Phenikaa Hue Mineral Processing, Vietnam
Chooses CFlo’s Plug & Play Technology
CFlo collaborated with Phenikaa Hue Mineral Processing, part of Vicostone Group, to design and install a 30-35 TPH silica sand processing plant in Hue Province, Vietnam. The project aimed to supply high-quality silica sand for Cristobalite, a specialised form of silica prized for its industrial applications due to its high-temperature stability, chemical resistance, and fine particle properties.
Background
Phenikaa acquired silica sand mines to secure raw material supply for their operations across Southeast Asia and India, needing better control over silica sand quality and costs. CFlo was selected for their expertise in silica sand processing and proven record in delivering reliable solutions.
Properties of Cristobalite
- Thermal Stability: Ideal for high-temperature applications, such as refractory materials.
- Chemical Resistance: Essential for ceramics, paints, and coatings
- Optical and Cosmetic Applications: Suitable for fillers and pigments due to its fine particle size and brightness
Solution Implemented by CFlo
CFlo installed the Micrograder BT50, a custom silica sand washing system that meets Phenikaa’s stringent quality requirements for Cristobalite production by delivering high-grade, low-iron content sand.
CFlo’s Plug and Play technology is a modular, pre-assembled approach wherethe machine parts are fully assembled, wired, and tested at the factory before being sent to the project site in shipping containers. These parts are designed to be easily and quickly connected or "plugged in" on-site. Installation is streamlined, as components are delivered ready for immediate setup, similar to how Lego blocks fit together. The system minimises the need for complex on-site assembly and electrical work, allowing for faster installation, reduced downtime, and fewer potential issues.This approach is especially advantageous for projects with tight timelines, as it ensures a swift and efficient deployment.
The effectiveness of the Plug and Play technology can be witnessed on the timelapse video recorded on this job site.
Other Features of the Micrograder BT50
- Integrated System: Handles feeding, trash removal, screening, washing, dewatering, stockpiling, water recycling, and sludge management. Fully automated, reducing manual input and ensuring consistent product quality
- Energy Efficiency: Processes 30-35 TPH with optimised power consumption of 196 kW.
- Water Recycling: Recycles 95% of water, using only 5-7 cubic meters per hour, minimising environmental impact
This setup has created a reliable, high-quality silica sand supply chain, enabling Phenikaa to control quality and manage costs more effectively.
Challenges and CFlo’s Approach
Phenikaa’s previous reliance on external suppliers resulted in fluctuating costs and inconsistent quality. CFlo addressed these issues by analysing Phenikaa’s needs, conducting lab tests on their raw materials, and designing a plant tailored to meet their quality and cost requirements.
Why Phenikaa Chose CFlo
- Complete Solution: CFlo offered an end-to-end solution with efficient power and water usage
- Proven Expertise: After a site visit to a CFlo plant that had been operational for over five years, Phenikaa’s team saw firsthand CFlo’s ability to maintain high performance and long-term support
- Sustainability: CFlo’s focus on reducing waste aligned with Phenikaa’s commitment to environmental responsibility
When I met the Phenikaa team, I recognised the opportunity to partner in a way that would deliver real, measurable value. We worked closely with them to understand their unique challenges and goals. By showcasing CFlo’s experience in high-quality silica sand processing, we were able to demonstrate our commitment to quality, efficiency, and sustainability. It’s been rewarding to see this project come to life and make such a strong impact on their operations.”
"Securing this project was a significant achievement for CFlo, as it involved understanding and meeting the high standards set by Phenikaa. We knew our technology and expertise could offer them an edge in quality and operational efficiency. Through this collaboration, we’ve strengthened Phenikaa’s supply chain and set up a sustainable processing solution that reflects CFlo’s dedication to innovation and customer satisfaction."
Conclusion
Since the plant’s launch in September 2024, CFlo’s Micrograder BT50 has delivered strong outcomes for Phenikaa, enhancing product quality by consistently producing low-iron silica sand that meets high standards required for Cristobalite and other industrial applications. The optimised plant design, with efficient power and water usage, has significantly reduced operational costs, while the advanced water recycling system has minimised environmental impact, supporting Phenikaa’s sustainability goals. Together, these benefits have strengthened Phenikaa's position in the market, providing them with a reliable and cost-effective silica sand supply chain.
In pictures
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