Geopolymer Technology
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Unique Technologies for Recycling and Processing Coal Ash and Red Mud Year 2024

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ARTIFICIAL SAND from COAL ASH and MUD
Summary
We have invented a new technology and have patented it now
  • United States: Patent number US 11,629,097
  • Vietnam: Patent number 34529
  • India: Patent number 390491
This technology can recycle solid waste, forming hard particles, which can reduce the leaching of toxic substances in coal ash by dozens of times (even hundreds of times), and does not disperse in water or sea water. ..., sustainable for thousands of years (according to geopolymer material theory). Types of solid waste can be::
  • Fly ash , thermal coal ash and slag
  • Ash from a waste incineration plant to generate electricity
  • Bauxite red mud from aluminum mining industry
  • And other types of sludge .
These types of solid waste will be recycled into artificial sand, which can meet aggregate standards for building road foundations, leveling, aggregate for concrete, and sea reclamation. With the capacity of a recycling line, it can reach millions of tons per year.
Characteristics of this new technology and material are:
  • Special linings may not be needed in coal ash dumps to meet the requirements of EPA's 2024 coal ash rule, because after being compressed into pellets, the leaching of toxic substances will be significantly reduced.
  • The recycled product, artificial sand from this ash material, has a feature that has never been researched and known, which is achieves a very high CBR (California Bearing Ratio) index for road materials (tested according to ASTM D1883) or even airport runways. It can replace or mix natural materials such as sand and stone to make road foundations, sea reclamation , etc. Currently, the country with the largest need for sea reclamation in the world, Singapore, is facing difficulties due to limited natural sand resources, and artificial sand products will be an effective solution for Singapore. This product can also replace sand as road foundations in most countries due to the increasingly limited supply of natural sand (for example, Vietnam is lacking tens of millions of tons of natural sand to renew roads through current projects).
  • This artificial sand product from ash is suitable and sustainable for the environment frequently flooded , alkaline soil, sea water , frost, etc.
  • Waste incineration , waste incineration , or coal-fired thermal power plants will become "clean plants" when connecting this fly ash processing line to the plant's operating system.
  • Land used to bury solid waste will become "clean land" when the waste is processed into products useful to society.
  • The production line is a collection of common equipment in different industries, supplemented with technical know-how to suit the technology and has a large enough capacity to recycle all stored and untreated solid waste in countries.
Test Results

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PRESENT
The above-mentioned wastes are mostly buried or stored in reservoirs, causing pollution to the air environment (dust and ultra-fine dust causing respiratory diseases) and water sources (due to toxins that can cause cancer such as arsenic, mercury, lead, and cadmium accumulate over time and seep into water sources) . Our technology will solve the above pollution.
The need to process billions of tons of fly ash that have been stored for more than 40 years in countries such as the US, India, China... is urgent because toxic substances that have accumulated for many years from fly ash landfills have been and are being used directly affects the groundwater resources of these countries. Currently, the US is storing about 2 billion tons according to Earthjustice statistics, of which about 1 billion tons need to be processed immediately.
Vietnam's need for road embankment materials is also very large and there is a shortage of more than 10 million tons. With this technology, this is a dual-benefit solution, both solving the amount of coal ash and slag remaining in landfills (including saline ash) and creating materials to meet the need for backfill materials for roads at affordable prices.

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SOLUTION
We granulate solid waste such as fly ash, red mud, sewage sludge, etc., using the high-speed and high-capacity pressure compression method. This process creates artificial sand pellets with a satisfactory CBR load-bearing index for sea reclamation materials, road foundation materials, or even airport runway construction. The CBR can reach 130, and compressive strength can exceed 60 MPa, tested according to ASTM D1883 and ASTM C330.
Please see the 3D model of the artificial sand production line from fly ash below. The fly ash is placed into the mixer to blend well with water and binder to achieve the required moisture. This mixture is then fed into the granulator to produce fly ash pellets of various sizes and arbitrary length. The fly ash pellets follow the conveyor belt into the oven to harden, a process that takes only a few minutes. The fly ash pellets, now transformed into artificial sand, will be naturally cooled and ready for immediate use.
The compressive strength and CBR of fly ash pellets are adjustable.

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BENEFIT
  • In addition to the public health and environmental benefits of eliminating solid waste. This artificial sand product can be used as a foundation for roads, construction works , sea reclamation and can be used as lightweight aggregate for concrete.
  • Reduce the use of natural sand and stone , which is a non-renewable resource.

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FAVORABLE
  1. We have patents in the US, Vietnam and India and are waiting to be granted patents in China .
  1. The world's largest industrial waste such as coal ash and the problem of incinerator ash , red mud, etc., are a major environmental problem for most countries in the world. We can handle them all.
  1. Packaged fly ash products (fly ash pellets) comply with the US EPA's criteria for beneficial uses of coal ash.
  1. This Geopolymer material from fly ash has also been approved by the Indian government for use in road construction from December 31, 2021.

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EXPERIENCE
We can advise, provide equipment, and transfer technology to factories recycle fly ash waste to produce artificial sand according to our patented design .
Patent granted by the USA
Technology Patent granted by VIETNAM
Equipment Patent granted by VIETNAM
Patent granted by INDIA