Realtime quality monitoring of Hematite Ore & Hematite Siliceous Ores

Theme: Quality Excellence

Expected Pilot Duration - 15 Days samples
Number of tests on site with lab comparison

Challenge Summary

Lack of a real time monitoring system for assessing the percentage of Fe % , Mn %, SiO2%, Al203%, P%, S% in the ore leads to a time consuming process of transporting samples to the laboratory and waiting for results leads to continued excavation in the wrong zone. Which in turn leads to degrade in quality of ROM

Challenge Scenario

When the iron ore is excavated in the mining region, the amount of Fe % , Mn %, SiO2%, Al203%, P%, S% in the ore has to be assessed in a periodic timeline to ensure high quality of mineral concentration. Currently the sample of the excavated ore is sent to the lab to perform a test which usually takes a minimum of 4 hours for the results to arrive. This causes quality loss of min 3.5 hrs of ore handling and wrong allocation of grades.

The site supervisors don't have real time accurate data to decide on whether to continue excavation in the region or change to a new location bed on the ore concentration. A solution to get the real time data of Fe & Mn concentration will help in moving forward to deciding the highest quality of ore which will result in customer satisfaction.

Profile of the end users

Coal Oven Team

Quality Team - To ensure required grade of Fe % in ore to meet customer requirements

Procurement Team

Operations Team - Needs to figure out exact content of mineral and other radicals to ensure high quality ore is extracted

Solution Requirements

Real Time analysis of Fe % , Mn %, SiO2%, Al203%, P%, S% monitoring in Hematite Ore & Hematite Siliceous Ore and Other materials.

Data Logging that can be used for monitoring & trending analysis

Instant notification to operation & mining team to plan corrective measures in case of quality drop

Accurate data with minimum deviation on the Fe & Mn concentration on the ore

Faster procurement of Raw Material/Biomass

Portable equipment that can be carried out by supervisors, Geologist & Laboratory persons

Safe and rugged enclosure to protect sample integrity from ore variation or moisture etc., during testing

Training - Ease of use by mining employees

Time Consumption - Instantaneous results to be produced

Data Storage - GPS tagging to grades, Time stamping for each analysis

Report generations - Smart reports generation and analysis

Personal/physical Risk - Should have safety provisions in case of chemical agents used for testing

Raw Material - Quality of the processed biomass fit to be used in the boilers

Expected Outcomes

1. Quantified Metrics & Outcomes:

Operational KPIs/Metrics	Current Value	Expected Target Value
Time to generate results	4 Hours	Instant
Sample Quantity	1 Kg	Not Required
Transport Distance	Greater than 5 Kms	Direct / Cloud

2. Qualified Outcomes:

Operational KPI/Metrics	Current State	Expected Target State
Sampling & Testing	Manual sampling & Analysis of crude ore at lab	Realtime sample analysis at excavation site.

3. ESG Impact:

ESG Metric	Target State (Expected)
Fuel Consumption for Transportation	Zero Pollution
Harmful Chemical Reduction	Less or Zero Chemical Usage
Reduced Pollution	Systematic segregation of material

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