Livic Minerals produces AFS 50-55 foundry sand at 100 TPH with the Micrograder BT100
Livic Minerals LLP commissioned CFlo's Micrograder BT100 silica sand processing plant in Bharuch, Gujarat: a 100 TPH modular facility with Zero Liquid Discharge (ZLD) technology producing foundry-grade sand of AFS 50-55 for precision automobile casting. Raw material costing Rs 250 per tonne is upgraded to a primary product fetching around Rs 1,200 per tonne, with by-products at Rs 600 per tonne.
Automotive casting requires sand that is clean, uniformly sized and of high quality to ensure casting integrity; green sand casting relies on high-quality silica sand alongside bentonite clay, water and coal. The customer was missing a lucrative opportunity by being unable to supply the required grade for this application. Water shortage was another major constraint, demanding a system with a high percentage of water recycling.
CFlo's Micrograder BT100 integrates wet sizing, precision separation at 600 microns, Hydrocyclone clay removal extracting a final 600-106 micron product, dewatering, water recycling and sludge management on a modular platform. AFS grade can be adjusted using interchangeable parts, and coarse and fine graded construction sand is produced as a by-product.
The plant runs up to 20 hours per day on 300 kW of power and 24 m³/hour of water, recycling 95% of process water with ZLD so no liquid waste is discharged. The modular design minimised footprint and civil works, allowed the whole plant to be housed inside a building, and achieved operational start-up in less than 2-3 weeks of equipment arriving on site. A PLC control panel in an air-conditioned cabin automates the entire process, and settled clay can be collected for making cold-bonded bricks.
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