Densification of coal fly ash

A method of producing densified fly ash pellets having a specific gravity of about 2.0 to 2.3 consisting essentially of the steps

• a. sizing the fly ash to produce a fraction substantially finer than -200 mesh (U.S. Standard);
• b. moistening the sized fraction with sufficient water to form green pellets;
• c. sizing the green pellets;
• d. tumbling the sized green pellets to effect particle packing until excess water has been squeezed out, said pellets being kept dusted during tumbling with sized fly ash from step (a) to absorb the squeezed out water and thereby prevent agglomeration;
• e. drying the packed green pellets below about 300.degree. F to remove the free water therefrom;
• f. heating the dried pellets from about 1000.degree. F to about 70-90% of the absolute softening temperature of the ash until the iron oxides are converted substantially to the .alpha.-Fe.sub.2 O.sub.3 form of hematite and carbon is burned off to a residual value of no more than about 3 to 5% and;
• g. sintering the treated, dried pellets of step (f) at a temperature of 70 to 90% of the absolute softening temperature of the ash.