Coal: Size Matters

Our client’s current coal size process relied heavily on manual surveys, which often detected oversize material too late in the flow. Delayed detection meant oversize coal was not addressed immediately, increasing the likelihood of customer complaints when product specifications were not met. The situation also exposed the company to potential client penalties and declining customer satisfaction due to inconsistent product quality.

COSMOS: Turning Conveyor Vision into Coal Quality Intelligence

SQE introduced COSMOS, a Smart Coal System, CCTV- and computer vision–based platform that automatically measures coal size on the conveyor belt and identifies the frequency and volume of oversize material in real time. With NVIDIA-powered processing, COSMOS delivers high-speed video analytics, low-latency detection, and scalable edge deployment—enabling our client to:

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Continuously analyzes coal flow to detect oversize material

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Receive notifications when oversize exceeds defined limits

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Generate structured reports to support quality evaluation and continuous improvement.

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Adjust crusher settings to reduce oversize occurrence.

Impact

Measurable Outcome

100% Real-Time

Coal size detection coverage enabling immediate field response for crusher adjustments

Field Assessment · Coal Quality Team

Earlier oversize detection

Oversize coal flagged before reaching processing stage, preventing costly equipment damage and quality failures

Manual → Automated

From periodic field inspections to continuous size monitoring, directly improving downstream customer satisfaction

Coal: Size Matters