YTL Cement, a leading cement company, overcame concrete quality issues by using a CFlo washing plant to convert crusher dust into graded M-Sand.
YTL Cement, a subsidiary of conglomerate company – YTL Corporation, is widely recognized as the nation's foremost and largest homegrown cement company. With a remarkable 70-year history, the company has been a driving force behind the construction of homes, buildings, and infrastructure projects in South-East Asia. Presently, YTL Cement operates across Malaysia, Singapore, and Vietnam.
In addition to its cement plant, YTL Cement also operates its own quarry to source raw materials. They possess a mine in Kuala Lumpur, Malaysia with a dedicated crusher. However, the unwashed dust (0-5mm) produced by the crusher remained unsold and unused. YTL uses this material for captive consumption in their batching plants, supplying sand for concrete manufacturing. Unfortunately, the sand they were using did not meet the required segregation standards, resulting in inferior-quality concrete.
Seeking a solution, they searched for a washing plant to utilize the dust from their crushing plant.This quest led them to us, as we offered a suitable washing plant to efficiently convert the crusher dust into graded M-Sand.
The process of producing M-Sand involves crushing hard rocks into smaller fractions in a controlled manner to achieve a desirable particle shape. However, this crushing operation results in a significant amount of ultra-fines, which not only reduces the commercial value of the crushed material but also poses technical challenges for its use in concrete production.To overcome these issues, our advanced wet processing techniques were employed to consistently grade the sand, ensuring it remains free from adulteration and impurities. This improvement in sand quality also led to enhanced project efficiency by reducing cement consumption.
In 2016, YTL approached CFlo, the pioneer of wet processing equipment, to meet their need for an ecologically sound and quality- controlled supply of M-sand. As the first sand-washing company that came to their minds, we took the responsibility of finding the ideal solution for YTL's sand-washing requirements. After careful site scouting and understanding their needs, we proudly introduced them to the revolutionary Combo X70, a state-of-the-art sand-washing equipment perfectly suited for their Batu Tiga Quarry situated near Kuala Lumpur, Malaysia.
The Combo X70 is a highly sought-after wet sand processing equipment that can operate for more than 16 hours a day, conserving power and recycling water efficiently. The plant has a rated power capacity of 110 KW and can produce 70 TPH (tons per hour) of construction-grade M-Sand for the ready-mix concrete industries. Additionally, it can process fine particles with an accurate cut point of 75 microns, enabling zero liquid discharge, 95% water recycling, and requiring minimal maintenance. By converting fine stone dust to high-quality M- Sand, the plant not only adheres to strict cost-effectiveness but also ensures a high output quality and great returns for the owner.
The integration of the Combo X70 into their operations brought about transformative benefits for YTL. By leveraging the cutting-edge technology and innovative design of the Combo X70, they experienced significant improvements in the efficiency of their sand-washing processes. Notably, the equipment facilitated the sustainable production of construction-grade M-sand, which is an environmentally friendly alternative to natural sand.
In response to the escalating demand and the resounding success of the initial sand-washing plant in consistently meeting YTL's expectations without compromising on product quality, the company swiftly expressed the need for a second sand-washing equipment with similar features.
We being a customer-centric organization, promptly acknowledged their requirements and swiftly provided a fitting solution - another Combo X70, renowned as one of our best M-Sand Plants. The decision to opt for the Combo X70 was a testament to the trust YTL had in our capabilities to deliver top-notch equipment and address their specific needs.
Throughout the process, our dedicated sales experts collaborated closely with YTL, ensuring the client's peace of mind by offering detailed insights into the plant's efficiency and its ability to effectively address YTL's pain points.The sales team left no stone unturned in assuring our client that the second Combo X70 would seamlessly integrate with their operations and maintain the high standards set by the first plant.
The seamless cooperation and resounding success of the initial plant paved the way for the 2nd Combo X70 to be commissioned within an impressively short period of less than 12 months from the installation of the first plant.
We are delighted with CFlo's Combo X70 sand-washing plants! Their outstanding efficiency and reliability have greatly contributed to our quarrying success. The Combo technology has helped us to enhance the quality of M-Sand by controlling the level of silt and delivering the right gradation. As we continue to expand, we eagerly anticipate more achievements with CFlo as our trusted partner.
We are delighted to play a significant role in such sustainable projects like YTL Cement and eagerly anticipate the opportunity to be involved in many more in the near future.
