Fly ash is the dust removed from the smoke of coal-fired power plants by using air pollution abatement equipment. Each year, the United States consumes approximately 1.1 billion tons of coal, generating more than 70 million tons of fly ash. About 40% of the fly ash generated nationwide is used in various applications, such as for use as a concrete ingredient or for constructing roadbeds. The remaining 60% is unused, and must be disposed of in slurry ponds or landfills, which can cause water pollution under the wrong circumstances.  Therefore, increased beneficial use of fly ash not only saves money but also solves a solid waste disposal problem.

Manufacturing clay bricks requires intensive heating in kilns , which consumes much energy derived from burning fossil fuels. The process causes air pollution and generates carbon dioxide, which in turn causes global warming. In contrast, no heating is necessary in making fly ash bricks, thereby saving fossil fuel and reducing global warming.

At present, approximately 46 million tons of fly ash in the nation is land filled or stored in disposal ponds or mine pits, often causing groundwater pollution and creating eyesores. About 35% of the nation’s fly ash is recovered, most of which goes into concrete and roadbeds. The new brick technology will significantly increase fly ash recovery rate.