STAR ® - STAGED TURBULENT AIR REACTOR

The STAR® process is a thermal beneficiation process, which treats fly ash in such a way as to lower the LOI for use as pozzolan in concrete.

WATCH STAR® Process Video

Benefits of STAR®

  • No Waste Stream.

  • Adapts to variations in raw feed.

  • Sustainable recycled product.

  • Modular design. / Small footprint.

  • Consistent, reliable fly ash meets or exceeds all concrete specs.

The SEFA Group, a long time leader in the fly ash utilization industry, developed the Staged Turbulent Air Reactor (STAR®) Process. The STAR® Process is a thermal beneficiation process, which treats fly ash in such a way as to lower the LOI for use as pozzolan in concrete. The STAR® process can also remove all the carbon in fly ash so that the purified mineral matter can be used as raw feed material in other products and processes that historically have been unable to use fly ash as raw feed material because of the deleterious effect of residual carbon in fly ash. The STAR® Process also does not generate any solid waste stream and generates hot water as a by-product, which can be beneficially used by the Utility.

Benefits of the STAR® Process

  • No waste stream.
  • Beneficial utilization of all product ash.
  • Heat recovery from carbon.
  • Adapts to variations in raw feed.
  • Removes ammonia.
  • Modular design.
  • Small footprint.
  • Eliminates negative effect on air entrainment.
  • Sustainable recycled product.
  • Consistent, reliable fly ash that meets or exceeds all concrete specifications.

star-map-locationsThe first STAR Plant was built at SCE&G’s McMeekin Station in Lexington, South Carolina. To date, the McMeekin STAR has processed high LOI fly ash originating from more than 16 facilities into premium quality fly ash for use in construction.

Lessons learned from the first STAR Plant were incorporated into the design of the next generation STAR II facility. This STAR II facility is owned by NRG and is located in Newburg, Maryland.

The third STAR facility began operations in 2015, and is located in Georgetown, South Carolina, at the Santee Cooper Winyah Generating Station. It is the only facility capable of processing ash from surface ponds.