Delivering Sustainable, Multi-Element Analysis at the Train Loadout
Coal | Open Pit Mine | Sustainable Mining
How a leading coal operation utilised real-time elemental analysis to manage ash, moisture and sulphur content at the train loadout (TLO)
- 1.8m Tonnes analysed per month
- 0.23% Within laboratory accuracy
BACKGROUND
In the coal industry, sustainable mining practices increasingly rely on precise, data-driven quality control to reduce waste, emissions and energy consumption. Ash content remains a key indicator of coal quality, influencing calorific value, combustion efficiency and environmental impact.
At a large Australian coal operation, maintaining consistent ash and moisture levels at the train loadout (TLO) is essential for meeting environmental standards and export requirements. Traditional laboratory testing delivers results long after trains are loaded, making it difficult to correct out-of-specification product. Real-time elemental analysis provides a faster, more sustainable approach, enabling operators to continuously monitor quality, optimise blending and deliver specification-compliant coal that supports both operational and environmental goals.
THE CHALLENGE
Coal quality at the TLO can vary significantly due to differences in feed material and blending conditions. Variations in ash and moisture not only affect product value and energy yield but also carry environmental and safety implications. Transportable Moisture Limits (TML) are especially critical at loadout, as exceeding them can compromise shipping safety and compliance.
Each train carries thousands of tonnes of product, requiring rapid resets between trains to ensure accurate, independent tracking of quality data. Delays in laboratory analysis meant operators often had to rely on historical information rather than live data when making loading decisions. The operation needed a solution capable of continuously measuring ash, moisture and other elements in real time, allowing precise per-train tracking and instant feedback to maintain both product quality and sustainable operating standards.
THE SOLUTION
RTI deployed its AllScan elemental analyser at the train loadout conveyor, providing continuous, on-belt elemental measurement. The system offered real-time insight into ash, moisture and sulphur content, along with additional parameters such as calorific value, fluorine and silica, giving operators a complete picture of product composition.
This versatile system also supports compliance with Transportable Moisture Limits, ensuring safer, specification-compliant coal shipments. By integrating the analyser into the site’s control network, operators could view live dashboards showing ash, moisture and other elemental trends as each train was loaded.
The ability to quickly reset between train loads allowed accurate, train-specific quality data to be captured and reported instantly. This functionality not only improved traceability but also provided the site with reliable per-train performance insights, ensuring every shipment left within contractual limits.
IMPLEMENTATION & DISCOVERY
RTI worked closely with the site’s process and quality teams to tailor the analyser setup for local conditions and variable coal seams. Calibration trials showed strong correlation between real-time readings and laboratory results across multiple parameters, confirming system accuracy and stability.
During implementation, the team observed that ash and moisture could fluctuate by several percentage points over short timeframes, highlighting the importance of continuous measurement. Real-time data allowed operators to make immediate adjustments to blending or feed composition, reducing the likelihood of off-spec product being loaded.
The AllScan’s intuitive interface and reset functionality between trains also improved efficiency for operators, ensuring fast turnaround and consistent quality verification. The system’s non-contact design reduced the need for manual sampling, enhancing both safety and sustainability outcomes.
THE RESULTS
The introduction of real-time elemental analysis has delivered measurable improvements in both operational performance and environmental accountability.
High Accuracy: During the September 2024 reporting period, the analyser maintained an average ash reading within 0.23% of laboratory results and a standard deviation of 2.22%, confirming strong correlation and stability.
Reliable Moisture Tracking: Moisture readings averaged 10.68%, with a bias of 0.59%, ensuring precise management against TML requirements.
Sulphur and CV Correlation: The analyser recorded an average 0.55% sulphur and 6,337 MJ/kg CV, both closely aligned with lab data.
Outstanding Uptime: The system achieved 98.8% good analysis uptime over the month, analysing more than 1.8 million tonnes of product.
Operational Efficiency: Rapid reset between trains enabled accurate, train-specific reporting and improved throughput visibility.
Sustainability Impact: Continuous analysis reduced sampling frequency, improved energy efficiency and supported lower carbon intensity across the export process.
By implementing RTI’s AllScan, the operation enabled accurate reporting on their moisture content.
INDUSTRY IMPLICATIONS & FUTURE APPLICATIONS
This project demonstrates the versatility of real-time elemental analysis at the train loadout. By tracking multiple elements simultaneously, operations can achieve a deeper understanding of product quality, reduce environmental impact and enhance operational transparency.
Processing Plants: Optimise recovery and blending using continuous ash, moisture and sulphur data.
Stockpiles: Track compositional changes over time to maintain feed consistency.
Other Commodities: Apply the same technology to iron ore, bauxite and nickel to support sustainability and process control initiatives.
CONCLUSION
By implementing real-time elemental analysis at the train loadout, this Australian coal operation achieved new standards of efficiency, accuracy and sustainability. Continuous, multi-parameter monitoring now allows operators to manage ash, moisture and volatiles with precision, ensuring every train meets quality and compliance expectations.
RTI’s AllScan has proven to be more than an ash analyser, it is a comprehensive tool for sustainable, intelligent mining, delivering Real Time Insights, Operational Certainty.