Maximizing Resource Efficiency with CFlo Combo Mega E5 at Power International Mines UAE

To maximize 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 minimizing environmental impact. Located in Fujairah, the limestone mine utilizes the Combo Mega E5 to transform production waste into valuable resources for diverse industries.

A Bathwal Group company, partnered with CFlo

 

Challenges

Bathwal Group’s Low Silica Limestone ore, highly valued by steel producers across the world, including India, 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.

A Bathwal Group company, partnered with CFlo


This discarded material presented challenges related to waste management, with stockpiles taking up limited land at the mining site in Ras Al-Khaimah, and the need to maximize 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 optimized 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 sale of construction sand to high-demand markets in Abu Dhabi and other regions.

A Bathwal Group company, partnered with CFlo

 

Benefits

Increased Resource Utilization

The Combo Mega E5 installation at Power International Limestone Mines in Ras Al-Khaimah 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.

  • Combo Mega E5 processes waste feedstock with high clay and silt content, effectively removing impurities to produce clean, high-grade construction sand. Previously rejected material is now transformed into profitable products, maximizing the mine’s resource utilization. High-quality construction sand produced is sold to projects across Abu Dhabi and other locations, enhancing Bathwal Group's product portfolio and profitability.
  • Low Silica Limestone Recovery system enables recovery of 5-10mm Low Silica Limestone, meeting quality standards for use in steel manufacturing.
  • The modular design of Combo Mega E5 allows for easy integration into existing operations, minimizing downtime and maintenance, and enhancing operational efficiency.
  • With 95% water recycling during processing, Combo Mega E5 minimizes wastewater, supporting Bathwal Group’s commitment to sustainable practices.

 

Testimonials

"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 Combo Mega E5 allows us to remove impurities from the waste, transforming it into a sellable product. This not only maximizes the use of resources but also benefits our customers in terms of higher quality product, faster production, and sustainability. It also gives us a significant edge over other miners in the industry."
Soham Bathwal
Managing Director, Bathwal Group

"Having personally visited the installation at Power International’s site in Ras Al-Khaimah 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 the exacting quality standards."

Enda Ivanoff
Global Sales Director, CFlo

 

NBM&CW - January 2025

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