The Technology

SonoAsh employs a unique, patent-protected, process in the beneficiation of coal ash – sonication. Sonication is the application of low frequency, high energy transmission of mechanical energy through shear vibration.

The “sonicator” technology was developed by Placer Dome with an expenditure of $10 million between 1985 – 1995 for application in the mining industry. It has since been successfully deployed to continue application development, with a $60 million expenditure, for PCB soil destruction (2004 – 2007) and heavy oil de-asphalting (de-asphalting IP sold in 2012 plus royalty stream). An additional $4 million to pursue the concept and IP for coal ash beneficiation.

The SonoAsh method is a wet process making it particularly suitable for most coal ash impoundments as the ash is often stored wet to mitigate fugitive dust. A raw coal ash slurry flows through the sonication chamber where the high-intensity, mechanical energy fractures and de-agglomerates the coal ash. The fractured ash is then separated using well-proven mineral processing technology known as froth flotation.

Sonication + froth flotation can be used to recover coal ash that has been disposed of in impoundments or landfills. Older coal ash storage sites can thus be reclaimed so that the construction of new disposal sites can be avoided or postponed. Since dry fly and coal ash is not required for sonication + froth flotation processing, the ash producers do not need to alter their conventional wet ash handling practices.

Ash in slurry form can be transported cost-effectively via slurry pipelines, enhancing the flexibility of location of both source material and engineered product.

There are currently 738 coal ash storage facilities in 47 states across America, primarily in rural settings. Over 90% of these have been assessed as leaching into groundwater, causing local environmental impacts. This issue provides a nonpartisan opportunity for social justice, rural economic renewal, and community sustainability.

By upgrading stored waste coal ash, we can offer green cement replacement products for next-generation infrastructure, reducing energy intensity and greenhouse gas emissions while creating sustainable industries and jobs. This waste-to-value opportunity supports the transition legacy coal communities need, fostering modern jobs in an industry that backs construction projects and national defense.