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RockTron’s proprietary process, refines fly ash (PFA) from power stations fired with bituminous hard coals. This offers, for the first time, a range of high quality pozzolans with controlled particle size for combination with Portland cements. The resulting products are of defined and consistent quality and are available throughout the year.
The process, based on flotation, removes and separates the majority of those compounds in the fly ash which are either unwanted in, or deleterious to, cement and concrete. These include coke (coal without volatiles), cenospheres and magnetite. The resulting refined pozzolan is classified into two particle size ranges for use in combination with Portland cement.
The RockTron proprietary process can refine both stockpiled and run-of-station fly ash to offer consistent supplies of quality-controlled pozzolans to meet the demands of the cement and concrete industries.
Removal of the deleterious constituents from fly ash, together with the achievement of controlled quality, allows RockTron pozzolans to be used in higher proportions with Portland cement than has been viable for fly ash in the past. Thus, each product gives all manufacturers of concrete, mortars, grouts and specialist cementitious materials the opportunity to regain the advantage over alternative construction materials.
The RockTron process successfully removes the constraints associated with the use of run-of-station (unprocessed) fly ash, namely: char (LOI), variable particle size and problems with availability. Thus, with RockTron pozzolans concrete can be manufactured more cost-effectively to provide a durable product with lower embodied energy.
The ability of the RockTron process to refine fly ash from dumps enables the large-scale removal of polluting industrial waste, site remediation and conservation of natural resources.
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The RockTron process represents a major opportunity to both reduce the cost of concrete and significantly decreases the large-scale carbon emissions currently associated with the concrete industries.
In recent years the lack of consistent quality run-of station fly ash has resulted in the increased use of ground granulated blastfurnace slag (GGBS). The RockTron process for refining fly ash from bituminous hard coal-fired power stations produces a pozzolan of increased competitiveness when used with Portland cement.
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