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Titan - 'Separation Technologies' Triboelectric Ash Beneficiation Process

Added on 22-03-2013

Company

Titan

Year

2011

Business challenge

The main environmental challenge of the cement industry world wide is to control and even minimise its direct CO2 emissions evolving from the production of cement. At the same time, other heavy industries seek different ways to efficiently manage and even utilise their waste. Fly ash, produced as a residue of coal fired Power Plants, is usually considered a waste product; due to its high content in carbon particles, it cannot be used as a suitable mineral in the construction industry, nor can its carbon content be a useful and cost-effective additive or replacement of cement. 

Description

The proprietary technology of Separation Technologies LLC (ST), from Titan Group company, consistently transforms, through separation, a waste poduct into coal which is recycled as a fuel on one hand and into a quality material for application in the cement and concrete industry, on the other.

The use of the beneficiated mineral product offers a cost-effective cement additive or replacement, depending on the case, that directly reduces CO2 emissions from clinker producing kilns, by substituting the cement otherwise produced from clinker.

It is a solution that requires no additional chemicals, produces no emissions and in addition offers a fuel replacement for coal-based industries.

ST operates commercial-scale fly ash beneficiation facilities, processing poor quality fly ash into high quality pozzolanic material. ST's triboelectric process reduces the carbon content of fly ash, producing a consistent, low loss on ignition (LOI) ash for use as a substitute for cement in concrete and cementitious products.

Impact

  • Seasonality of both the Electricity and the Construction Sectors, i.e. more electricity (energy) is consumed in the winter means much more fly ash is produced while cement and concrete consumption is usually low. Accordingly storage space for the processed ash is needed for optimal operations and logistics all year round.
  • Quality of the feed fly ash may impact the efficiency of production

Challenges/Lessons learned:

  • Nearly 5 million tons of ProAsh®, processed low carbon ash, have been produced from "waste", since 1995,reducing CO2 emissions and waste landfilling.
  • Two Carbon ReturnTM systems operate in the US and Canada with 2 more under construction in the UK, to store and convey the ECOTHERMTM, carbon-rich product. Power generating facilities using these systems recover the otherwise wasted fuel value of the carbon.
  • An innovative approach in "waste management" has offered new environment-friendly products for construction.

In other words:

With every ton of Pro Ash used :

  • Enough energy is saved to provide electricity to an average home for 24 days
  • The landfill space conserved equals 455 days of solid waste produced by the average citizen in a developed country
  • The reduction in CO2 equals 2 months of emission from an automobil

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