Optically Tunable Functional Nano-Coatings of Fly Ash-Based Ceramics

There is increasing focus on environmental remediation and waste resource utilisation to combat issues of pollution and resource availability.  Even with decreasing reliance on coal-fired power, there remains the need to remediate larger tonnes of the coal combustion by-product fly ash, which are stockpiled in landfill/tailings ponds/silos in Australia, leading to issues for land use and environmental contamination. There also are issues for titania, of which Australia has the major global reserves, which are costs, strategic importance, and environmental risks. The project aims to address these problems by converting fly ash into a high-value product. The developed product would have the capacity to be used as a pigment/filler in paints, the global industry of which is valued at A$251 billion p.a. with other applications in plastics and polymers. 

This nanotechnological approach involves the design of a new system for the engineering of fly ash scaffolds into advanced ceramics through a proprietary process.  The laboratory- to pilot-scale manufacturing extension will enable high-volume use in different applications generating significant economic and environmental outcomes.

• Develop value-added aluminosilicate fly ash products as a partial replacement for commercial mineral pigment/filler in the paint/coating industries using a patented process

• Tune the optical properties using graded nanocoatings to simulate the natural minerals and enhance whiteness and opacity through chemical processing and doping approaches
• Extend the process from laboratory-scale to pilot-scale, and
• Conduct life-cycle assessment (LCA) and costing (LCC) of the process.