Client Success
Stories & Case Studies

The Below Case Studies demonstrate how partnering with RTI will allow you to make Intelligent Decisions in Real Time, so you can Recover More, Waste Less, and Take Control of your operations.

Clients are using our High-Technology, World-Leading elemental and moisture analyzers play a critical role in the delivery of integrated solutions which empower our clients to achieve Maximum Yield and Real-Time Results.

AllScan assists screening to improve material grade by up to 50%

RTI's AllScan cf-252 elemental analyser on site

Our customer operates a screening plant that upgrades mined ore before being stored on stockpiles, prior to further processing. 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 maximize the upgrade of the ore or control the levels of deleterious components.

By determining the levels of Ni, Fe, SiO2, MgO and other elements in the mined ore the customer was provided with real-time oversight of the in feed to the ore upgrading process. This meant they could make decisions about in pit operations and screening operations to control and maximize the grade of stockpiled material.

RTI’s first step was to understand our customer’s specific challenges. From there we adjusted the calibrated result of the Allscan to report material parameters defined by the client as best being suited to inform their decision-making process such as the SiO2/Mg, Fe/Ni and Ni/Co ratios. RTI worked with the customer to validate the analyser performance of the Allscan to allow process control decisions to be made based on the generated results with confidence.

By tailoring an integrated solution using the AllScan, our customer was able monitor their feed material from the mining operations. The ability to control the ore upgrade process in real time allowed for a 50% increase in the grade of the product at the infeed to the furnace. This combined with ability to greatly reduce the variation in deleterious competent has had a positive impact on both power consumption costs and CO2 emissions.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Industry to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal
Cement – Raw Mill Application
Cement – Stock Pile Application
Coal
Coal Waste Material
Iron Ore
Other Minerals
Slurry Applications

AllScan delivers better stockpile control, on-spec ore and 5%pa productivity boost

RTI’s AllScan elemental analyser on site.

Our customer had varied grades of iron ore but was unable to identify the quality of the 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, meaning there was an unacceptable lag and an inability to make critical decisions when it mattered.

Knowing the Iron (Fe) content of the product, empowered our customer with real-time oversight of the ore blending process. This meant they could gain maximum yield, best exploit ore value and meet content specifications.

RTI’s first step was to understand our customer’s specific challenges. From there we developed a high-value, tailored solution which became an integral part of the stockpile software. By installing an AllScan on the stockyard conveyor belts, operators immediately saw the real-time results. As the product was stacked, the stockpile management software logged the same data to include in the result. By doing so, this provided an in-depth display showing what product was where, as well as the quantity, and most importantly, where to reclaim it.

By tailoring an integrated solution using the AllScan, our customer was able monitor their stockpile in real time, blend product to specification, and not ‘give away’ any high-quality iron ore. The ability to blend high-grade ore with regular ore, to create a superior product, in larger quantities, resulted in a profit increase of approximately 5%; and a significant improvement to revenue.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Industry to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal
Cement – Raw Mill Application
Cement – Stock Pile Application
Coal
Coal Waste Material
Iron Ore
Other Minerals
Slurry Applications

AllScan helps mine operators deliver quality coal to power station in real time

RTI’s AllScan elemental analyser on site.

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.

Knowing the composition of the coal in real time would enable mine operators to make changes to wash plant conditions in situ. Specifically, where product is too low, less coal is rejected, saving money on reclaiming. Similarly, if product was too high and not within specification, this would enable more to be washed or rejected, to bring product back within specification, saving fines from the power station.

RTI was able to prescribe an AllScan to a targeted install location, enabling real-time analysis of ash, moisture, specific energy and elemental composition of the product. The operators were given full access to the instantaneous results, as well as a rolling 12-hour average, that operators could use to understand the tonnes-weighted average of the previous 12 hours.

The application was a success. The operators use the instantaneous results to monitor, in real time, the composition of the product, and minorly adjust the plant accordingly. Additionally, the rolling 12 hour results enabled the maintenance of an average quality for their shift, which remains within power station specification. Daily average data shows the operation was within its specified 28% ash, 74% of the time, and the operation never missed spec by more than 1%. The site is satisfied with the AllScan’s performance; such that the customer is now working to calibrate AshScans coming directly from the Run of Mine. These are placed immediately prior to the entrance of the plant, enabling operators to know product quality received from the mine and being fed into the plant. The AllScan has proven vital to this customer’s plant operations; so much so, that if the analyser is not operating, the whole plant is shut down. For this reason site has an extensive 24/7 PSA (Product Service Agreement) with RTI to maintain the analysers and ensure they are working at their best.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Industry to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal
Cement – Raw Mill Application
Cement – Stock Pile Application
Coal
Coal Waste Material
Iron Ore
Other Minerals
Slurry Applications

AllScan provides accurate online Ash Analysis, Improving Air Quality

RTI personnel on site demonstrating the use of the AllScan to the end-user.

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.

By knowing the real time ash content of the coal being fed into their bunkers, NTPC can make real-time decisions on the feeding of their boilers. This allows the operators to accurately blend their coal during reclamation to ensure that all environmental targets are being met.

RTI visited multiple power plants in India to tailor a viable solution for the global issue faced by all coal fired power stations. We were able to identify ideal installation locations for our clients and develop appropriate commissioning procedures that maximized accuracy and minimized disruption to process. This allowed our client to rapidly respond to product changes by blending appropriate coal qualities to ensure that their plant is running at maximum efficiency.

In having a high accuracy instrument, the AllScan, on the infeed to their bunkers, our client can monitor their coal quality in real time. This enables the operators to blend their products to ensure the coal fed into their plant is of a lower ash content. This greatly reduces the negative impacts of burning coal to produce power, greatly improving the air quality and the respiratory health of the people living around these power stations. An analyser utilised in this application could see the reduction in more than 1400t of CO2 and the saving of more than 25,000t of Coal per unit per year of operation.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Industry to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal
Cement – Raw Mill Application
Cement – Stock Pile Application
Coal
Coal Waste Material
Iron Ore
Other Minerals
Slurry Applications

Consistent kiln feed leads to better quality clinker

Our Customer is a large cement company in China. The cement complex includes two raw mills, one with a very large capacity and the other with a smaller capacity. Because the factory is located at high latitude, the plant operates from March to November. At other times of the year, it is too cold to operate the kiln. The plant has a very large storage capacity to enable it to supply cement all year round.

The AllScan cross-belt elemental analyzers continuously measure the chemistry of the raw mix. This data is relayed to specialist raw mix proportioning software that controls dosing from the corrective feeder bins according to pre-defined quality parameters.

Analysers are installed on the conveyors upstream of the raw mills and downstream of the feeders.

This enables the plant to reduce the variability in the raw mix, and ultimately the kiln feed. Consistent kiln feed chemistry in turn leads to better quality clinker and lower fuel consumption per ton of clinker produced.

The AllScan is a new-generation online elemental analyser that uses PGNAA (prompt gamma neutron activation analysis) technology to accurately measure the chemical composition of most bulk materials. The analyser combines practical operational features with sophisticated hardware and software resulting in an analyser that is easy to install, calibrate, and maintain, and above all, is extremely accurate.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Industry to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal
Cement – Raw Mill Application
Cement – Stock Pile Application
Coal
Coal Waste Material
Iron Ore
Other Minerals
Slurry Applications

AllScan provides operators real time quality control of ore grading

RTI’s AllScan cf-252 elemental analyser on-site

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-situ, online, real-time sampling analysis solution.

To enable full-spectrum visibility of elemental composition, RTI worked with our customer to deliver highly-accurate data, minute by minute. This informed an ability to achieve the specific, desired outcome, to maintain a specific alumina level, while simultaneously limiting silicon dioxide levels.

Working with our customer, RTI’s Research and Development team found the AllScan to have a unique advantage in addressing the challenge, in providing real-time analysis of the product to deliver accurate estimates for the alumina and silicon levels, empowering operators to make key decisions.

The AllScan allowed operators to respond to product deviations, in real time, according to the data available to them. This enabled the maintenance of product to specification. The Data collected when the MoistScan analyser was initially installed, showed alumina value regularly falling below sites limits. Six months later, having had visibility and control over moisture levels, the site reported an increase of almost 60% in Good Alumina recorded and a reduction in reject product from 56% to zero.

The challenges faced in the context of alumina are applicable in across a number of ores and bulk materials. Where product quality and elemental composition are key variables in an operations cost and grade control, there is a proven application for AllScan technology.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Industry to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal
Cement – Raw Mill Application
Cement – Stock Pile Application
Coal
Coal Waste Material
Iron Ore
Other Minerals
Slurry Applications

MoistScan detects high-moisture events, saving 13 hours of production monthly

RTI’s AllScan cf-252 elemental analyser on site.

Persistent ‘high moisture events’ occurring during plant operation, led our customer to work with RTI in developing a solution which gave them real-time visibility and control. When their product moisture passed 12%, processes were forced to be stopped and reset to avoid blockage and malfunction of apparatus. This meant unproductive – and costly – downtime; and once the plant was forced to stop, it would take five hours to be restored to full capacity. Further, as moisture was measured by the laboratory, results would typically take between two and four hours to be returned.

Our primary focus was to give the customer visibility and control over the product moisture in real time. This would enable plant operators to increase uptime and minimise downtime on plant feed by monitoring added moisture content, to ensure the 12% mark is never breached.

Once the problem of consistent ‘high moisture events’ was discussed with RTI, we were able to provide a real-time moisture analysis solution by implementing a MoistScan on plant feed-in and feed-out . By doing so, operators could see the moisture value as it happened, enabling them to avoid breaching moisture limits, meaning the plant could continuously, and more reliably, run at optimum capacity.

Since the implementation of the MoistScan solution, this site has reported a complete eradication of ‘high moisture events’, going so far as using the MoistScan to automate the plant. By preventing the constant plant downtime, an average of 13 hours of production have been recovered – which equates to about $2.7M – per month. When throughput is 2,100-plus tonnes / hour, that adds up to millions of dollars in recovered revenue.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Process Location to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal:
Belt Conveyor
Horizontal Belt Filter
In Pipe or screw

Measuring Moisture in crushed Nickel Ore in Canada

Crushed Nickel Ore

Our customer, located in Canada and is known to be one of the highest grade phosphate mines in the world.

The MoistScan® analyser is used to measure the moisture content of the ore as it is important for accounting purposes, allowing accurate assessment of throughput and yield.

A MoistScan® MA‐500HD online microwave moisture analyser is installed immediately after the weigh‐ feeders at the base of the storage bins and is responsible for measuring the moisture content of crushed ore before it is milled in the rod mills.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Process Location to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal:
Belt Conveyor
Horizontal Belt Filter
In Pipe or screw

MEASURING MOISTURE IN COAL IN INDIA

Measuring moisture in coal india

The customer is one of the world’s largest steel companies with an existing crude steel production capacity of 30 Million Tonnes Per Annum. The customer has a balanced global presence in over 50 developed European and fast growing Asian markets, with manufacturing units in 26 countries.

The MoistScan® is used to provide feed‐back control of water addition so that the feed to the coke oven has optimal moisture content.

A MoistScan® MA‐500 online moisture analyser is installed on the conveyor taking the coal from the crusher to the stamper feed storage hopper, prior to feeding the coke ovens.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Process Location to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal:
Belt Conveyor
Horizontal Belt Filter
In Pipe or screw

MEASURING MOISTURE IN CONFECTIONARY IN USA

Measuring Moisture in Confectionary

Our customer is a large snack food and confectionary company located in the USA. They manufacture a range of well known chocolate bars and confectionery.

The MoistScan® analysers are used to measure the moisture of the caramel and the frappe for quality control. Controlling the moisture content of both the caramel and frappe is critical to the product quality (firmness) and shelf life.

Two MoistScan® MA‐700 in pipe moisture analysers are installed on the caramel and frappe pipe prior to the layering of the snackfood.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Process Location to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal:
Belt Conveyor
Horizontal Belt Filter
In Pipe or screw

CONTROLLING MOISTURE IN BRICK MANUFACTURING IN AUSTRALIA

Controlling moisture in brick manufacturing

The customer, bases in Australasia is a large manufacturer of pavers, bricks, building materials, facade systems and landscaping products.

The MoistScan® analyser monitors the percentage moisture which controls the amount of water added to the product.

A MoistScan® MA‐500 online microwave moisture analyser has been incorporated into a new brick extrusion line. The analyser is installed on the conveyor between the storage silo and the water sprayer lined chute.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Process Location to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal:
Belt Conveyor
Horizontal Belt Filter
In Pipe or screw

MEASURING MOISTURE IN COAL IN KOREA

Measuring moisture in coal korea

Our customer, based in Korea operates two steel mills has an annual production capacity of 28 million tonnes.

The Moistscan® analyser has been installed as an alert for when the coking coal is an incorrect moisture level to help improve efficiency.

The Moistscan® MA‐500 online microwave moisture analyser is installed on conveyor 1 running in parallel with conveyor 2 from the filters to the calciners.

Want to see what we can do for your application?

So that we can assist you with the best advice and recommended options for your application we need to know which Industry you are looking at a solution for.
Click the below Process Location to be taken to the relevent application data sheet to complete and provide for your tailored no-obligation proposal:
Belt Conveyor
Horizontal Belt Filter
In Pipe or screw

CALCULATING ACCURATE CALORIFIC IN LIGNITE IN BULGARIA

RTI’s AllScan elemental analyser on site.

The customer is a major electricity generation company in Bulgaria.

analysers are used in conjunction with the coal ash analyser to calculate accurate calorific value of the incoming product coal and the feed coal to the burners.

Four (4) MoistScan® MA‐500HD Series II online microwave moisture analyser’s are installed on two (2) stacker‐reclaimers to the stockpile. The units measure the moisture of coal fed to the stock piles and coal reclaimed from the stockpiles which is crushed and then fed to the burner. The units are installed in association with several coal ash analysers.

Want to see what we can do for your application?

To provide the best advice and recommended options for your application we need to know some additional information.

If your measuring parameters and/or variables in Ash only applications, and your:
Belt Loading is under 100kg/m – Click Here to complete your data sheet
Belt Loading is over 100kg/m – Click Here to complete your data sheet

If your measuring parameters and/or variables in Ash, Moisture & Calorific applications, and your:
Belt Loading is under 100kg/m – Click Here to complete your data sheet
Belt Loading is over 100kg/m – Click Here to complete your data sheet

Providing accurate online Ash Analysis, Improving Air Quality

RTI personnel on site demonstrating the use of the AllScan to the end-user.

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.

By knowing the real time ash content of the coal being fed into their bunkers, NTPC can make real-time decisions on the feeding of their boilers. This allows the operators to accurately blend their coal during reclamation to ensure that all environmental targets are being met.

RTI visited multiple power plants in India to tailor a viable solution for the global issue faced by all coal fired power stations. We were able to identify ideal installation locations for our clients and develop appropriate commissioning procedures that maximized accuracy and minimized disruption to process. This allowed our client to rapidly respond to product changes by blending appropriate coal qualities to ensure that their plant is running at maximum efficiency.

In having a high accuracy instrument, the AllScan, on the infeed to their bunkers, our client can monitor their coal quality in real time. This enables the operators to blend their products to ensure the coal fed into their plant is of a lower ash content. This greatly reduces the negative impacts of burning coal to produce power, greatly improving the air quality and the respiratory health of the people living around these power stations. An analyser utilised in this application could see the reduction in more than 1400t of CO2 and the saving of more than 25,000t of Coal per unit per year of operation.

Want to see what we can do for your application?

To provide the best advice and recommended options for your application we need to know some additional information.

If your measuring parameters and/or variables in Ash only applications, and your:
Belt Loading is under 100kg/m – Click Here to complete your data sheet
Belt Loading is over 100kg/m – Click Here to complete your data sheet

If your measuring parameters and/or variables in Ash, Moisture & Calorific applications, and your:
Belt Loading is under 100kg/m – Click Here to complete your data sheet
Belt Loading is over 100kg/m – Click Here to complete your data sheet

MEASURING MOISTURE IN ASH COKING COAL & ASH THERMAL COAL IN AUSTRALIA

Measuring Moisture in Ash Coking Coal

Our customer, located in Australasia produces a mixture of premium coking, semi‐soft and thermal coals for the export market

The MoistScan® analyser is used to provide moisture readings to the plant control system allowing for instant feed‐back control.

A MoistScan® MA‐500 online moisture analyser is installed on the product conveyor feeding the stockpiles.

Want to see what we can do for your application?

To provide the best advice and recommended options for your application we need to know some additional information.

If your measuring parameters and/or variables in Ash only applications, and your:
Belt Loading is under 100kg/m – Click Here to complete your data sheet
Belt Loading is over 100kg/m – Click Here to complete your data sheet

If your measuring parameters and/or variables in Ash, Moisture & Calorific applications, and your:
Belt Loading is under 100kg/m – Click Here to complete your data sheet
Belt Loading is over 100kg/m – Click Here to complete your data sheet

MEASURING MOISTURE IN COAL IN MINING IN AUSTRALIA NSW

Measuring moisture in coal Australia

The customer is a major coal producer located in NSW, Australia. Run of mine coal passes through a number of beneficiation processes before the final product is transported via conveyor to the stock pile.

The moisture content of the ore is important for accounting purposes, allowing accurate assessment of throughput and yield.

A MoistScan® MA‐500HD analyser is installed on the product conveyor between the wash plant and the sampling station.

Want to see what we can do for your application?

To provide the best advice and recommended options for your application we need to know some additional information.

If your measuring parameters and/or variables in Ash only applications, and your:
Belt Loading is under 100kg/m – Click Here to complete your data sheet
Belt Loading is over 100kg/m – Click Here to complete your data sheet

If your measuring parameters and/or variables in Ash, Moisture & Calorific applications, and your:
Belt Loading is under 100kg/m – Click Here to complete your data sheet
Belt Loading is over 100kg/m – Click Here to complete your data sheet

Once we recieve your completed applicaiton data sheet our team will work on a tailored and customised proporal for your applicaiton.

Should we need any more information we will make contact using the details provided on your submitted application data sheet.

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