Real-Time Analyser Delivers 100% Visibility and Cuts Processing Variability by 20%
Iron Ore | Open Pit Mine | Process Control
How a leading iron ore producer tapped into real-time analysis to drive efficient decision making and boost operational reliability
BACKGROUND
Iron ore operations rely on consistent product quality and efficient processing to remain competitive. However, traditional quality control methods—such as periodic lab sampling—often introduce significant delays. These time lags limit operators’ ability to respond to changing material conditions, resulting in waste, inefficiencies, and increased rework. At one Australian mine, the inability to make timely adjustments was compromising operational control and output quality.
THE CHALLENGE
The mine’s processing plant lacked real-time insight into the composition of conveyed materials. Lab sampling typically took hours to return results, by which time the opportunity to adjust processing parameters had passed. This caused frequent fluctuations in feed quality, inefficient crusher and mill settings, and inconsistent product grade. The operation needed a faster, more responsive feedback loop between material analysis and plant control.
Having real-time visibility over material quality at every point in the process has completely changed the way we operate. We’re no longer guessing — we’re making confident, data-backed decisions.
THE SOLUTION
To address this, Real Time Instruments (RTI) deployed its AllScan Cf-252 elemental analyser at a key point along the conveyor system. The analyser delivered live, continuous data on iron content and other key parameters. Unlike batch testing, AllScan measured the composition of conveyed material in real time, providing immediate feedback to plant operators. With live data available 24/7, the team could adjust crusher settings, feed rates, and blending strategies on the fly. This shift from reactive to proactive processing allowed for smoother transitions and improved control throughout the circuit. The AllScan system became an integral part of the plant’s automation and decision-making infrastructure.
IMPLEMENTATION & DISCOVERY
RTI collaborated with site engineers to identify the ideal installation point for AllScan, ensuring optimal measurement accuracy. The unit was calibrated for the site’s specific ore type, and training was provided for operators and supervisors on interpreting the live data stream. Initial readings revealed significant fluctuations in iron content—variations that previously went undetected due to the lag in lab testing. With AllScan, the team gained immediate awareness of material changes and quickly adjusted processing parameters, resulting in reduced variability and increased throughput stability.
THE RESULTS
The introduction of real-time feedback control through AllScan marked a significant shift in operational capability. With access to live, accurate data, the site was able to fine-tune its processing strategy, reduce inefficiencies, and realise measurable improvements across multiple performance indicators.
Real-Time Visibility: Operators had 100% visibility into the composition of conveyed materials, empowering data-driven decisions.
Reduced Processing Variability: A 20% reduction in variability was achieved through timely adjustments to processing inputs.
Improved Efficiency: Faster decision-making and feed quality control reduced energy use and rework.
Consistent Product Quality: Continuous monitoring ensured the final product met export-grade specifications with greater reliability.
Implementing RTI's sensor solution led to a more consistent final product, meeting specifications more reliably
INDUSTRY IMPLICATIONS & FUTURE APPLICATIONS
AllScan’s success in iron ore feedback control positions it as a valuable solution across various industries. Similar benefits can be realised in:
Ore Sorting: Enhancing the accuracy of automated sorters with real-time grade data
Crushing and Screening: Adjusting machine settings dynamically to match material properties.
Blending Operations: Maintaining precise grade targets across complex blends.
CONCLUSION
By implementing RTI’s AllScan system, the mine transformed its operational control strategy. With access to real-time data, the team eliminated the delays and guesswork of lab-based analysis, gaining the ability to respond to material changes as they occurred. This case proves the powerful impact of continuous analysis in delivering efficiency, quality, and control across the mining value chain.
