The fly ash, discharged by coal-fired power plant, can pollute soil, water and air badly, which is also harmful to people’s health. It not only occupies a great deal of land, but also heavily pollutes local environment.
HANDA’s HDFR series fly ash recycling plant will convert waste fly ash into a kind of hard and honeycombing artificial lightweight aggregate, a product which can be used to economically replace mined stone in concrete, as well as other uses. Fly ash recycling plant uses approximately 95% fly ash mixed in some cases with water and in some cases a small volume of additives. After agglomeration and pelletizing, the green pellets are sintered, creating an aggregate whose characteristics are superior to natural aggregates.
1. HDFR fly ash recycling plant process
Taking fly ash (dry-discharged fly-ash or wet-discharged fly-ash) as main raw material (mixing amount always over 95%), through measurement, mix and agitation, prilling, balling and over 1100°C calcination process, HDFR fly ash recycling plant can produce light, high strength and multiple functional new materials.
2. The technical features of HDFR fly ash recycling plant
■ With PLC process control, real-time monitor and Chinese menu display, operators can not only control continuously but also perform individual operations. It only needs 3 to 5 workers for the whole line normal production with low labor intensity.
■ Large scale: large-scale automated production with 60,000m3, 100,000m3, 200,000m3 and 300,000m3 production line to choose. We can also design and produce specific scale production line according to customers’ requirements.
■ Large quantity recycling of fly ash: With the unique nucleation technology of fly ash, without adding other additive, the blending amount of fly ash is up to 95%~100%.
■ High yield: over 95% yield.
■ Environmental protection: Using negative pressure induced air for concentrated dust collecting. The concentration of flue gas and dust discharged from the chimney outlet of dust catcher meets national standard.
■ Low energy consumption: static sintering, good sealing, low air leakage rate, over 50% energy conservation.
3. The technical data of HDFR fly ash recycling plant
| Annual consumption of fly ash (m3/y) | 78,000 | 130,000 | 195,000 | 260,000 |
| Annual output of lightweight aggregate (m3/y) | 60,000 | 100,000 | 150,000 | 200,000 |
| Degree of automation | Full auto | Full auto | Full auto | Full auto |
| Area of main workshop (m2) | 750 | 1000 | 1200 | 1400 |
| Installed capacity(KW) | 580 | 720 | 1100 | 1300 |
| Production worker number in one shift | 4 | 4-5 | 5-6 | 5-8 |
| Blending ratio of fly ash | ≥95% | ≥95% | ≥95% | ≥95% |
| Range of fly ash | Dry-discharged fly-ash or wet-discharged fly-ash | Dry-discharged fly-ash or wet-discharged fly-ash | Dry-discharged fly-ash or wet-discharged fly-ash | Dry-discharged fly-ash or wet-discharged fly-ash |
| Yield | ≥95% | ≥95% | ≥95% | ≥95% |
| Dust emission index (mg/m3) | ≤20 | ≤20 | ≤20 | ≤20 |
4. Fly ash LWA properties by HDFR fly ash recycling plant
| Name | Unit | Index |
| Size grading | mm | 5-20 succession |
| bulk density | Kg/m3 | 650-850 |
| Cylinder compress strength | MPa | ≥5 |
| Strength grade | MPa | ≥30 |
| Water absorption | - | ≤1.7% |
| Particle form factor | - | ≤1.4 |
| Silt content | - | ≤0.02% |
| Sulfide, Sulfate | - | ≤2% |
| Ignition loss | - | ≤1.2 |
| Porosity | - | ≤0.17% |
5. Fly ash LWA applications
The fly ash is a kind of waste solid resource. HDFR fly ash recycling plant will convert waste fly ash into a kind of hard and honeycombing artificial lightweight aggregate, which could be applied into the following field. By this, it will realize the zero discharging of fly ash generated by the coal power plant.
■ Structural-Buildings
■ Structural-Bridges
■ Precast Concrete
■ Masonry
■ Geotechnical Landfill
■ Drainage
■ Green Roofs
■ Aquaponics
■ Biological filter systems
■ A growing medium
■ Refractory
■ Pipe bedding
■ Sports surfaces and play areas