Coal Fired Electrical Generation

As the coal-fired electrical generation industry turns to fluidized bed combustion (FBC) to meet Clean Air Act standards, it confronts the challenge of managing high-lime content residuals, also produced by Powder River Basin (PRB) coal. The client contracted with DustMASTER to develop a system for successfully preparing FBC fly ash for dustless landfill disposal.

DustMASTER specified a 60 TPH Series II mixing system, which is made up of a Turbin style pan mixer, a hydraulically operated discharge door, a metered water system and control with a programmable controller which includes 100% manual override and load cell readout. The fast and powerful action of the Turbin mixer, combined with precise water metering and control, enabled the operator to achieve a dust-free product while minimizing the risk of forming a cementitious paste.

Prior to implementing this system, our technicians conducted manual tests of the fly ash at our facility, with results being monitored and recorded while moisture percentage was added by weight. Our batch mixing system can control the reaction of mixing water with FBC materials containing lime to prevent self-cementing. The final product was dust free, transported well, had favorable compaction, and retained its consistency through successful landfill disposal.

This project had a fast turnaround time of just one week for testing and documenting results. To learn more about how DustMASTER handled FBC and PRB fly ash, please see the chart below or contact us directly. For a PDF of FBC application, click here. For a PDF of PRB application, click here.