Maximising Resource Efficiency with Combo Mega E5 at Power International Limestone Mines in Fujairah, UAE
To maximise resource efficiency and meet stringent quality standards, Power International, a Bathwal Group company, partnered with CFlo to find a solution capable of processing their rejected material while enhancing product quality and minimising environmental impact. Located in Fujairah, the limestone mine utilises the Combo Mega E5 to transform production waste into valuable resources for diverse industries.
Challenges
Bathwal Group’s Low Silica Limestone ore, highly valued by steel producers in India and beyond, demands precision in particle sizing and quality. During production, particles below 10mm are rejected due to their high clay and silt content in the form of ultrafines, which can negatively impact limestone quality. This discarded material presented challenges related to waste management, with stockpiles taking up limited land at the mining site in Fujairah, and the need to maximise resource recovery. Bathwal Group required a system capable of processing these ultrafine particles effectively, transforming waste into high-value products.
Solution
The Combo Mega E5 installation has optimised this process by transforming the minus 10mm feedstock into high-quality construction sand and recovering valuable 5-10mm particles as Low Silica Limestone. This efficient solution not only enhances resource recovery but also provides a new revenue stream through construction sand sales catering to the high-demand markets in Abu Dhabi and other regions.
- Construction Sand Production: Combo Mega E5 processes waste feedstock with high clay and silt content, effectively removing impurities to produce clean, high-grade construction sand.
- 5-10mm Low Silica Limestone Recovery: The system also enables recovery of 5-10mm Low Silica Limestone, meeting quality standards for use in steel manufacturing.
Benefits
- Increased Resource Utilisation: Previously rejected material is now transformed into profitable products, maximising the mine’s resource utilisation.
- New Revenue Stream: High-quality construction sand produced by Combo Mega E5 is sold to projects across Abu Dhabi and other locations, enhancing Bathwal Group's product portfolio and profitability.
- Operational Efficiency: The modular design of Combo Mega E5 allows for easy integration into existing operations, minimising downtime and maintenance.
- Environmental Impact: With 95% water recycling during processing, Combo Mega E5 minimises wastewater, supporting Bathwal Group’s commitment to sustainable practices.
" I am thrilled to announce that we have installed a state-of-the-art wash plant at our limestone mine in Fujairah. This marks a major advancement for Bathwal Group. Mining often produces a lot of waste, but we saw an opportunity to turn this waste into something valuable. Our new wash plant allows us to remove impurities from the waste, transforming it into a sellable product. This not only maximises the use of resources but also benefits our customers in terms of Higher quality product, faster production and sustainability but also gives us a significant edge over other miners in the industry."
Having personally visited the installation at Power International’s site in Fujairah and observed the quality of the end products, I can confidently say that this installation exemplifies what the Combo Mega E5 was designed to achieve. We are thrilled to see the Combo Mega E5 helping Bathwal Group transform what was once waste into valuable, high-grade construction sand and Low Silica Limestone that meet exacting quality standards."
Conclusion
The Combo Mega E5 installation at Power International Limestone Mines in Fujairah has redefined waste processing, turning production challenges into profitable opportunities. With solutions like these, CFlo and Bathwal Group are pioneering sustainable, efficient mining practices that serve multiple industries.
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