As the demand for sustainable practices in the energy and construction sectors continues to rise, finding effective ways to manage byproducts like fly ash has never been more important.
Fly ash is a fine particulate material generated during the coal combustion process. It is carried up through the flue gases and captured using pollution control technologies such as electrostatic precipitators or baghouses. Traditionally, this material was stored in landfills or ash ponds, but that practice poses long-term environmental risks.
A Better Solution: Reuse Over Disposal
Rather than allowing fly ash to accumulate in landfills, many coal-fired power plants are turning to beneficiation—the process of upgrading waste byproducts for beneficial reuse. One of the most valuable applications for fly ash is as a cement replacement in concrete production.
To be suitable for use in concrete, fly ash must meet specific particle size requirements—typically around 45 microns (325 mesh). Consistent sizing not only improves concrete performance but also opens the door for large-scale reuse of fly ash that would otherwise be discarded.
The Role of Air Classification
Achieving this level of precision requires advanced processing technology. That’s where air classifiers come in.
Air classification is a screen-less, efficient method of separating fine and coarse particles using centrifugal force, drag force, and gravity. It allows producers to control particle fineness without the wear and maintenance issues associated with traditional mechanical screens.
The Side Draft Air Classifier: Precision Meets Efficiency
Sturtevant’s Side Draft Air Classifier is a high-performance solution engineered to meet the rigorous specifications required for fly ash used in concrete. This system can classify particles in the 100- to 400-mesh (150–38 micron) range, making it ideal for fly ash processing.
Tested in our full-service materials lab, the Side Draft Air Classifier consistently demonstrated its ability to separate fly ash to required specifications, making it suitable for beneficial reuse.
Why It Matters
By using air classification to process fly ash:
- Power plants can reduce landfill volume
- The construction industry can benefit from a cost-effective cement alternative
- The environmental impact of mining for raw materials is reduced
In short, Sturtevant’s air classification technology helps close the loop—transforming a byproduct into a valuable resource and contributing to a more sustainable future.
Learn more about our solutions for fly ash beneficiation and other industries here.