Maximising resource efficiency with Combo Mega E5 at Power International limestone mines, Fujairah

Power International (Bathwal Group) Fujairah, UAE Limestone Beneficiation

Power International, a Bathwal Group company, partnered with CFlo to process rejected material at its Fujairah limestone mine. The Combo Mega E5 now transforms minus 10mm production waste into high-quality construction sand and recovers 5-10mm Low Silica Limestone, with 95% of process water recycled.

The Challenge

Bathwal Group's Low Silica Limestone ore, highly valued by steel producers in India and beyond, demands precision in particle sizing and quality. During production, particles below 10mm were rejected due to high clay and silt content in the form of ultrafines, which can degrade limestone quality. The discarded material created waste management problems, with stockpiles taking up limited land at the mining site, and the group needed a system capable of processing these ultrafine particles and transforming waste into high-value products.

The Solution

CFlo's Combo Mega E5 transforms the minus 10mm feedstock into two product streams. It removes clay and silt impurities to produce clean, high-grade construction sand, and it recovers 5-10mm Low Silica Limestone that meets quality standards for steel manufacturing. The construction sand is sold into high-demand markets in Abu Dhabi and other regions, creating a new revenue stream, while the modular design allowed easy integration into existing operations with minimal downtime.

95%

process water recycled

5-10mm

Low Silica Limestone recovered from rejects

<10mm

reject feedstock converted into saleable construction sand

The Results

Previously rejected material is now transformed into profitable products, maximising the mine's resource utilisation and adding a new construction sand revenue stream across Abu Dhabi and beyond.

"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 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 but also gives us a significant edge over other miners in the industry."
– Soham Bathwal, Managing Director, Bathwal Group

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