Abstract: There is provided a process for converting wet fly ash into a useful product such as cement replacement or industrial filler. A first amount of wet fly ash is provided. The wet fly ash is fed into a mixing chamber. An amount of aggregate, such as stone, is provided. The aggregate is also fed into the mixing chamber where the wet fly ash is mixed with the aggregate. The mixed wet fly ash and aggregate is fed into a drying chamber where the mixture is heated, thereby drying the fly ash and heating the aggregate. The heated aggregate is separated from the fly ash. The heated aggregate is fed back into the mixing chamber. A second amount of wet fly ash is added to the mixing chamber where is it mixed with the heated aggregate. The heated aggregate assists in drying the second amount of wet fly ash. Once in cycle, the process is continuous.

Abstract: There is provided a method and apparatus for segregating ponded coal combustion materials for use in various products, such as block sand products, concrete or mid-size sand products and fine ash products. After screening ponded coal combustion raw materials to remove the first size material for use as a block sand product, the remaining material passes through a rotating magnetic separator to remove iron bearing materials and then to a hydraulic classifier for separating coarse materials, middling size materials and fine materials. The coarse materials are combined with the first size materials and are de-watered to form the block sand product. The middling size materials are segregated into low, middle and high specific gravity materials by the use of spirals. The low specific gravity material is passed through a sizing sleeve and coarse low specific gravity material is combined with the middle specific gravity material and are de-watered to form a concrete or mid-size sand product.