Zero-Water Coal Separation Technology | Successfully Operating in South Africa
We are proud to present our largest and most technologically advanced project to date – the successful design, manufacture, installation, and commissioning of a Patented Air-Based Coal Beneficiation Plant in South Africa.
This breakthrough project replaced conventional water-based coal washing systems with our proprietary Air-dry separation technology, enabling coal beneficiation using 100% air – with zero water consumption.
Project Overview
Under a formal supply agreement with Genet Mineral Processing (Pty) Ltd, South Africa, we engineered and delivered a complete Aria Dry Coal Beneficiation Plant designed to separate coal from ash and stone using controlled airflow dynamics.
The plant has been successfully operating for the past 3+ years, delivering consistent and reliable performance in real mining conditions.
The Technology – Dry Coal Beneficiation by Air
Traditionally, coal beneficiation relies heavily on water-intensive washing systems. Our patented Aria Dry Coal Beneficiation system eliminates water entirely by using:
- High-capacity centrifugal fans
- Aerodynamically designed separation chambers
- Multi-stage cyclones with ceramic lining
- Precisely controlled airflow dampers
- Real-time instrumentation & PLC-based control systems
As per the Technical Offer, the plant is designed for airflow volumes exceeding 237,000 m³/hr, ensuring optimal separation efficiency
The system is hot commissioned and guaranteed to perform within 95% of technical specifications, as defined in the agreement.
Why This Project is a Game Changer
100% Water-Free Operation
No water usage. No tailing ponds. No slurry management.
Environmentally Sustainable
Ideal for water-scarce regions and environmentally regulated zones.
Reduced Operating Costs
Eliminates water procurement, pumping, settling, and treatment costs.
Lower Civil Infrastructure
No need for large water handling infrastructure.
Faster Installation & Commissioning
Structured commissioning protocol with staged load testing up to 100% rated capacity
Scope of Supply
- Complete airflow-based coal separation plant
- Structural screen enclosure assembly
- Multi-stage cyclone systems
- Ceramic-lined separation chambers
- Screw conveyors & rotary valves
- High-pressure industrial fans
- Electrical panels, VFDs & automation
- Instrumentation & pressure monitoring systems
- Full commissioning and performance validation
The total commercial value of the project exceeded R17.7 million (excluding VAT), reflecting the scale and complexity of the installation.
Proven Performance – 3 Years of Continuous Operation
Since commissioning, the Aria Dry Coal Beneficiation Plant:
- Has operated reliably under mining conditions
- Achieves stable separation efficiency
- Meets design airflow and pressure parameters
- Delivers consistent coal quality improvement
The plant continues to operate successfully, demonstrating the long-term viability of dry coal beneficiation technology.
Introducing This Technology to the Indian Market
With increasing pressure on water conservation, environmental compliance, and sustainable mining practices, Air-Based Coal Beneficiation is the future of mineral processing in India.
This technology is particularly suitable for:
- Coal washeries
- Power plants
- Sponge iron industries
- Mining companies in water-scarce regions
- ESG-compliant operations