Stabilising Lithium Production Through Continuous Moisture Monitoring
Lithium | Open Pit Mine | Moisture Analysis in Mining
How a leading lithium mine utilised moisture analysis to stabilise their moisture content in adverse conditions.
BACKGROUND
Lithium operations rely on precise moisture control to stabilise processing circuits and maintain reliable product quality. Moisture influences ore handling, screening efficiency, transfer chute performance, energy consumption and downstream processing such as dense media separation and flotation. Too much moisture creates blockages, carryback and increased wear on equipment, while material that is too dry can create dust hazards, reduce screening efficiency and cause inconsistent plant feed.
At a major Australian lithium operation, operators required continuous visibility of material moisture across multiple conveyors. Laboratory samples provided accurate reference data but were delayed by several hours, limiting their usefulness for real time decision-making. MoistScan technology offered a faster, continuous solution that could stabilise operations and reduce unplanned variability at key points in the pro
THE CHALLENGE
As production rates increased, the site experienced moisture variability driven by weather, ore-body water content and stockpile management conditions. This variability impacted several areas of the plant. Excess moisture reduced throughput in crushing and screening, while insufficient moisture created handling issues and elevated dust levels. Moisture shifts also influenced performance in downstream beneficiation stages, where stable moisture is needed to maintain separation efficiency.
The site needed a system that could measure moisture continuously and accurately, respond to rapid changes in the ore stream and integrate smoothly with the plant’s control system. Critically, they required an analyser capable of maintaining accuracy despite the naturally variable nature of spodumene ore and the operational environment.
THE SOLUTION
RTI deployed multiple MoistScan microwave moisture analysers across key conveyors at the operation. Two analysers provided real time moisture measurement at different stages of the plant, allowing operators to track variability through the process and adjust equipment settings as ore conditions changed.
The continuous data stream allowed operators to respond instantly to changing moisture conditions—adjusting feed rates, managing spray systems, modifying screening parameters and preventing overloading events. The MoistScan’s non-contact design also improved safety by reducing reliance on manual sampling, particularly in areas where access is difficult or hazardous.
By stabilising moisture in real time, the operation reduced downtime by an estimated 20–40 hours per month and improved throughput by 2–5 percent. Across a typical lithium processing facility, these gains represent a combined operational benefit valued at $10–30 million per year.
IMPLEMENTATION & DISCOVERY
RTI worked closely with the site’s processing and maintenance teams to calibrate each analyser using representative samples collected during normal production. Calibration included targeted sampling from multiple ore types and operational conditions to ensure robust performance across the full range of moisture variability.
During commissioning, operators gained new visibility into the causes of moisture spikes, including stockpile drainage patterns, ore-body moisture domains and weather-driven surface water ingress. The ability to correlate moisture changes with specific ore sources allowed the site to optimise stockpile reclaim strategies and better plan blending decisions.
The MoistScan’s integration with the plant’s control network allowed operators to view moisture trends in real time on existing dashboards, making it easier to identify process constraints, predict bottlenecks and prevent overload conditions before they occurred.
THE RESULTS
Real time moisture measurement delivered several operational, reliability and process-efficiency improvements.
Improved Throughput: More stable feed moisture reduced crusher and screen interruptions.
Higher Plant Reliability: Continuous monitoring prevented moisture-related blockages and carryback.
Enhanced Beneficiation Performance: Consistent moisture improved downstream separation efficiency.
Safer Operations: Reduced manual sampling improved safety and decreased exposure to dust and moving equipment.
Better Stockpile Management: Moisture insight allowed operators to anticipate variability based on ore source and weather conditions.
INDUSTRY IMPLICATIONS & FUTURE APPLICATIONS
Real time moisture analysis has broad value across lithium operations and other critical mineral supply chains.
Sprayer and Water Control Automation: Use MoistScan data to regulate water addition automatically.
Filter Belt Optimization: Control moisture to improve filter cake consistency and product quality.
Stockpile and Ore Source Characterisation: Identify wet and dry ore domains to improve reclaim planning.
Integration with Digital Twins: Combine moisture data with modelling tools for predictive plant control.
CONCLUSION
By implementing MoistScan technology across key conveyors, this Australian lithium operation achieved consistent, real time visibility of moisture at critical stages of production. The high calibration accuracy and continuous monitoring improved throughput, stabilised downstream processing and reduced manual sampling requirements. With more predictable moisture control, the site strengthened operational performance and reinforced its position in the rapidly expanding global lithium supply chain supported by Real Time Insights & Operational Certainty.