InGlobal Resources, New Delhi  focuses on sourcing advanced 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.

InGlobal Resources has its main office in NewDelhi and at present  exclusively represent Honcho Block/Brick making machine based on Flashy and also offers Coal Gasifier Producer Gas Fuel equipment from Lead horse, China along with Gas Burners.

To build-up a Fly Ash LWA plant envisaging full utilization of Fly Ash resources, InGlobal Resources provides the followings in co-operation with  China Co. to customers for the entire project:
         – Testing for making LWA from customer fly ash;
         – Tailormade Process design;
         – Equipment sourcing , procurement and supply;
         – Plant Installation, start-up, commission and training;
         – Initial plant trial operation and production.

InGlobal Resources sourced Fly Ash LWA Project proposal

The process uses above 90%  Fly Ash as major raw material mixing with small volume additive, carbonaceous solid fuel and water. The additive can be clay, and coal contributes the carbon depending on the particle size and loss of ignition in fly ash. After agglomeration and pelletizing, the green pellets will be transferred to a sinter machine for sintering. The physical characteristic of LWA product is superior to Natural Aggregates.

TYPICAL PHYSICAL CHARACTERISTICS OF LWA PRODUCT:

Aggregate Size              : 5~16 mm (The size is adjustable by process)
Bulk Density                   : 650-850 kg/m3         
Particle Density              : 1250~1450 kg/m3
Aggregate Strength       : >5.0 MPa (Variation as per size)
Water Absorption          : < 15 %

Capacity Available for LWA Plant

Annual Capacity (m3)100,000
Fly ash consumed, Per year (tons)85,000
Budget equipment price for whole plant(USD) 
Size of building (m2)1200
Power load (kw)720

LWA Properties and Applications:

  1. Structural Lightweight Concrete:-Lighter in weight than standard concrete, but just as strong, LWA offers significant deadload savings. This allows for long cantilevers, slimmer general sections and reduced foundations sizes, enabling designers to produce structures that would be very difficult to build in other materials.
  2. Floor and Roof Screeds:- LWA screeds are easily placed in depths from 30mm to over 450mm. They provide an excellent method of making up levels and offer thermal and sound insulation, which is especially useful on refurbishment projects. Only half the amount of cement is used than with a sand/cement screed, bringing time and cost savings.  Density is also approximately half that of sand/cement screeds, again reducing costs.
  3. Roof tiles:-Specially crushed and blended grades of LWA allow roof tile manufacturers to maximize strength and density, producing lighter units to reduce costs and dead load.
  4. Land Drainage:- Allowing six times more water through its void space than gravel, LWA is anexcellent material for drainage, either in slit trenching or in bulk.
  5. Bulk fill:- LWA can be used bonded (with cement) or unbounded (loose) for maximum flexibility. It’s free draining properties allow significant reductions in hydrostatic pressure. LWA is low density and requires only limited compaction.
  6. Precast:- LWA’s strong but light concrete offers 25% weight savings over normal concrete – ideal for cladding panels, floor decking, lintels, staircases and other structural units.
  7. Arrestor beds:-LWA does not compact over time, so runaway vehicles will always sink into the bed allowing drag forces to stop them safely and minimal damage. LWA is ideal for roadside runway, race circuit and dockside arrestor beds.
  8. Hortag – a growing medium:- Hortag is a special type of LWA which can rapidly absorb up to 15% of its own weight when immersed in water. Water is then released over time to provide a controlled environment.
  9. Filter Media:- LWA is an ideal material for use in biological filter systems where a bacterial film has to anchor and develop.
  10. Refractory:- LWA has excellent thermal insulation properties and is a class 1 fire resistant aggregate.

Energy-Saving and Environmental Protection:

Energy-saving in production process:- Electricity is used for ignition in the 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 draft 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 about 48%-86% 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 of  InGlobal Resources  offered technology would enable handling large quantity of fly ash, thereby not only saving large volume of farming land but also protecting air from pollution.
Dust collector is used in the process to ensure air exhaust to meet environmental protection.

Typical Fly Ash specification:

Fineness factor:                <45μ (325 mesh) about 35%
Fly ash fusion point:         < 1200°C.
Typical Chemical Analysis:  Loss of Ignition: ≤5.0
                                              SiO2: 40~50%
                                              Al2O3: 20~35%
                                              Fe2O3: 10~15%
                                              Na2O: 0.5~1%
                                              K2O: 0.5~1%
                                              CaO: 3~5%

  1. Materials :Dry fly ash from power plant, additives determined by chemical content analyzed at designated  Lab in China. If LOI( mainly carbonaceous fraction)  < 5%, coal needs to be added to assist sintering process. If the fly ash is too coarse, some binder will be required for pelletizing.  Total additive and carbon contributing coal should be less then 5% in the process.
  2. Mixing and Agglomeration – Twin shaft mixer will be used for mixing, pin mixer for agglomeration.
    – Pan type pelletizer will be used for pelletizing, tilting and speed adjustable.
  3. Ignition:– Electricity, Natural Gas or Oil etc. can be used for ignition, depending on cost and availability. The ignition temperature is about 1,000~1,200 oC
  4. Sintering— The green pellets will be sintered to high strength at temperature about 1,200oC with sintering process.
  5. Screen:-  Regular LWA: 5-16mm, Fines: 5-0.160mm
  6. Dust Collection:- Dust in the process can be collected by dust collector with negative pressure, exhaust from chimney < 50mg/m3.
  7. Control system:- Computer control system, real-time monitoring system, user friendly interface,
    Computer controls:
    – temperature at ignition;
    – temperature at dust collector;
    – metering control of fly ash, water, coal and admix (if needed);
    – pelletizing control; operation status of complete plant;
    – emergency stop;
    – diagnosis of fault and trouble shooting;
    – Daily, weekly and monthly reports cover all material consumption and products produced.

Model Plants in China

Fly Ash Silos And Finished Product Storage

Dust Collector

Material handling

Sintering System

Control Panel