Brazil Potash AI ore sorting doubles KCl grade in early Autazes tests
Brazil Potash subsidiary Potássio do Brasil reported positive early results on October 13 from AI-driven X-ray transmission (XRT) ore sorting at its Autazes project in Amazonas. In tests with engineering firm ERCOSPLAN, the system raised potassium chloride (KCl) content in an ore sample from about 13% to about 27%, while the rejected fraction held only 1% to 2% KCl, Minera Brasil reported.
Roughly one-fifth of the lower-grade material could be removed before reaching the processing plant. That would free plant capacity for higher-grade ore, which could lift fertilizer output or extend mine life.
“This gives us an interesting opportunity to potentially unlock production flexibility in the future, whether through a higher production rate and/or a longer mine life, subject to further testing and studies,” said Matt Simpson, CEO of Brazil Potash.
The company stressed that the sample was small and the results are preliminary. Industrial-scale performance remains unproven, and adoption depends on further technical and economic studies.
Brazil imports almost all of its potash, which is why BHP is already targeting Brazil with Jansen potash. Any lift in domestic output from Autazes would trim that import bill.
Source: Minera Brasil
Brazil Potash AI ore sorting: five things to know
The system scans individual ore particles with X-rays and uses deep learning models, trained on millions of images, to judge shape, size and color. High-speed valves then fire air jets to knock low-grade particles out of the stream before conventional processing.
ERCOSPLAN estimates that 40% to 55% of the material planned for extraction will be coarser than about 8 millimeters, the particle size used in the initial tests.
Two routes are under study. One pre-concentrates ore before hot leach processing to raise output without sinking a third mine shaft. The other makes lower-grade parts of the deposit, currently uneconomic, viable to mine, extending the operation’s life.
Brazil Potash plans initial production of up to 2.4 million tonnes of potash a year, which management estimates could cover about 20% of current Brazilian demand, with all output sold domestically.
The company plans tests on a much larger sample after commercial production begins, along with engineering and economic studies. The XRT trials were first announced in December 2025.
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