📋 Case Study

Underground Iron Ore Mine Real-Time Grade Steering

Rapid grade fluctuations causing magnetic separation inefficiency

🏗️ Project Overview

Swedish Kiruna-style high-grade hematite operation

🎯 Challenge

Rapid grade fluctuations causing magnetic separation inefficiency

🔧 Design Approach

In-line XRF + conveyor belt sampling + PLC-driven feed splitter logic

📐 Key Calculations

Split Ratio Adjustment

Target Grade / Measured Grade × Current Split

Result: 1.23

Diverts low-grade material pre-crushing

📊 Results

92% grade consistency maintained; 8% recovery uplift in final concentrate

💡 Lessons Learned

• •XRF calibration drift must be hourly validated
• •Splitter mechanical hysteresis requires dead-band tuning

✅ Key Takeaways

• 1XRF calibration drift must be hourly validated
• 2Splitter mechanical hysteresis requires dead-band tuning