Asset Utilisation Optimisation · MINING
Find the throughput your CHPP is leaving in the plant.
Coal handling and preparation plants lose throughput in a hundred small ways — equipment failures, process bottlenecks, feed-quality variation — most of which never get to the daily report. The XMPro AO Platform monitors equipment condition, process flow and feed quality continuously, identifies where throughput is being lost, and ranks the interventions that will recover it.
What's getting in the way today.
CHPP throughput is the result of many tightly coupled processes, and losses hide across all of them. Five pressures compound:
Equipment failures
Breakdowns in conveyors, crushers and screens cause significant disruption — and the root cause is rarely the asset that stopped first.
Process inefficiencies
Bottlenecks, poor-quality feed and incorrect process settings drag throughput quietly until aggregate output drops.
Unplanned downtime
Reactive maintenance and unexpected equipment failure compound throughput loss — each event costs more than the asset itself.
Feed-quality variation
Coal quality drifts shift by shift, and the plant rarely adjusts process parameters fast enough to keep up.
Compliance overhead
Maintaining environmental and safety compliance while pushing throughput rates is a tightening squeeze.
CHPP Throughput Loss Monitoring — how it works.
A continuous picture of equipment condition, process flow and feed quality — mirrored as a digital twin, with ranked throughput-loss recommendations routing to the right responder.
The platform integrates equipment-condition signals across conveyors, crushers and screens, process flow rates at each stage, incoming coal-quality measurements, energy consumption and historical downtime/maintenance records. A digital twin of the CHPP supports bottleneck visualisation and what-if process tuning. Predictive analytics anticipate component failures with confidence scoring and time-to-action; process models adjust parameters for varying coal quality and flow conditions. Threshold breaches and detected bottlenecks generate ranked recommendations, with timely interventions routed to operators before throughput loss compounds.
*Illustrative dashboards from the platform. Layout, signals and decision points are scoped per site.
Scope this for your operation.
Tell us about your fleet, your control maturity and the lever that matters most. We’ll map this use case to your starting point.
What this looks like in operation.
Throughput loss made visible
Aggregate output drops are decomposed into specific equipment, process and feed-quality causes — with ranked recovery actions.
Bottlenecks before they bite
Live flow modelling surfaces process bottlenecks while they’re still adjustable, not after they’ve dragged the shift.
Predicted equipment windows
Conveyor, crusher and screen condition signals move maintenance into scheduled slots, protecting throughput.
Built for these industries.
Other solutions you might explore.
Not a concept. In production.
XMPro is deployed at Tier 1 global operators across asset-intensive and mission-critical industries — delivering measurable results across predictive maintenance, process optimisation and operational intelligence.
Now pushing the frontier.
MAGS agents are achieving what no other industrial platform has demonstrated — sustained autonomous operations at enterprise scale.
