Production of useful silica sand from lignite overburden for a world leader in glass
CFlo has supplied two silica sand processing plants to a world leader in the glass industry, converting lignite mining overburden into clean, washed silica sand. The first plant was supplied in 2012 at Jhagadia Industrial Estate near Rajpardih, Gujarat, and a 50 tons per hour plant has since been commissioned at Neyveli, Tamil Nadu, both recycling more than 95% of process water.
India holds huge lignite reserves in Gujarat, Rajasthan and Tamil Nadu, mined principally by GMDC in Gujarat and Neyveli Lignite Corporation in Tamil Nadu. Mining generates large volumes of overburden with the properties of silica sand, but it needs processing to reach quality specifications for glass, foundry and construction applications. These overburdens had been stockpiled in the mines for years because no economical recovery process existed.
CFlo designed, supplied and installed a MicroGrader range silica sand washing plant with Fine Screen to wash and screen sand at 600 microns. The washed and sized sand is further cleaned in a two-stage Hydrocyclone system to remove clay, producing washed, sized and clean sand ready for market. The plant includes a water recycling system as standard, recycling more than 95% of process water.
The Neyveli plant, the second supplied to the glass leader, is an integrated unit with a dual-pass sand washing and water recovery unit on the same chassis, fed by conveyor from a feed hopper and belt feeder. The customer was drawn to the plant's compact, interconnected layout, which saves space and power, and its fully automatic operation, which reduces dependency on manual labour and eliminates manual error. CFlo is now working with both customers to further reduce iron content, with beneficiation test work indicating suitability for float glass quality.
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