SonoAsh - Fly Ash Beneficiation

The SonoAsh process utilizes several process stages depending on the product requirements and the fly ash feedstock. The key aspect of the process is to produce a product whose quality is independent of the characterization of the feedstock, just as a manufactured product would be.

For SonoAsh cement products, the process utilizes a physical ash conditioning stage to improve the particle size distribution and surface area. For the best quality results we utilize our proprietary sonic reactor which utilizes vibrational energy. We also classify and separate small particle size ash for use in premium concretes.

Secondary stages of magnetic and electrostatic classification help remove carbon, arsenic, iron, ammonia and mercury compounds. The resulting SonoAsh is a non-hazardous and non-leachable product which can be utilized in construction and concrete products.

Particle Size Distributions

The following table shows a summarized particle size distribution for SonoAsh versus typical Class F fly ash produced from power stations burning bituminous coals in the USA. Our process operates on both wet lagoon ash and dry ash (shown below) directly from the power plant. The table shows the particle sizes that 10, 50 and 90 % of the ash is smaller than.

Carbon Reduction

Carbon exists in fly ash mainly as a result of incomplete combustion of the coal. The ASTM standards for the use of fly ash in concrete set a maximum carbon content because of the adverse impact of carbon upon air entrainment admixtures used to control setting. The increasing use of activated carbon to control mercury emissions from power stations adds to the carbon content in fly ash. While mercury in activated carbon does not leach from concrete, the activated carbon in fly ash is problematic to air entrainment and behaves differently, making removal more difficult. The SonoAsh process makes removal of carbon much easier as can be seen from the example in the data below.