Subscribe
Share
Share
Embed
Powering the Process℠ is a podcast for engineers, plant managers, and operations leaders focused on industrial systems, plant optimization, and manufacturing efficiency. Hosted by ProcessBarron experts, each episode delivers practical insights on material handling, air and gas systems, industrial equipment, and reducing downtime.
Powering the Process Podcast – Ash Handling with David Cantu
00:00:00:07 - 00:00:31:20 – Jen Little:
This podcast is brought to you by ProcessBarron. Handle everything better. Welcome to Powering the Process, the podcast focused on the real work behind industrial manufacturing. Each week, I dig into the systems, equipment, and strategies that keep plants running efficiently—from everyday operational challenges to emerging engineering solutions. We’re here to share practical insights that help you keep your process moving.
Let’s get started.
00:00:31:23 - 00:00:35:12 – Jen Little:
Welcome to Powering the Process, where we explore the innovations and ideas shaping the future of manufacturing and energy. Today, we're diving into a topic that turns waste into valuable ash byproducts.
00:00:35:15 - 00:01:15:16 – Jen Little:
For decades, ash from industrial processes was seen as a challenge—something to just get rid of. But over time, manufacturing plants have found valuable uses for ash and needed an economical and efficient way to move it. Ash isn’t just a byproduct; it’s a resource—from construction materials to fertilizer. Ash can play a vital role in building a cleaner, stronger future.
00:01:15:19 - 00:01:31:00 – Jen Little:
This episode will uncover how ProcessBarron helps plants manage ash efficiently. Today, we’re joined by David Cantu, Director of Material Handling at ProcessBarron, who’s been with the company for nearly 14 years.
00:01:31:02 - 00:01:37:21 – David Cantu:
Thanks for having me today. Glad to be here. Hopefully we’ll have some good information for the listeners.
00:01:37:23 - 00:01:50:25 – Jen Little:
Alright, David. Big picture—ash to opportunity. Can you explain where ash comes from and why it’s a byproduct in the first place?
00:01:50:27 - 00:03:09:05 – David Cantu:
Sure. Ash is basically the solid residue left after something is burned. A few things, like natural gas and highly filtered hydrocarbons, don’t produce ash at all—they burn clean.
But materials like wood, biomass, coal, waste, or trash produce ash. Coal produces the most, usually 10–20%, because of its high carbon content. Biomass produces less, about 3–10%, and waste energy can vary widely, from 10% up to nearly 100%, depending on what’s being burned.
00:03:09:07 - 00:03:22:11 – Jen Little:
Right, so all of those products are used as fuel in boilers, and once burned, that’s when ash handling becomes a challenge.
00:03:22:13 - 00:03:53:17 – David Cantu:
Exactly. People often don’t realize ash can be considered hazardous waste. Historically, it was dumped wherever convenient, but now regulations—especially from the EPA—require proper handling. Recycling ash makes a huge difference environmentally. Every ton of ash recycled is one less ton in a landfill.
00:03:53:21 - 00:04:22:23 – Jen Little:
And how does turning ash into a resource benefit the economy?
00:04:22:25 - 00:05:06:28 – David Cantu:
Customers can sell ash instead of paying landfill fees. Depending on the product, it can be worth $25–$80 per ton. Cement plants use a lot of ash, and even paving stones you buy at stores like Lowe’s might contain 50–70% ash.
There are also emerging technologies where wood ash or biochar can be used in plastics and other products. Some farms use chicken litter ash as fertilizer, creating a circular economy: burn fuel, produce electricity, and return ash to the land.
00:05:06:28 - 00:06:38:12 – Jen Little:
That’s a fascinating circular economy example. Can you explain the environmental impact?
00:06:38:12 - 00:07:32:10 – David Cantu:
Using ash in concrete and other products reduces CO2 emissions. For example, using one ton of fly ash in concrete saves roughly one ton of CO2. This is significant globally—potentially 70–110 million tons of CO2 saved per year.
It also helps plants reduce their footprint while supporting industries like cement and agriculture.
00:07:32:13 - 00:08:58:10 – Jen Little:
Let’s talk about disposal. Many plants used to rely on landfills or settling ponds. How has using ash as a resource changed that?
00:08:58:10 - 00:10:19:07 – David Cantu:
It’s changed a lot. Settling ponds can cost hundreds of thousands to clean, so convincing customers to recycle ash with smaller, localized equipment saves time and money. We help plants avoid large pumps, miles of piping, and multi-year cleanup schedules, and instead implement weekly or daily collection systems.
00:10:19:09 - 00:11:01:26 – Jen Little:
Which industries rely on ash recycling today?
00:11:01:27 - 00:11:38:00 – David Cantu:
Mainly cement (50–60%), agriculture for fertilizer, and carbon black for plastics. The industry has evolved dramatically over the last 20–30 years.
00:11:38:00 - 00:12:58:05 – Jen Little:
How does ProcessBarron support customers?
00:12:58:05 - 00:14:29:19 – David Cantu:
We assess their existing systems—whether old pneumatic conveyors or newer mechanical systems—and design upgrades to improve efficiency, sealing, and environmental safety. Solutions are customized based on the plant layout, material types, footprint, and budget.
Mechanical conveyors handle hot ash and embers safely, keeping everything sealed to prevent fires. Pneumatic systems are used carefully because introducing air can ignite embers. Every system is unique; cookie-cutter solutions rarely work.
00:14:29:25 - 00:15:21:12 – Jen Little:
How does recycling ash reduce landfill waste?
00:15:21:12 - 00:15:52:22 – David Cantu:
By diverting ash from landfills, we reduce environmental impact, transportation costs, and fuel consumption. Handling ash locally is more sustainable.
00:15:52:22 - 00:17:12:06 – Jen Little:
What misconceptions exist about ash byproducts?
00:17:12:06 - 00:17:40:04 – David Cantu:
People assume all ash is hazardous and unusable. Fifteen years ago, I didn’t know its applications either. Now, it’s widely used in construction, agriculture, and emerging tech.
00:17:40:06 - 00:18:23:00 – Jen Little:
Can you describe the process your team follows at ProcessBarron?
00:18:23:02 - 00:18:49:01 – David Cantu:
Our engineers and draftsmen evaluate the site, gather data, and design a system that is then manufactured and installed. It’s a full circle—assessment, design, manufacturing, and field services.
00:18:49:04 - 00:19:06:21 – Jen Little:
What makes ash projects unique compared to other material handling?
00:19:06:23 - 00:19:50:16 – David Cantu:
Ash is environmentally sensitive and often very hot—up to 1800°F—so it requires specialized handling. Unlike fuel at ambient temperature, it presents safety and environmental challenges.
00:19:50:19 - 00:21:18:21 – Jen Little:
Can you share a memorable project?
00:19:17:09 - 00:21:18:21 – David Cantu:
A waste-to-energy plant in the Northeast was an eye-opening experience—walking through 3–4 inches of ash on the floor. Today, that same plant is clean and modern, thanks to upgraded conveyors and proper ash handling systems. We always see projects through until the customer is satisfied.
00:21:18:23 - 00:21:37:29 – Jen Little:
Thanks, David, for letting us see behind the scenes and explaining how ProcessBarron supports customers with ash handling.
00:21:35:10 - 00:21:37:29 – David Cantu:
No problem. Thanks for having me.