Vedanta FACOR Chromite Ore Beneficiation

Vedanta FACOR (Ferro Alloys Corporation Limited) Jajpur, Odisha, India Chromite Ore Beneficiation Oremax

Vedanta FACOR Achieves Sustainable Chromite Ore Beneficiation with CFlo Technology

Industry Challenge: Lower Grade Chrome, Higher Costs

The ferrochrome industry has been dealing with decreasing chromite ore quality, requiring costly and resource-intensive beneficiation processes that often trade yield for purity. FACOR, a leader in chrome ore mining, and CFlo, a champion of sustainable wet processing solutions, have collaborated to improve chrome concentrate production at FACOR's Jajpur, Odisha mines. This initiative aims to enhance FACOR's Ferrochrome production and minimise chrome value loss in tailings, contributing to a more eco-friendly and efficient future.

Benched terraces of an open-cast mine with dark overburden in the foreground

FACOR: 40 Years of Excellence in Ferrochrome

Ferro Alloys Corporation Limited (FACOR), one of India's oldest and most respected producers of High Carbon Ferrochrome, embodies the spirit of responsible and sustainable mining practices. For four decades, they've been known for consistent supply, best-in-class quality, and service in the domestic and global markets. Excellence is their motto, achieved through stringent quality and cost control measures, coupled with a deep commitment to ESG principles. But even heroes face challenges. FACOR's abundance of low-grade chromite ore threatened their sustainability goals and production capacity

Wet slurry discharging from a screen deck onto the material below

FACOR Aims to Improve Chromite Ore Processing

Traditional beneficiation methods, while improving the final product, came at a hefty price: low yield and high processing costs. FACOR needed a solution that could unlock the potential of their low-grade ore, maximising resource use and minimising environmental impact.

Higher Yield & Lower Cost with Oremax: CFlo's Advanced Mineral Beneficiation Solution

After a thorough assessment of the client's feed, CFlo recommended a custom-designed Oremax, a chrome beneficiation plant offering the following features:

Feeding
Product Dewatering
Basic Scrubbing
Product Stockpiling
Intense Washing
Water Management
Efficient Screening
Sludge Management
Double-stage De-sliming

Oremax offered a multi-faceted solution:

Boost in Yield Grade: Oremax meticulously separates valuable chromite from waste, significantly improving the feed for FACOR's existing beneficiation plant. This resulted in both higher final product grade and increased yield thereby maximising resource utilisation.
Cleaner Tailings, Greener Future: The process also yields cleaner tailings, minimising environmental impact and potentially opening doors for future repurposing opportunities.
Streamlined Production: Some of the high-grade fine particles processed by Oremax, could be directed straight to the ferrochrome plant with no further beneficiation & hence streamlining the process.
Sustainable Design: Oremax embodies CFlo's commitment to sustainability. The compact, skid-mounted design minimises space and relocation needs, while the water and sludge management system facilitates zero discharge and 95% water recirculation, minimising environmental footprint. The patented plant design ensures minimum unit power consumption.

Table depicting the feed and product grades

	Feed	Product 1	Product 2	Tailing
Record	Input Grade	Grade	Recovery	Grade	Recovery	Grade	Recovery
Data 1	22.43	24.33	34.7	30.91	37.52	11.4	27.78
Data 2	16.34	16.22	47.7	19.51	33.79	12.16	18.5
Data 3	15.33	21.03	53.78	20.4	35.43	7.73	10.79
Data 4	20.27	24.96	55.05	33.07	36.42	8.87	8.53
Data 5	22.05	23.19	49.53	26.48	39.43	9.76	11.04
Data 6	19.01	20.53	42.66	32.69	25.12	8.24	32.22
Data 7	16.6	20.02	35.87	25.21	27.81	8.11	36.31

The data in the Table above indicates how low-grade ore bordering on waste value has been upgraded to plant-grade feed. This has resulted in a great boost in resource utilisation, reduction of unusable ore inventory, and at the same time ensuring the final reject grade remains well within government-specified limits.

"CFlo's Oremax system has been a game-changer for FACOR at Jajpur," says Dr. A. Bandyopadhyay, Chief Technologist at CFlo. "It has not only improved their yield and product quality but has also helped them achieve significant cost savings and environmental benefits. CFlo's innovative solutions and commitment to sustainability make us a true partner in progress."
Dr. A. Bandyopadhyay, Chief Technologist at CFlo

Beyond Words: A Partnership for Progress

FACOR's success story underscores the transformative power of innovative technology and collaborative partnerships. By embracing CFlo's Oremax solution, they have not only navigated the challenge of low-grade ore but have emerged as a leader in sustainable and efficient ferrochrome production, paving the way for a greener future for the industry