ZAP Engineering fly ash separation facility EPCM — United States

Mineral Processing

EPCM Delivery of a Fly Ash Separation Facility

EPCM delivery of a brownfield fly ash separation facility integrating electrostatic separation technology with an existing power plant.

Project Overview

ZAP performed detailed engineering, procurement, and construction management for a brownfield fly ash processing facility utilizing electrostatic separation technology. The work integrated the existing power plant, the fly ash separation technology, and balance-of-plant material handling equipment into a single coordinated facility, converting a power-plant byproduct into a marketable low-carbon mineral product.

Electrostatic Separation & Silo Integration

The existing Unit #2 fly ash silo was modified to receive raw fly ash from both power generation units, with a silo penetration adaptor installed to convey raw ash to the new electrostatic separator. The separator produces a low-carbon mineral product and a high-carbon ash product, sorting the byproduct stream into two distinct, marketable outputs.

Product Handling & Existing Infrastructure Tie-In

Low-carbon product ash is pneumatically conveyed to a new drive-through loadout silo equipped with a truck loading spout and truck scale, while the high-carbon ash is conveyed to the existing Unit #1 silo for continued use. The project demonstrates ZAP’s capability to deliver beneficiation facilities that convert a power-plant byproduct into a marketable low-carbon material.

Client

Power Generation & Materials Producer

Markets

Mining, Minerals, & Advanced Materials, Power Generation

Location

United States

Services

  • Detailed Engineering & Design
  • Procurement
  • Construction Management

Engineering Disciplines

  • Process/Chemical
  • Mechanical
  • Civil
  • Structural
  • Electrical
  • Instrumentation & Controls

Shane Wilson

Vice President of Business Development


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