RFID testing system lifts yield at Australian coal mines

HID and Partition Enterprises have deployed an RFID-based testing system for Australian mining operations. In audits with major Australian coal producers, the system delivered average yield gains of 6% per site.

The system is used in dense medium separation testing, which helps coal and other minerals operators assess how effectively material is separated from waste. At the centre of the set-up is a customised RFID tag from HID, built to operate in mineral processing conditions and integrated into Partition Enterprises' CurvePRO platform.

According to Partition Enterprises, the approach reduces a testing process that previously required up to eight workers and around two months for laboratory results to a task handled by one operator in about 30 minutes, with results available immediately. This gives site teams faster data on separation performance and allows them to adjust processing densities during operations.

Meandu Mine in Queensland is among the sites using the technology. BUMA Australia has been the statutory operator and primary mining services contractor for the mine since 2021.

"It has enabled real-time performance data capture at Meandu Mine, replacing the long wait for traditional washability results," said Rocco Prochilo, Operations Supervisor and Metallurgist at BUMA Australia.

"By simultaneously capturing performance across all circuits, the solution provides valuable insight into circuit operation and enables timely adjustments that have resulted in increased yield. It's a practical tool that adds real value," Prochilo said.

Commercial results

The roll-out reflects a wider push in mining to reduce labour-intensive testing and shorten delays between sampling and process adjustments. Dense medium separation has long relied on manual tracer retrieval and laboratory analysis, which can slow operational decision-making on site.

During the prototype and early commercialisation phase, Partition Enterprises completed more than 250 audits with major Australian coal producers. Across those audits, it recorded an average annual profit increase of AUD $10.7 million per site alongside the average yield gain.

It has since signed 25 clients to annual leases for the system, with renewal rates close to 100%, indicating that operators see enough value to continue using the service after the initial deployment period.

HID said the project shows how RFID can move beyond conventional identification uses in industrial settings. In this case, the tags are part of process testing in a specialised mineral recovery application.

"Mining operations are lean, and sites are under constant pressure to do more with less," said Tony Hilder, Sales Director, APAC, Identification Technologies at HID.

"What this project shows is that smart RFID design is not just about identification. It can become a practical tool for operational decision-making, helping miners access reliable data quickly so they can improve yield and strengthen safety outcomes," Hilder said.

Tag design

The hardware used in the system is a customised HDX E-rod RFID tag developed by HID for the dense medium separation environment. The companies said the tag fits within an 8-millimetre cube and was designed for durability, readability at distance and consistent performance in the application.

Partition Enterprises said supplier customisation was important because ferrite rods are used in the dense medium separation process and the tag needed to meet strict operating requirements. The company also cited product support and updates as factors in its decision to work with HID.

"We wanted to partner with a supplier with the ability to customise ferrite rods (used in the DMS process) and deliver ongoing product support and updates. HID RFID tags met our strict quality requirements, and their performance is the best we have encountered for the solution type and small size," said Ray Wood, Manager at Partition Enterprises.

"This has been critical to our product's success," Wood said.

Broader use

Partition Enterprises said the technology is expanding beyond coal operations to other mineral industries that use dense medium separation. That could broaden its use across processing plants where operators are seeking tighter control over cut points, yield and waste streams.

The company has also introduced a companion product called MatchPRO, designed to fine-tune the cut point between useful material and waste. In the first month of test work at five Australian coal mines, the product identified potential yield improvement worth up to AUD $100 million a year.

Founded in 1982, Brisbane-based Partition Enterprises focuses on yield improvement for dense medium cyclones in mineral processing. HID, part of the ASSA ABLOY Group, employs more than 4,500 people worldwide and supports customers in more than 100 countries.