How a mining company achieved maximum XRF accuracy – without months of method development

When your XRF measurements directly determine commercial valuations, accuracy isn’t just a nice-to-have – it’s everything. A mining company recently faced this reality when it needed a turnkey solution for iron ore analysis with stringent accuracy requirements. What happened next demonstrates why calibration strategy matters more than you might think. 

The challenge: When every percentage point means money 

The mining operation came to us with clear requirements: analyze iron ore with maximum possible accuracy. At typical transaction volumes, even minor analytical errors translate into substantial financial losses. When you’re buying or selling iron ore by the thousands of tons, a 0.1% error in Fe₂O₃ measurement can mean hundreds of thousands of dollars — especially at the million‑ton scales typical in iron ore operations. 

They needed measurements they could trust, which would stand up to commercial scrutiny and contractual obligations. 

The initial requirements 

The customer provided a detailed list of elements with concentration ranges spanning from major components (Fe₂O₃ at 20-70%) down to trace elements at 0.005%. They needed coverage for 15 different elements, each critical to ore valuation and processing decisions. 

Why standard calibration approaches fall short 

You might think the solution is straightforward: buy some certified reference materials, create calibration lines, and start measuring. But for high-accuracy applications, that approach has serious limitations. 

The problem with universal calibration  

Synthetic standards can enable universal calibrations where a single method works acceptably across diverse sample types. When you need general-purpose analysis, this approach works well. 

But remember what’s at stake in the mining use case: concentration measurements directly determine commercial valuations. At their transaction volumes, “acceptable” accuracy isn’t good enough. 

Why matrix matching matters 

Maximum accuracy demands matrix-matched calibration – reference materials that replicate your actual sample mineralogy. Natural iron ore has complex matrix effects. The way X-rays interact with iron-rich minerals differs from synthetic oxide mixtures. Using non-matrix-matched standards introduces systematic errors that no software algorithm can fully correct. 

The customer needed calibrants that behaved like real iron ore, not just materials with similar elemental compositions. 

The solution: A comprehensive calibration strategy 

Here’s how we assembled a calibration suite that delivered maximum accuracy without the customer spending months sourcing materials and developing methods. 

Layer 1: Synthetic standards for coverage 

We started with WROXI CRM Base with PRO extension, providing initial coverage for 21 elements across wide concentration ranges. This established the fundamental calibration framework with interference-free formulations and complete elemental coverage. 

These synthetic standards eliminated the gaps and overlaps that would have complicated method development. 

Layer 2: Matrix-matched natural CRMs 

We conducted comprehensive market screening and identified 12 commercially available iron ore CRMs that met matrix-matching requirements. These weren’t random selections – we used our knowledge of reference material vendors worldwide to assemble the optimal suite for iron ore analysis. 

This is where our vendor expertise matters. The customer would have spent weeks researching catalogs and still might have missed critical materials. We identified the right standards in days. 

Layer 3: Custom synthetic standards for gaps 

Even with 12 market CRMs, compositional analysis revealed insufficient reference values for copper, barium, lead, and zinc at the concentrations needed. Natural iron ore CRMs simply don’t provide coverage for these elements at relevant concentrations. 

We designed and manufactured three custom synthetic standards specifically to address these gaps. Because we’re an ISO17034-accredited producer, we could create exactly what the application required. 

Layer 4: Independent validation 

We selected three additional market CRMs for independent validation, ensuring the entire calibration system performed accurately on materials that weren’t used to build the calibration lines. 

The outcomes that matter to your operation 

The results speak for themselves: 

Time savings: Independent CRM sourcing would have required months. The customer lacked comprehensive vendor knowledge and would have made suboptimal selections. Without our synthetic standard production capability, compositional gaps would have persisted indefinitely. 

Accuracy beyond customer capabilities: The achieved accuracies exceeded what the customer could have accomplished independently. Insufficient XRF expertise would have prevented them from anticipating critical requirements for high-quality method development. 

Immediate operational deployment: Complete application deployment occurred immediately post-installation. Without expert support, method development would have extended over multiple weeks – potentially months – creating serious operational disruptions. 

Think about what that means for your operation. XRF systems must achieve operational status rapidly following installation. Extended method development severely impacts production processes dependent on XRF for process control. Every week spent developing methods is a week of compromised operations. 

Commercial confidence: The mining company now makes buying and selling decisions with measurement confidence. Their XRF results withstand contractual scrutiny because the calibration strategy was designed for maximum accuracy from the beginning. 

The questions you should be asking 

When you’re evaluating XRF solutions, don’t just ask about instrument specifications. Ask about calibration strategy: 

• Who will define your realistic analytical requirements? Vendors who just take your specifications without a feasibility analysis will let you discover limitations after installation. 

• How will you source matrix-matched reference materials? General-purpose catalogs often don’t include the specialized materials you need. 

• What happens when commercial CRMs don’t cover all your elements? Without access to custom synthetic standard production, you’re stuck with gaps. 

• How long will method development take after installation? Instruments sitting idle while you develop methods represent enormous opportunity costs. 

The difference between buying equipment and solving problems 

This mining company didn’t just buy an XRF spectrometer. They received a complete analytical solution designed by experts who understand what it takes to achieve maximum accuracy in real-world applications. 

They got matrix-matched calibrations deployed rapidly, minimizing operational disruption while maximizing analytical performance. They got measurements they can trust for commercial decisions worth millions of dollars. 

Most importantly, they avoided the months of frustration that come from trying to piece together calibration materials and methods without comprehensive XRF expertise. 

Your application deserves the same approach 

Whether you’re analyzing iron ore, cement, steel, geological samples, or any other complex matrix, your calibration strategy determines your analytical success. 

Malvern Panalytical delivers integrated solutions: ISO17034-accredited production of certified synthetic standards, comprehensive requirements assessment, strategic market analysis, and custom standard design. We provide the complete turnkey approach – sample preparation protocols, method creation, and analytical validation after installation at your facility– so your XRF system achieves operational status immediately. 

The question isn’t whether you can develop XRF methods independently. The question is whether you can afford the time, compromised accuracy, and operational disruption that come with doing it alone. 

Contact Malvern Panalytical to discuss your specific application requirements and discover what’s possible when a calibration strategy is designed by true XRF experts.