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.
Case Study
ALLSCAN PROVIDES OPERATORS REAL TIME QUALITY CONTROL OF ORE GRADING
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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ALLSCAN HELPS MINE OPERATORS DELIVER QUALITY COAL TO POWER STATION IN REAL TIME
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.
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ALLSCAN PROVIDES ACCURATE ONLINE ASH ANALYSIS, IMPROVING AIR QUALITY
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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MOISTSCAN DETECTS HIGH-MOISTURE EVENTS, SAVING 13 HOURS OF PRODUCTION MONTHLY
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.
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ALLSCAN DELIVERS BETTER STOCKPILE CONTROL, ON-SPEC ORE AND 5%PA PRODUCTIVITY BOOST
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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MEASURING MOISTURE IN WOOD CHIPS – AMERICA
Our customer located in America is a leading manufacturer of engineered wood products, laminated veneer lumber, a high‐strength engineered lumber often used in beams, I‐joists, a structural support typically used in floors and roofs.
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MEASURING MOISTURE IN SLAG – INDIA
Our customer based on India has an existing annual crude steel capacity of 30 million tonnes. They are a diversified steel producer, with operations in 26 countries and commercial presence in over 50 countries.
Installation
A MoistScan MA‐500 online microwave moisture analyser is installed on the conveyor belt that takes the material from the dryers to the silos for storage and sale.
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MEASURING MOISTURE IN SINTER BLEND – SERBIA
The customer is a major producer of iron. The iron is produced at two blast furnaces and then converted to raw steel at a three-furnace converter shop and continuous casting complex.
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MEASURING MOISTURE IN NICKEL ORE – INDONESIA 2
The customer based in Indonesia undertakes all stages of the mining process from exploration, mining, smelting, and refining through to marketing. Their main products are ferronickel, nickel ore, gold, silver and bauxite.