Balaji Quartz quadruples output with India's first quartz washing plant

Balaji Quartz Pvt. Ltd (Goyal Group of Minerals) Rajasthan, India Quartz Washing

Balaji Quartz, part of the Goyal Group of Minerals and one of India's largest quartz mine owners, replaced a labour-intensive dry screening and washing system with CFlo's tailored Combo Exo, India's first quartz washing plant. Production rose from 70-80 TPD to 300-350 TPD, and material once discarded as waste is now converted to M-Sand, making it a zero wastage plant.

The Challenge

Since 2018, the owners had been struggling with labour costs and overuse of water that failed to match the quality of output. The rudimentary dry screening and washing system was extremely labour intensive and did not wash quartz lumps thoroughly. With no means to recycle water, wastage was at its maximum, and the abrasive lumps routinely damaged the system, making it dysfunctional, especially during monsoons. Attempts to convert -5mm dust to M-Sand had also failed.

The client wanted better dust removal from quartz lumps, efficient size categorisation to industry standards, and increased production of pristine snow-white quartz.

The Solution

As one of CFlo's early quartz washing projects, rigorous laboratory tests were conducted using various grades of quartz particles before introducing the Combo Exo, a washing and beneficiation system that economises manpower, recycles water, increases production capacity and produces multiple grades of industry-ready products from a single, easy-to-install plant.

A Jet Attrition System liberates dust from the surface of quartz lumps, and the plant segregates output into three products: +25mm to -80mm, +5mm to -25mm, and +0.075mm to +5mm. The same plant produces washed quartz for the quartz industry and M-Sand for the construction industry. It is fully automatic, compact, low on power consumption, has zero effluent discharge and includes a superior sludge management solution. The Combo Exo was launched on 17 September 2020, and the client is now investing in a second plant with a higher running capacity of 50-60 TPH.

300-350 TPD

production, up from 70-80 TPD

product grades from a single plant, plus M-Sand

Zero

wastage, with former waste converted to M-Sand

Zero

effluent discharge

We have a lot of quartz stock and with this plant, we are getting more recovery. Not only are we getting different industrial grades but the material that was earlier considered wastage is now being converted to M-Sand. So this is a zero wastage plant!
– Nakul Goyal, Director, Balaji Quartz Pvt. Ltd.

More proof