Kumar Cargo Solutions pioneers India's first coal overburden to M-Sand plant

Kumar Cargo Solutions (KCS) Singrauli, Madhya Pradesh, India Mining Overburden (OB) to Sand

Kumar Cargo Solutions (KCS), a mining and minerals turnkey contractor with a 20-year track record, partnered with CFlo to commission India's first overburden conversion project: a 160-180 TPH plant at Northern Coalfields Limited's site in Singrauli, Madhya Pradesh, that repurposes coal overburden into high-quality graded M-Sand.

The Challenge

Northern Coalfields Limited (NCL), one of India's leading coal producers and a subsidiary of Coal India Limited, faced a pressing challenge with the overburden generated during mining operations. Committed to responsible mining, NCL envisioned repurposing this overburden into valuable IS:383 grade sand and began a competitive public-private partnership (PPP) process to establish a plant separating sand and aggregates from overburden (OB).

The Solution

KCS partnered with CFlo to commission a 160-180 TPH overburden-to-sand plant at NCL's Singrauli site. CFlo's patented wet processing facility transforms high-silt mining overburden into graded M-Sand: -5mm overburden is fed into dual-wash technology with Hydrocyclones to remove waste solids, then dewatered and screened for a low-moisture finished product.

The compact all-in-one plant reduces water usage by up to 95% through recycling and maintains a strict silt content limit of 4-5% for top product quality, with systematic sand and silt management, wastewater control and slurry management. The extracted sand has wide applications in the construction industry.

India's first

overburden conversion project, a Coal India (NCL) pilot

160-180 TPH

plant capacity

95%

reduction in water usage through recycling

4-5%

silt content limit maintained in the finished M-Sand

The Results

The project sets new benchmarks for eco-conscious mining, easing riverbed erosion and preserving aquatic ecosystems by substituting river sand with M-Sand recovered from mining waste.

More proof