50 Day ROI for Coal Mine with Enhanced Ash Quality Control
Coal | Open Pit Mine | Sustainable Mining
How a leading coal mine utilised elemental and moisture control to maintain contract ash levels.
- 36k per day in extra profit
- 50 days ROI for sensors
BACKGROUND
Coal mines face constant pressure to maintain product quality, reduce penalties, and maximise operational efficiency. Two critical factors in achieving these goals are elemental composition and moisture content. Elemental analysis ensures coal meets specifications for ash, sulfur, and calorific value—vital for buyer contracts and processing optimisation. Moisture control prevents blending inconsistencies, improves handling, reduces dust, and avoids combustion issues for customers. Coal quality varies significantly as it moves from pit to plant to loadout. Without continuous, on-belt analysis, operators rely on batch sampling and lab testing, which often take hours. By the time results arrive, off-spec coal may already be loaded into trains, leading to penalties, rehandling, or inefficient blending. Real-time elemental and moisture monitoring at the loadout stage gives operators the ability to make instant adjustments and protect value.
THE CHALLENGE
At a major Australian coal mine, variability in both elemental composition and moisture created regular quality control issues. Ash levels and moisture percentages sometimes exceeded the contract target of 10% ash, leading to penalties of $5,000–$20,000 per train, inefficient blending, and costly rehandling that impacted throughput. With lab results delayed for hours, the operations team had no way to detect and address issues before coal was dispatched. They needed a solution that could continuously measure both elemental composition and moisture on the conveyor, enabling immediate intervention. For this mine, with an average throughput of 2,200 tonnes per hour, even small improvements in quality equate to tens of thousands of dollars in daily value.
By using the analysers provided by RTI, we could ensure our product was consistently at the contract target, saving us from paying large penalties.
THE SOLUTION
RTI installed a suite of AllScan elemental analysers and MoistScan moisture analysers at key points in the processing plant and train loadout. The AllScan provided real-time elemental data to ensure ash and calorific value targets were met, while the MoistScan tracked moisture deviations instantly. With a contractual specification of 10% ash, the AllScan was calibrated against the mine’s infeed ash, averaging 15%. This gave operators continuous visibility into whether they were maintaining the control point. The system enabled the setpoint to be adjusted from 9.8% ash to 9.9%, tightening control while still meeting contract limits. Operators could detect off-spec coal in real time, adjust blending before trains were loaded, and consistently keep shipments within buyer requirements. By integrating the analysers with the mine’s control system, the team monitored live dashboards, received automated alerts, and acted immediately to protect compliance.
IMPLEMENTATION & DISCOVERY
The analysers were integrated seamlessly into existing processing and loadout infrastructure. RTI provided onsite training so operators could interpret the data and make proactive adjustments. Within days of commissioning, the mine recorded reduced variability, fewer blending delays, and more consistent train loads. Operators reported greater confidence in meeting specifications without reactive rehandling or last-minute corrections.
THE RESULTS
- ROI: The project achieved a payback period of 50 days, supported by operational efficiencies and improved yield.
- Financial Gain: Operators now realise approximately $36,000 per day in extra profit, directly attributable to better ash control and reduced variability.
- Precision in Ash Control: With an infeed ash of 15% and a contract limit of 10% ash, the AllScan enables operators to manage ash at a setpoint of 9.9%, ensuring shipments consistently meet buyer specifications whilst maximising throughput.
- Throughput Impact: At 2,200 tph and a profit of $60 per tonne, even minor improvements in yield and product quality deliver substantial financial benefit.
By implementing RTI’s AllScan, the operation gained enhanced control over ash content, keeping percentage within contract range.
INDUSTRY IMPLICATIONS & FUTURE APPLICATIONS
- Coal Handling & Preparation Plants (CHPPs): Optimise processing through live monitoring of ash and moisture.
- Stockpiles: Manage changes during storage to reduce variability and rehandling.
- Other Commodities: Apply the approach to bauxite, iron ore, and mineral sands, where composition and moisture directly affect sale value.
CONCLUSION
By combining AllScan elemental analysis with MoistScan moisture measurement, the mine has achieved real-time quality control at the loadout stage. The system has delivered a rapid return on investment and long-term operational benefits, allowing the mine to confidently meet customer specifications, avoid costly penalties, and optimise every train load.