineral sand recovery with ilmenite, zircon, monazite, and so on. Also, lower maintenance costs, because traditional spirals do wear. Operationally, you can change the fluidisation in the reflux classifier, which gives you a lot more levers to pull compared to spirals.
“Plus, the units are much larger. You have single units that handle quite high capacity rather than spirals. A triple start might have three tonnes an hour capacity. You need lots of spirals. So, by comparison, there is simplicity of circuits.”
Uptake may be cautious
That said, Mr Connelly says adoption of reflux classifiers may initially be slow, given the risk of implementing new technologies – and that it is a “big call” to say they will replace spirals altogether.
“It will probably take a few people to install and try them, and then the industry will look at the feedback and how successful they are. And then of course, if the advantages are compelling, the industry will move with a flood.
“But it needs those first early adopters to try it and then the industry will judge and usually there will be enhancements or improvements and then I guess that’ll be the final determinant in terms of whether they replace spirals.”
Despite already being on the radar of major companies, Mr Connelly adds that reflux classifiers will initially appeal mainly to junior miners.
“It tends to be junior companies and people with development projects that are more experimental with this technology. I think some of the majors are well locked in with their existing infrastructure and they know spirals well. So, they’ll likely watch and wait.”
Turbo spirals are also coming
However, the outlook around adoption of reflux classifiers is not certain, with the spiral industry having made innovations of its own.
Turbo spirals – which are encased in a shroud – can process greater tonnage than their traditional counterparts and could potentially rival the throughput of reflux classifiers.
“They’ve lifted their game,” Mr Connelly said. “If you tried to push more tonnage through a conventional spiral, it’d spill over the edge, and it wouldn’t handle it. But they’ve overcome that with this innovation.
“These turbo spirals reduce the footprint and CAPEX, and allow higher throughput. We don’t yet have concrete data comparing them with reflux classifers, but, at a minimum, I expect the difference on these metrics will be more material than when comparing classifiers with conventional spirals.”
As with classifiers, Mr Connelly rules out an overnight switch to the technology, claiming most mineral sands companies are committed to their existing infrastructure.
“People aren’t going to rip out their existing spirals because they’ve got a capital investment. But for new projects, they might look at the turbo spiral and say, compare that, with the reflux classifier and based on the results of that, make a switch.
“So, we might find a growing number of new projects putting in turbo spirals. And over the next five years, the landscape could really change.”
Advice for industry
Mr Connelly said that in a high risk, high return industry, this caution is valid, but says innovating is also an imperative.
“In the mineral sands sector, there are no limits. Competition can come from anywhere. So, it’s important to use the best possible technology and maintain the lowest possible cost.
“But, we’ve also got to manage how we innovate. Not all new technology gets off the ground; and, for a new project, if your technology doesn’t deliver, it will destroy the whole project.
“On top of that, financiers still have the bitter taste of earlier innovations in their mouths – technologies that led to bacterial leaching, for example which failed and other examples.
“So, there is definitely a balance that needs to be struck,” he concluded.
Further insights
Sharing more thoughts on mineral sands processing innovations, Damian Connelly will present at the upcoming Mineral Sands Conference, hosted by Informa.
This year’s event will be held 25-26 March 2026.
Learn more and register your tickets here.
Informa Australia is the nation's leading event organiser. Our events comprise of large scale exhibitions, industry conferences and highly specialised corporate training.
