Summary

Super Material from Fly Ash Year 2024
Nghia Tran Co-Founder ProtectGD LLC
3413 Looking Glass Dr, Bellevue, NE, 68123, USA
Email: Nghia.tran@protectgd.com
Tel 402-215-8946
Coal ash from thermal power plants, compressed coal ash particles. We have invented a new technology, patented in the United States, Vietnam, and India. This technology can produce Geopolymer materials from solid waste such as fly ash from thermal power plants, ash from waste-to-energy plants, red mud from bauxite, and other sludge wastes, forming HARD PARTICLES that do not disintegrate in water or seawater, enduring for thousands of years.
Summary
We have invented a new technology, patented in:
United States: Patent No. US 11,629,097 B2
Vietnam: Patent No. 34529
India: Patent No. 390491
This technology can produce Geopolymer materials from solid waste such as fly ash from thermal power plants, ash from waste-to-energy plants, red mud from bauxite, and other sludge wastes, forming HARD PARTICLES that do not disintegrate in water or seawater, enduring for thousands of years (according to Davidovits (1991)).
The Geopolymer materials exhibit valuable properties as follows
Reduces leaching of toxic heavy metals (Arsenic, Lead, Mercury, and Cadmium) in fly ash hundreds of times compared to the original fine powder form. This complies with the strict fly ash management regulations of the US EPA 2024 and protects water sources without the need for expensive lining systems at ash disposal sites.
Can absorb other heavy metals such as Pb, Cd, Cu, Zn, and Ni from water, seawater, sludge, and air, similar to the capability of activated carbon.
Can absorb and permanently retain CO2 from air and seawater up to 20% of the material's weight.
Can be used as a base material for road construction, load-bearing materials for road and airport runway foundations, and can be used with natural sand for land reclamation.
Can last thousands of years, resistant to alkaline, acid, and harsh weather conditions. Continuous hydration and chemical reactions within the material increase its hardness and durability over time.
Technology Features
Capable of producing artificial sand Geopolymer products with a capacity of up to 2,000 tons/day.
The production line consists of common equipment from various industries, supplemented with technical know-how for compatibility with the technology and large enough capacity to recycle all stored and untreated solid waste in different countries.
Supporting Documents
Leaching test results of heavy metals in fly ash and original fly ash particles at the Institute of Environment and Resources, Vietnam National University, Ho Chi Minh City.
Load-bearing capacity (CBR) test results of fly ash particles at SGS.
Compressive strength and density test results of fly ash particles at SGS.
Compare Coal Ash Disposal Costs
Compare Coal Ash Disposal Costs
Radiation Reduction table
Radiation Reduction table
CO2 absorption chart of coal ash pellets
llustrating how geopolymer pellets capture up to 5% of their weight in CO2
Reduction in heavy metal leaching (As, Hg, Pb, etc.). Analysis Result: 
Reduction in heavy metal leaching (As, Hg, Pb, etc.). Analysis Result:  
Current Situation
The mentioned wastes are mostly buried or stored in ponds, causing air pollution (dust and fine dust causing respiratory diseases) and water pollution (due to carcinogenic substances like Arsenic, Mercury, Lead, and Cadmium leaching over time into water sources). Our technology addresses these pollution issues.
There is an urgent need to handle billions of tons of stored fly ash over the past 40 years in countries like the US, India, China, and Vietnam due to long-term hazardous accumulation at fly ash disposal sites directly affecting water sources. Currently, the US has about 2 billion tons in storage, with approximately 1 billion tons needing immediate treatment, according to Earthjustice.
Solution
We compact solid waste like fly ash, red mud, sludge, etc., at high speed and large capacity to form hard fly ash particles.
Please see the 3D model of the artificial sand production line from fly ash below. Fly ash is mixed with water and binder to achieve the necessary moisture, this mixture is then pelletized to form fly ash particles of various sizes. These particles are conveyed to a continuous dryer for hardening, a process that takes only a few minutes. The artificial sand fly ash particles are naturally cooled and ready for immediate use. The compressive strength and CBR of fly ash particles can be adjusted.
Please see the 3D model of the artificial sand production line from fly ash below. Fly ash is mixed with water and binder to achieve the necessary moisture, this mixture is then pelletized to form fly ash particles of various sizes. These particles are conveyed to a continuous dryer for hardening, a process that takes only a few minutes. The artificial sand fly ash particles are naturally cooled and ready for immediate use. The compressive strength and CBR of fly ash particles can be adjusted.

Benefits
Significant reduction in toxic leaching: Our patented technology reduces the leaching of harmful substances hundreds of times, ensuring that toxic elements do not pollute groundwater or surface water. This is crucial for public health and environmental protection.
Compliance with the 2024 US EPA Regulations: The new EPA regulations on fly ash management require stringent measures to prevent environmental pollution. Our technology meets and exceeds these requirements, providing a cost-effective solution for utilities to achieve compliance. By converting fly ash into stable pellets, we eliminate the need for extensive and expensive lining systems at disposal sites.
Creating valuable construction materials: The recycled artificial sand from fly ash has a high California Bearing Ratio (CBR) making it ideal for use in road bases, land reclamation projects, and even airport runways. This not only addresses the disposal problem but also contributes to the construction industry by providing a sustainable alternative to natural sand and aggregates.
Environmental and economic benefits: Our technology transforms fly ash from waste into a resource, reducing the need for landfilling and associated disposal costs. It supports a circular economy by recycling industrial by-products into valuable materials, promoting sustainability and economic efficiency.
Geopolymer technology for CO2 reduction: The Geopolymer materials derived from our technology can effectively reduce and absorb CO2. Independent tests have shown that our Geopolymer materials can absorb up to 20% of their weight in CO2. This not only mitigates the environmental impact of fly ash but also contributes to climate change mitigation efforts. Using our Geopolymer technology in construction projects can significantly reduce carbon emissions and help achieve sustainability goals.
Advantages
We have patents in the US, Vietnam, and India, with pending patents in China.
The world's largest industrial waste, such as coal fly ash and the problem of waste incineration ash, red mud, etc., is a major environmental issue for many countries worldwide. We can handle it all.
Fly ash packaged products (fly ash pellets) meet the beneficial use criteria of the US EPA.
Geopolymer materials from fly ash have been approved by the Indian government for use in road construction as of December 31, 2021.
Experience
We can provide technical advice for the installation and operation of coal ash recycling plants to produce geopolymer artificial sand according to our patented design.
Patent granted by the USA
Patent granted by the USA

Technology Patent granted by VIETNAM
Technology Patent granted by VIETNAM

Equipment Patent granted by VIETNAM
Equipment Patent granted by VIETNAM

Patent granted by INDIA
Patent granted by INDIA