ABSTRACT:

The increasing generation of coal combustion ash from thermal power plants presents significant challenges in waste management and resource utilization, particularly due to the presence of residual unburnt carbon. This study focuses on the identification, characterization, and efficient separation of carbon from power plant ash to improve ash quality and promote sustainable resource recovery. A systematic investigation was conducted to evaluate suitable analytical and separation techniques for the recovery of carbonaceous material from the ash matrix. Energy Dispersive Spectroscopy (EDS) and Thermogravimetric Analysis (TGA) were identified as effective techniques for detecting and quantifying the presence of unburnt carbon. Based on a comparative assessment of separation methods, dry cyclone separation and electrostatic separation demonstrated promising performance for the concentration and recovery of carbon-rich fractions. In addition, Computational Fluid Dynamics (CFD) analysis of a conventional cyclone separator was performed to investigate the flow characteristics and validate its separation efficiency. The study further examined the composition and forms of carbon present in carbon-rich ash and assessed the potential benefits of improved ash management strategies. The findings indicate that the integrated application of analytical characterization, dry separation techniques, electrostatic separation, and CFD-based process evaluation can provide a practical and scalable approach for carbon recovery from power plant ash. The proposed methodology can enhance the utilization potential of low-carbon ash in sectors such as construction and agriculture while enabling the recovery of carbonaceous material for potential industrial applications. The study therefore contributes to sustainable ash management, waste minimization, resource recovery, and improved economic value generation in coal-based power plant operations