Facile Route for Effective Separation and Full-Scale Recycling of Fly Ash and Unburned Carbon

The synchronous production of high-quality unburned carbon concentrate and cleaned ash from high LOI (loss on ignition) fly ash without yielding secondary solid waste is a dilemma issue. In this study, a viable flotation process with one rougher and two cleaners is developed for simultaneously obtaining carbon concentrate with a yield of 18.00% and an ash content of 17.49% and cleaned ash with a yield of 82.00% and a LOI of 4.63% from fly ash, reaching 84.72% of combustible substance recovery and 80.66% of flotation perfection index. The characteristic analyses of the stage by stage releasing products using laser particle size analysis, XRF, XRD, and SEM-EDS demonstrate that the inevitable factors that lead to a remaining higher ash content in the one-step flotation carbon concentrate are the random entrainment of mineral particles in the size range of 0-20 μm, especially the quasi-colloidal parts within 0-12.5 μm and the weak selective collection of fine-grained conjoined granules in the size range of 0-40 μm. Consequently, at least two cleaning steps are required for the effective separation of unburned carbon and ash. Furthermore, batch flotation test results show that diesel is superior to kerosene in the collection of unburned carbon, with an optimum dosage of 800 g/t; no. 2 oil acts more positively than MIBC for the separation of unburned carbon and ash, with an optimal dosing amount of 600 g/t; the optimum pulp concentration and flotation time are as follows: 100 g/L and 3.5 min for the rougher, 45 g/L and 2 min for the first cleaning, and 30 g/L and 3 min for the second cleaning. This study provides an economically feasible technological solution for the full-scale recovery of high-LOI fly ash in one step and avoids the problem of secondary solid waste that would have been generated in previous studies.