The Case: AllScan | Elemental Analysis, Iron Ore, Stockpile Management.
Introduction.
The efficient management of iron ore stockpiles is crucial for maximising yield and meeting content specifications. This case study explores how a comprehensive real-time stockpile management solution significantly improved operational efficiency and profitability for a customer facing challenges in identifying the quality of their iron ore post-processing.
The Challenge.
Our customer was dealing with varied grades of iron ore but struggled to identify the quality of the product after it had been processed and stacked. Although a comprehensive stockpile management system was in place, it required manual updates with lab data, which became available 6-8 hours post-stacking. This delay hindered critical decision-making, as operators lacked timely information to optimise the ore blending process.
The Solution.
To address this challenge, it was essential to provide the customer with real-time insight into the Iron (Fe) content of the ore. This would enable them to maximize yield, exploit ore value optimally, and meet stringent content specifications. The first step taken by Real Time Instruments was to thoroughly understand the customer’s specific challenges. Based on this understanding, a tailored high-value solution was developed and integrated into the existing stockpile management software.
An AllScan was installed on the stockyard conveyor belts to provide immediate real-time results as the ore was stacked. The stockpile management software was then updated to log this real-time data, offering a detailed display of the product’s location, quantity, and quality. This integration allowed operators to have precise, up-to-the-minute information about the stockpile, enabling them to reclaim and blend the ore effectively.
The Result.
The implementation of the AllScan and the integration of real-time data into the stockpile management system yielded significant benefits:
- Real-Time Monitoring: Operators could monitor the stockpile in real time, ensuring that high-quality iron ore was not inadvertently ‘given away.’
- Optimised Blending: The ability to blend high-grade ore with regular ore resulted in the production of a superior product in larger quantities.
- Increased Profitability: This optimised blending and improved quality control led to more than a 5% annual profit increase and a substantial improvement in revenue.
By providing a customised, integrated solution, RTI enabled the customer to enhance their stockpile management processes, resulting in improved operational efficiency and financial performance.
