STAR® Technology
Reclaiming and Recycling Coal Ash
STAR Technology transforms non-specification coal ash from landfills, surface impoundments, and production material into a consistent, high-quality product for the concrete industry and other industrial applications.
Our proprietary, commercially proven thermal beneficiation process provides a superior, low-carbon, low-loss-on-ignition (LOI) material that exceeds all specifications for additives in concrete.
Sustainable Solution
The STAR Process removes carbon, moisture, and other impurities from coal ash to make material that can be recycled into useful construction materials. The high-quality, consistent material is used in constructing roads, bridges, and buildings because it improves the durability and strength of concrete products and results in a higher-quality finished project.
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Harvested
coal ash is transformed
into high-quality fly ash -
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Recycled
for beneficial use in concrete
and other industrial applications -
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Utilized
to build more durable, lower-cost
roads, bridges, and buildings -
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Renewed
environment with complete
clean-up of coal ash ponds
Best Practice
Economical CCP management strategy
Proven Technology
Over 7.5 million tons of harvested coal ash recycled
Permanent Solution
Removes coal ash from the environment
Sustainable
Environmentally friendly, high-quality products
EPA Qualified
Beneficial and encapsulated use meets all environmental agency requirements
Advanced Design
17 years of technology refinement and operational development
The STAR Process
Self-Sustaining and Exothermic
The STAR Process is digitally monitored and controlled at each STAR Facility. Our proprietary thermal beneficiation process is self-sustaining and exothermic, meaning no fuel is required for continuous treatment, including any drying that may be needed.
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1.
Reclaimed ash is excavated and screened. Post-process material is considered a feed material, not a CCR.
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2.
Feed material is stored in a covered building before hte drying operation.
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3.
Dried feed material is pneumatically conveyed, fully contained, to the STAR Process Island.
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4.
The STAR Process transforms the feed material into a premium fly ash that meets ASTM C618.
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5.
Fly ash is cooled and captured in the product baghouse. Recaptured heat is used to dry the incoming feed material.
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6.
After the fly ash baghouse, sulfur oxides are controlled by a Flue Gas Desulfurization (FGD) Scrubber.
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7.
STAR Fly Ash is pneumatically conveyed to a truck loadout storage silo.
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8.
STAR Fly Ash is delivered in airtight pneumatic tankers to concrete suppliers and other industrial manufacturers.
Frequently Asked Questions
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STAR stands for Staged Turbulent Air Reactor, a process that removes impurities from coal ash in a self-sustaining, high-temperature vessel. Inside the unit, the ash swirls into a fine powder of uniform-sized particles. The transformed product is STAR Ash, a light beige, consistent fly ash suitable for use in a wide variety of concrete construction projects.
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Beneficiation describes improved physical or chemical properties in preparation for a second, beneficial use. In the STAR Process, impurities are removed, and the ash is refined into fine mineral particles for use as a sustainable material, improving the performance characteristics of concrete.
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Permanent removal of coal ash from the environment as it is excavated, processed, recycled, and ultimately encapsulated in concrete for infrastructure projects.
Conversion of coal ash previously stored in ponds or landfills into a sustainable material that improves concrete performance in infrastructure projects.
Adding STAR Ash to concrete significantly reduces its carbon footprint.
Reduced impact on natural resources for mined materials, such as limestone and shale, which are used in the production of cement.
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STAR Technology has ben safely used for more than 17 years. The first commercial STAR Plant began operating in 2008, as we recognized the need for additional innovatino to meet market needs for quality fly ash for concrete production. The next generation STAR processing facility opened in 2012. In 2015, we began commercial operations at the latest-generation STAR Plant, designed to reclaim and recycle coal ash from surface impoundments (ponds). STAR units are designed with the latest control technologies to ensure environmental, worker, and public safety.
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A STAR Plant will occupy a few acres of land, with the tallest structures approaching 120 feet. The tallest structures will be a concrete storage dome and a steel load-out silo. These structures store the fly ash.
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STAR facilities are designed to be at or below 85 decibels at a distance of three (3) feet from the equipment. The anticipated noise at the property boundary is estimated to be less than 70 decibels, which is equivalent to normal speech at three (3) feet. STAR facilities will comply with the county industrial noise ordinance at the property line.
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STAR facilities are equipped with modern emissions monitoring and control equipment that meet state and federal environmental regulations to protect air quality.
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There is no odor associated with the plant.
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Trace elements are immobilized within the concrete structure. For years, the U.S. Environmental Protection Agency (USEPA) has endorsed the beneficial use of fly ash as a supplemental filler in concrete. The EPA has performed thorough studies and risk assessments of fly ash in concrete and determined that it is safe.
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STAR Ash is loaded directly from storage units into pneumatic tanker trucks. Pneumatic tankers are vacuum-sealed, enclosed tanks that prevent outside air and moisture from entering. Because STAR Ash is delivered in these tanker trucks, no dust is released into the atmosphere.
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Each STAR Plant requires approximately 20 full-time employees to operate and maintain the facility 24/7. Some locations may also require part-time help for product load-out operators. The transportation of fly ash creates jobs for local drivers and mechanics. Approximately 25 professional CDL drivers are hired per plant.
