More coal with more efficiency

Rio Tinto Coal Australia (RTCA) has developed ways to yield more coal from the same amount of mining, helping to create the most sustainable value from our resources.

The yield increases have been the result of collaboration across the business, focusing on four cornerstone projects - sampling, dense medium cyclone performance, process control and flotation.

Coal processing specialist Jimmy Pollack said advances in flotation demonstrated how RTCA has used new technologies to boost efficiency.

"Flotation separates quality coal from waste material by combining diesel and frother with a mixture of water and coal," Mr Pollack said.

"The coal gets coated in diesel and attaches to air bubbles, which float the coal to the top of the tank, while reject material stays at the bottom. The frother helps stabilise the bubbles, like detergent in washing up, to then allow recovery of the coal.

"Previous methods allowed for just one phase of flotation, adding to the chance of fine coal being lost. RTCA has developed a new phased flotation system able to catch this fine coal, resulting in higher yields for the same amount of mining."

RTCA's Kestrel Mine has already benefited from the new technology, with preliminary results showing a one to two per cent yield increase.

"Identifying how to improve our processes to become more efficient is a key focus within the business," Mr Pollack said.

"Even small incremental improvements can create tens of millions of dollars in value, and deliver sustainable outcomes."