Case Study

Our customer operates a screening plant that upgrades mined ore before being stored on stockpiles, prior to further processing using AllScan. Management of the screening plant operations were undertaken based on the results of samples taken of the in-feed material, however the lag on waiting for analytical results from these samples made making meaningful real time decisions impossible. This limited their ability to maximise the upgrade of the ore or control the levels of deleterious components.

Out-of-specification product poses costly challenges for operations, leading to the unnecessary waste of time, resources and money with hefty penalties applied for non-compliance. To date, the most effective means of mitigating against this has been through sampling, Traditional laboratory testing was accurate but had a turn-around of two to three days, rendering the data obsolete in this specific context. This is what led our customer to work with RTI in developing an in-site, online, real-time sampling analysis solution.

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Our customer needed real-time data about the grade of product being sent to its power station, to help maintain running conditions in their wash plant. The three main results sought were around ash, moisture and specific energy data. However, elemental composition of the ash was also useful to them. Without the AllScan, the only means of determining these results was to wait for laboratory samples. This usually takes 2-3 days for critical results, and 2-3 weeks for full elemental analysis, by which time product has been delivered to the power station.

More than 90% of India’s population lives in areas where the air quality is below the World Health Organization’s standard, with coal fired power plants being a major contributor to this pollution. To combat this growing issue in 2014 the Ministry of Environment and Forest had imposed 34% ash limit on all NTPC’s power plants. Previously these power plants had to rely on manual laboratory data, taking up to 24 hours to receive a result, by which time the out of spec coal had already been burnt.

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Our customer was processing varied grades of iron ore but was unable to identify the quality of product once it has passed through the process facility and had been stacked. A comprehensive stockpile management system was already in place however operators needed to update that system with lab data as it became available – usually 6-8 hours after it has been stacked. This led to an unacceptable lag and an inability to make critical decisions when it mattered.

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