Enhancing Gold Mining Efficiency Through Real Time Moisture Control
Bauxite | Underground | Moisture Management
How a leading gold producer harnessed real time moisture control to take control of their underground operations
BACKGROUND
In gold mining, managing moisture is critical to maintaining safe, efficient and environmentally responsible operations. Conveyors in underground and surface environments face a constant challenge: too much water creates overburden and carryback, while too little leads to dust and reduced visibility. Both conditions affect throughput, increase maintenance and present safety risks.
Within large gold operations operators require precise, real time control over water additions to conveyor systems. Traditional manual spraying relied heavily on experience and guesswork, often leading to inconsistent results. Real Time Instruments’ worked with a site that sought to automate its dust suppression system by implementing real-time moisture analysis, optimising moisture in the ore stream to ensure effective suppression without impacting handling efficiency.
THE CHALLENGE
Moisture levels at the mine varied significantly due to weather and ore characteristics. The underground environment made balancing dust suppression with overwatering particularly difficult. Excess water increased conveyor load, spillage and wear, while insufficient spraying generated dust events and potential non-compliance with safety regulations.
Sampling underground added complexity. With no automatic sampler available, calibrations depended on manual collection during short production pauses. The operation needed a solution that could measure moisture continuously, integrate with sprayer controls and maintain accuracy despite limited calibration samples.
THE SOLUTION
RTI installed a MoistScan microwave moisture analyser on the main conveyor to provide continuous, real time moisture measurement. The analyser was integrated directly with the site’s automated water sprayer system, creating a closed feedback loop: when moisture dropped below target, sprayers automatically activated; once the setpoint was reached, they reduced or stopped flow.
Calibration used stopped belt cuts and controlled water addition via hose spraying, building an accurate model across the mine’s moisture range. The calibration achieved a Root Mean Square Deviation (RMSD) of 2.24%, confirming reliable alignment with laboratory samples. Even with calibration samples below 5% moisture, the analyser showed strong correlation and stable performance.
RTI’s service team supported calibration and commissioning, using spot samples and belt cuts to validate readings. This flexible approach was vital in underground conditions where continuous sampling is not possible. Extending to installation, by being readily available, the RTI team could assist across multiple opportune and scheduled shutdowns to get the sensor installed quickly to ensure the shortest time to first value possible.
Precise moisture control prevented spillage and carryback, contributing to a 20% reduction in conveyor stoppages and extending belt life.
IMPLEMENTATION & DISCOVERY
Integrating the MoistScan with the mine’s control network immediately improved consistency and visibility. Operators could see live moisture data through the control interface, ensuring water addition was optimised along the full conveyor length.
During commissioning, technicians noted seasonal variations, particularly during the rainy period, could raise moisture above 20%. RTI recommended a follow-up calibration to maintain precision across higher ranges.
The project also demonstrated the MoistScan’s compatibility with underground infrastructure. Its modular design allowed seamless integration with site control systems, and on-site training ensured safe operation and minimal production disruption.
THE RESULTS
Real-time moisture control delivered measurable operational, environmental, and safety improvements.
Automated Dust Suppression: The MoistScan feedback loop enabled fully automated sprayer control, reducing manual oversight and maintaining consistent dust suppression.
Water Efficiency: Automated spraying cut excess water use by 10–15% compared to manual operation, without compromising suppression performance.
Reduced Overburden: Precise moisture control prevented spillage and carryback, contributing to a 20% reduction in conveyor stoppages and extending belt life.
Improved Safety: Stable moisture levels reduced airborne dust concentrations by up to 30%, improving visibility and working conditions underground.
High Accuracy: Calibration achieved strong correlation between analyser readings and laboratory samples, with an RMSD of 2.24% across the calibration range.
Reliability in Underground Conditions: RTI’s use of stopped belt cuts and spot samples delivered dependable calibration despite limited sampling infrastructure
By implementing RTI’s MoistScan, the operation eliminated moisture related stoppages.
INDUSTRY IMPLICATIONS & FUTURE APPLICATIONS
The success of this project highlights how real time moisture control supports safer and more efficient gold mining operations.
Underground Conveyors: Automate dust suppression through direct MoistScan feedback.
Processing Plants: Maintain optimal feed moisture to improve handling and reduce carryback.
Surface Operations: Use continuous monitoring for environmental dust control and water efficiency.
Other Commodities: Apply the same moisture control approach to copper, nickel and coal.
Filter Belts: Maintain consistent discharge moisture to stabilise paste density, prevent segregation and blockages, and support reliable backfill production.
CONCLUSION
By implementing real time moisture analysis with RTI’s MoistScan technology, this gold operation achieved precise, automated water control across its conveyor network. Operators now maintain ideal moisture levels—reducing dust, improving safety and preventing overburden.
RTI’s adaptable calibration approach ensures accuracy even in complex underground environments, delivering safer, more efficient and more sustainable operations through Real Time Insights & Operational Certainty.