Solution Spotlights

Operational Certainty in Coal Power Generation Through 24/7 Performance Assurance Download Case Study Contact Us Coal | Mine & Power Station | Performance Assurance How

At a major Australian lithium operation, operators required continuous visibility of material moisture across multiple conveyors. The implementation of multiple MoistScans gave operators new visibility into the causes of moisture spikes and optimise reclaim strategies.

In copper smelting, moisture control is essential for maintaining safe, efficient and predictable kiln performance. Feed material entering the kiln must remain within a narrow moisture range.

Precise moisture management at an underground gold mine prevented spillage and carryback, leading to a 20% reduction in conveyor stoppages.

In iron ore production, managing variability is one of the most persistent challenges across the value chain. Ore composition can shift significantly and these variations directly affect plant performance and export value, particularly with elements iron (Fe), silica (SiO₂) and alumina (Al₂O₃).

Maintaining consistent ash and moisture levels at the train loadout (TLO) is essential for meeting environmental standards and export requirements. Real-time elemental analysis provides fast, sustainable monitoring of quality, optimising blending and delivering specification-compliant coal that supports both operational and environmental goals.

A major Australian coal operation improved power generation efficiency and sustainability using RTI’s AllScan elemental analyser. Real-time coal analysis enabled consistent fuel quality, reduced emissions, and 24/7 operational reliability — setting a new benchmark for sustainable energy production.

In coal export operations, RTI’s MoistScan delivered real-time moisture accuracy (±0.6% vs lab), enabling proactive blending and loadout control—ensuring compliance, reducing penalties, and optimizing shipping.

RTI’s AllScan & MoistScan systems deliver real-time ash and moisture control—cutting penalties, improving blending, and delivering an ROI in just 50 days, with ~$36,000/day in extra profit.

A major African copper operation improved grade consistency and material traceability using RTI’s AllScan analyser. Real time elemental data replaced slow lab sampling, allowing operators to respond instantly to variability and link copper quality to each conveyor and material movement. The result is a more efficient, transparent and data-driven production process.

AllScan sensors provided continuous real-time iron content monitoring across stockpiles—enabling precise reclaim, blending control, and achieving a 5% annual profit lift.

At NTPC power stations, AllScan enabled real-time ash control at bunkers—saving ~25,000 t coal and reducing 1,400 t of CO₂ annually while maintaining environmental compliance.

RTI installed AllScan in processing circuits, delivering 100% real-time material visibility and cutting variability by 20%—enabling automated, data-driven process adjustments.

An iron ore mine eradicated high-moisture shutdowns, recovered 13 hours of monthly production, and generated ~$2.7 million/month in value by enabling proactive moisture management with the MoistScan.

AllScan delivered real-time alumina monitoring, boosting compliant yield from 11% to 70%, eliminating reject material, and significantly improving efficiency and profitability.