Sintered Fly Ash Light Weight Aggregate Production

InGlobal Resources, New Delhi focuses on sourcing proven plant and technology, which can produce Artificial Lightweight Aggregate (LWA) from fly ash, a waste product of coal burning power plants. The product is an excellent alternative to natural quarried aggregate, being strong, light and consistent.
  • Sintered Flyash light weight aggregate substitutes natural stone aggregate/chips in Concrete, reducing dead weight.
  • It can also be used in production of light weight precast Concrete Blocks, for use in load and non-load bearing elements.
  • Local availability of Flyash from Thermal Power plant opens up good potential scope, and more so where stone aggregates are costly or scarce.
  • It meets Concrete properties requirements to achieve high compression strength, slump/slump loss, pumpability/workability measured by splitting tensile strength, flexural modulus and modulus of elasticity in Concrete.

Process:

Sintered Fly Ash
Finished Product Green Pallets
Adopted process uses above 90% fly ash mixed with water and in some cases a small volume of additives. After agglomeration and pelletizing, the green pellets are sintered at high temperature, producing light weight aggregate whose characteristics are similiar to natural aggregates.

Applications:

  1. Structural Lightweight Concrete
  2. Floor and Roof Screeds
  3. Roof Tiles
  4. Land Drainage
  5. Bulk Fill
  6. Precast
  7. Arrestor Beds
  8. Hortag – A Growing Medium
  9. Filter Media
  10. Refractory

Energy-Saving and Environmental Protection:

Fly Ash Lawa Process
- Energy-saving in production process
Producer gas from Coal is used for ignition / start of sintering process. After the first layer of sintering bed is ignited, the rest of green pellets will be sintered by the self-contained carbon in fly ash with downdraft air. Gas/Oil can substitute electricity wheresoever available and at economic cost.

- Energy-saving products
Fly ash LWA has an excellent thermal insulation property. The concrete made by fly ash LWA has thermal insulation ratio 0.118-0.6w/m.k, which is much lower than regular concrete.

- Environmental Protection
Fly ash is a by-product of coal burning power plant. Most of fly ash is dumped as waste material. Using InGlobal Resources sourced plant and technology; would enable handling large quantity of fly ash, thereby not only saving large volume of scarce land but also protecting air from pollution.

-Dust in the manufacturing process can be collected by dust collector with negative pressure; exhaust from chimney <50mg/m3.

Upcoming Project:

JSPL Angul, Orrisa :

LWA Capacity: 3,00,000 m3 per year
NBM&CW September 2013
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