Concrete with fly ash
Heyl Patterson

The Benefits of Fly Ash Beneficiation

Concrete with fly ash

Fly ash, a byproduct of coal combustion, has been accumulating in landfills for decades. However, through fly ash beneficiation, we can transform it into a valuable resource. Fly ash beneficiation involves reclaiming fly ash from slurry ponds and landfills using specialized equipment like Heyl Patterson’s rotary dryers and calciners

The reclaimed fly ash is then recycled into a consistent, high-quality product suitable for a wide range of industrial applications, particularly in the concrete industry. By repurposing fly ash, we mitigate waste and harness its potential for sustainable innovation.

What is Fly Ash Beneficiation?

Fly ash is composed of fine particles carried away by the flue gases produced during coal combustion. It is typically collected in electrostatic precipitators or baghouses to prevent it from causing air pollution.

The beneficiation of fly ash recovered from power plants or landfills involves the removal of excess carbon, organic compounds, water, ammonia, and other undesired elements. The goal is to convert this waste material into useful products and reduce its environmental impact.

Heyl Patterson’s Role in Fly Ash Beneficiation

Heyl Patterson’s rotary dryer and calciner systems are at the forefront of the fly ash beneficiation process.

Rotary Dryers: The Heart of Beneficiation

Heyl Patterson’s rotary dryers are crucial in fly ash beneficiation, customized for each use. They can efficiently handle fly ash with varying moisture levels. They speed up processing without degradation, yielding consistent, high-quality fly ash products that can replace Portland cement cost-effectively.

Key Features: 

  • Accelerated processing without product degradation
  • Customization for specific applications
  • Low energy consumption
  • High capacity and heat recovery for improved efficiency
  • Custom materials of construction, including carbon steel, stainless steel, and special alloys

Rotary Calciners: Precision in Action

Heyl Patterson’s rotary calciners provide drying and calcining of fly ash through an indirect heat source. This technology maintains enclosed processing space and specific process atmospheres, such as inert, oxidizing, and reducing environments, ensuring the highest quality product without degradation from heat sources.

Key Features: 

  • Feed systems featuring closed hoppers or pressurized tanks
  • Custom internals for maximum heat and mass transfer
  • Plug flow operation for product uniformity
  • Movement can be parallel or counter to material flow
  • Integral coolers to cool the product before discharge

Benefits of Using Heyl Patterson’s Equipment

The advantages of using HP’s high-quality equipment for recycling fly ash cannot be overstated. By choosing our rotary dryers and calciners, you can

  • Meet the stringent ASTM C-18 standards for Loss of Ignition (LOI).
  • Reduce carbon footprint while recycling fly ash.
  • Separate heavy metals like mercury and arsenic.
  • Consistently provide top-quality fly ash tailored to specific applications.

Unlocking the Full Potential With CPEG’s Lab Testing

With state-of-the-art equipment, CPEG’s lab supports the fly ash beneficiation process. CPEG’s Lab Testing capabilities cover several tests specifically designed for fly ash. Here are a few examples: 

  • LOI Analysis
  • Moisture and Chemical Content Analysis
  • Particle Size Distribution
  • Heavy Metal Analysis

CPEG’s lab testing ensures compliance and optimizes the fly ash beneficiation process for maximum profitability by performing several useful tests.

Here are some compelling reasons to use CPEG’s Test Lab: 

  1. Quality Assurance: Rigorous fly ash tests to meet industry and application standards
  2. Customization: Accurate lab results to tailor the beneficiation process for specific applications
  3. Eco-friendliness: Removal of impurities and heavy metals from fly ash to eliminate environmental concerns.
  4. Cost-Efficiency: Fly ash content optimization to enhance industrial process efficiency and reduce costs.

Expert Systems for Fly Ash Beneficiation

Heyl Patterson fly ash drying and calcining systems are specifically engineered to reduce air velocity and ash carryover, providing a consistent product that is easy to handle, store, and transport.

With decades of experience, accurate lab testing, and exceptional customer service, Heyl Patterson prides itself on offering high-quality, innovative solutions to industrial challenges.

Contact us today to optimize your fly ash beneficiation process or discover how we can assist your industrial processes.