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:


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:

Structural Lightweight Concrete
Floor and Roof Screeds
Roof Tiles
Land Drainage
Bulk Fill
Precast
Arrestor Beds
Hortag – A Growing Medium
Filter Media
Refractory

Energy-Saving and Environmental Protection:

- 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.