Fly Ash Processing Plant
Grinding system: finish grinding
Grinding mills: vertical roller mill
Fineness: R45μm <12%(Grade I) R45μm <1%(Superfine)
What is fly ash? Flyash is a by-product of coal power plants due to the combustion of coal. It was treated as trash at first. Nowadays, fly ash is collected and reused as an additive material to make mortar, concrete, and cement provided that after grinding to a certain fineness. The grinding process strengthens its volcanic ash like activity to serve in the building material industries. It not only reduces the cost of making concrete but also improves its workability and durability.
Why invest in fly ash processing? The reuse of fly ash conforms to the environmental protection principle, which means it is a sustainable business. What’s more, the profit is considerable. The raw material is resourceful, cheap, and easy to access. The ground fine fly ash has a high value in the perspectives of uses and selling price. The return period is short. According to the feedback of some clients, they got the payback only in one year.
Fly Ash Processing Process
There are different equipment configurations and processes for grinding fly ash. On the market, ultra fine ball mill grinding, Raymond mill grinding, and vertical roller mill grinding all exist. SINOMA prioritizes production efficiency and the quality of finished fineness and has developed the TRM series VRM for fly ash grinding and the TRMF series for fly ash grinding.
Process of TRM series VRM for fly ash grinding
The fly ash raw material is collected by an electrostatic dust collector or jet pulse dust collector and then transported to the powder tank for storage. The fly ash in the powder tank is sent to the fly ash grinding equipment by the wind lock feeder. The material after grinding is collected by a dust collector. The collected finished product is sent downstream or to the finished product warehouse, and then the finished product is loaded and transported.
- Raw material preparation: Fly ash is ground separately, only a silo for raw fly ash is needed.
- Metering system: A metering system under the flyash silo to scale moderate raw materials.
- Conveying: A belt conveyor transports the fly ash to the feeding system.
- Feeding: After electromagnetic separating, the fly ash is fed into the vertical roller mill.
- Grinding: The flyash is ground, selected, and dried in the vertical roller mill.
- Filtering: Processed fine fly ash enters the filter bag and is separated from other residues.
- Bucket elevator: Fine particles are transported to the bucket elevator through an air transfer chute and lifted by the bucket elevator to the finished product storage silo.
- Dust collecting: The gas from the VRM is treated by the dust collector and a draught fan. Some of it goes into the atmosphere, and some cycle into the mill.
Process of super fine fly ash grinding system
The super fine grinding system adopts an upgraded VRM named TRMF series. The TRM series grinding mill is fit to grind Grade I fly ash. Superfine TRMF series can improve the fineness.
This type of VRM has a special design with the grinding table, which has a “concave” shape. The material bed is formed at the inner side and can effectively restrict the eccentric movement of the material. Besides, it can make full use of the centrifugal force to compact and stabilize the material bed, thus appropriate for high fluid material.
TRMF series can grind super fine flyash and be used for Grade I fly ash. Most importantly, TRMF series VRM has lower unit energy consumption than TRM series.
For producing Grade I fly ash (R45μm <12%) For producing superfine fly ash (R45μm <1%)
Improved fineness
Improved stability
Lower consumption
Fly Ash Processing Plant Equipment
Equipment for a fly ash processing plant mainly includes raw material silos, a scale machine, a belt conveyor, a feeder, a grinding machine, a bag filter, a bucket elevator, and a dust collector. Among them, the grinding equipment is essential to the final product quality. SINOMA has created highly efficient VRM for fly ash grinding.
The benefit of the Fly Ash Grinding Mill by SINOMA
Flat or inclined grinding table and cone-type grinding roller.
We are using static and dynamic high-efficiency cage-type separators.
To pressurize the grinding table relatively independently.
Oil lubrication system for grinding roller.
Triple fluoro rubber framework oil seal for grinding roller.
Adjustable gas ring area and dam right height.
Auto lift-up grinding roller and no load startup.
Simple and stable operation, less vibration.
Strict and flexible control of the fineness of the product.
Auto swing-out grinding roller and easy maintenance.
Hardfacing for wear part and easy maintenance.
Configuration of TRM series VRM for fly ash grinding
| Annual output | 600000t/y | 300000t/y |
| Capacity | 90t/h | 45t/h |
| Fineness of product | R45μm≤12% | |
| VRM Power Consumption | 15~18 kWh/t | |
| System Power Consumption | <30 kWh/t | |
| Model of VRM | TRM4341F 2000kW | TRM3131F 1000kW |
| Fan Spec. | 360000 m3/h | 180000 m3/h |
Comparison between TRM series VRM vs ball mill system for fly ash grinding
| Ball mill | Vertical Roller Mill | |
| Fineness | R45μm≤10% | |
| Power consumption of main equipment, kWh/t | 30-45 | 15-18 |
| Drying capacity | Bad(separate drying) | ≤18%(in mill drying) |
| Factors impacting availability | Feed moisture not more than 5% | Repair to grinding table and roller after wear |
| In scale | Difficult | easy |
Types of fly ash
Class C (cementitious): Fly ash is collected from lignite or sub-bituminous coal. Calcium oxide content is above or equivalent to 10%.
Class F (Pozzolanic): Fly ash is collected by calcination of anthracite or bituminous coal. It generally contains less calcium oxide compared to Class C.
Use Of Fly Ash
After being ground by a grinding mill, fly ash can be applied in three ways in cement production.
First, fly ash can be incorporated directly into cement production, replacing part of the cement clinker to reduce the cost of cement and reduce the need for natural resources.
Secondly, fly ash can also be used as a concrete additive to improve the working performance and mechanical properties of concrete, and improve the durability of concrete.
Third, fly ash can also be used to prepare environmentally friendly building materials, such as lightweight aggregates, blocks, etc., to provide a more sustainable solution for the construction industry.
