📋 Case Study

Coal Mine Wash Plant Feed Blending Optimization

Ash and sulfur spikes exceeding contractual specs due to uncoordinated blending

🏗️ Project Overview

Australian thermal coal mine with multiple seam sources

🎯 Challenge

Ash and sulfur spikes exceeding contractual specs due to uncoordinated blending

🔧 Design Approach

GPS-tracked haul truck payload tagging + automated railcar blending algorithm using ash/sulfur assay history

📐 Key Calculations

Blend Ash Target Deviation

|Actual − Contract| / Contract

Result: −1.8%

Triggers automatic blend recalibration

📊 Results

Contract compliance improved from 68% to 99.4% over 12 months

💡 Lessons Learned

• •Truck payload sensors require weekly drift validation
• •Assay lag necessitates predictive moving-average weighting

✅ Key Takeaways

• 1Truck payload sensors require weekly drift validation
• 2Assay lag necessitates predictive moving-average weighting