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Real-Time Surface Moisture Measurement
Driving Accuracy, Efficiency, and Control in Mineral Processing
Microwave surface moisture measurement provides continuous, real-time data directly on conveyors and process streams—enabling immediate, data-driven decisions that improve plant performance.
Accurate metal accounting depends on precise dry mass determination. Moisture variability introduces significant reconciliation errors between plant, laboratory, and commercial figures.
Real-time measurement enables:
Continuous wet-to-dry mass correction
Reduced reconciliation discrepancies
Improved confidence in production reporting and sales contracts
2. Optimised Drying and Dewatering
Moisture is the primary control variable in filtration, thickening, and drying processes.
Benefits include:
Elimination of over-drying → reduced energy consumption
Prevention of under-drying → improved handling and transport
Optimised filter performance and cycle times
Better control of dryer residence time
3. Enhanced Process Control and Stability
Moisture directly impacts bulk density, flowability, and downstream efficiency.
Operational improvements:
Stable feed to crushers, mills, and furnaces
Improved blending and stockpile control
Early detection of process inefficiencies (e.g. poor thickener or filter performance)
Application Examples Across Commodities
Base Metals (Copper, Nickel, Zinc)
Concentrate moisture control to meet smelter specifications
Improved filtration efficiency and reduced penalties
Accurate dry tonnage for blending and feed consistency
Diamonds
Stabilised Dense Media Separation (DMS) performance
Reduced screen blinding and improved sizing efficiency
Enhanced sorting performance through controlled surface moisture
Gold
Improved slurry consistency in CIP/CIL circuits
Enhanced thickening and tailings management
Reduced energy consumption in smelting through controlled filter cake moisture
Ferrous (Iron Ore, Manganese)
Critical moisture control for sintering and pelletising
Compliance with product moisture specifications
Improved stockpile reclaim, blending, and dust management
Why Microwave Technology?
Non-contact, real-time measurement on moving belts
Insensitive to material colour and particle size variations
Increased revenue assurance through accurate metal accounting
Reduced operating costs via energy and process optimisation
Improved plant throughput and stability
Lower risk of penalties and off-spec product
Conclusion
Microwave surface moisture measurement bridges the gap between laboratory analysis and real-time plant conditions. By providing continuous, accurate moisture data, operations gain the control needed to optimise performance, reduce costs, and improve overall metallurgical efficiency.
