March 4, 2025

The Benefits of Water-Free Calcium Carbonate Beneficiation

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  • The Benefits of Water-Free Calcium Carbonate Beneficiation

Calcium carbonate is widely used in industries like plastics, paper, and paints to improve texture, quality, and reduce costs. Traditionally, calcium carbonate beneficiation involves water-heavy methods to remove impurities, but these processes can cause environmental and operational issues.

With the electrostatic separator developed by ST Equipment & Technology (STET), companies can now optimize their beneficiation processes with an alternative that offers a range of advantages for manufacturers seeking efficiency, sustainability, and higher-grade products.

What is Calcium Carbonate?

Calcium carbonate, a naturally occurring mineral found in limestone, chalk, and marble, is one of Earth’s most abundant minerals and plays a critical role in various industries. Used primarily as a filler and a pigment, calcium carbonate improves the quality, durability, and performance of products.

Additionally, it is a key ingredient in cement and construction materials, as well as a neutralizing agent in environmental applications like water treatment and flue gas desulfurization. Its versatility, affordability, and availability make it an essential material in modern manufacturing and industrial processes.

Challenges of Traditional Calcium Carbonate Beneficiation

For applications which require high purity or brightness, calcium carbonate is traditionally processed using wet methods such as flotation to remove impurities and achieve the desired level of quality for various applications. These methods are water-intensive and require large amounts of energy, chemicals, and equipment, making them costly and environmentally taxing.

High Water Usage

Wet-based calcium carbonate beneficiation methods consume large amounts of water. This is particularly problematic for local water resources, particularly in regions facing water scarcity or tight environmental regulations. Disposal of wastewater also poses environmental risks, as tailings ponds that are often used for containment, can leach harmful substances into nearby ecosystems.

High Costs for Water Treatment and Disposal

To operate water-intensive beneficiation processes, manufacturers must invest in advanced water treatment systems. These systems not only incur high upfront costs but also demand ongoing maintenance. Treating and disposing of wastewater frequently results in substantial long-term operational expenses.

Increased Energy Consumption

Once the calcium carbonate is refined, the product typically needs to be dried, as excessive moisture adversely impacts its usability in many applications. This drying phase consumes considerable energy, adding to production costs and environmental strain.

Limited Efficiency for Certain Grades of Calcium Carbonate

Water-based methods struggle with achieving precise separation of impurities, particularly in highly specific grades of calcium carbonate. This makes it harder to produce consistent, high-quality products, which are critical for industries like pharmaceuticals, high-end paints, and plastics.

Operational Challenges

The excessive use of water in beneficiation processes can also cause operational issues such as clogging, corrosion, and scale buildup. These challenges not only result in increased costs but also hinder the efficiency and sustainability of the manufacturing process.

Advantages of Water-Free Calcium Carbonate Beneficiation

Water-free calcium carbonate beneficiation processes have emerged as an alternative to traditional wet methods that address the inherent challenges of water-based approaches while unlocking new opportunities for businesses. Water-free beneficiation aligns seamlessly with the growing push for sustainable industry practices, making it an environmentally responsible choice for manufacturers.

Environmental Sustainability

Switching to a water-free beneficiation process significantly reduces the environmental footprint of calcium carbonate production.

  • Eliminates Water Usage: Water-free methods cut out the need for water entirely, conserving valuable resources and lowering operational complexity.
  • No Tailings Ponds: Since no wastewater is generated, manufacturers no longer need to maintain potentially hazardous tailings ponds, eliminating the risk of water contamination.

Cost Efficiency

By eliminating the need for water, one of the benefits of calcium carbonate beneficiation using dry methods for manufacturers is substantial cost savings. These cost reductions allow companies to reallocate resources toward innovation and operational growth.

  • No Water Treatment Costs: The absence of wastewater means businesses can forgo large-scale water treatment facilities, along with their hefty operational costs.
  • Reduced Drying Expenses: Without water-logged products, the need for energy-intensive drying processes is eliminated, reducing overall energy consumption.

Higher Product Purity and Quality

Water-free beneficiation processes deliver a higher purity product.

  • Precise Impurity Separation: This technology efficiently removes impurities and produces calcium carbonate with enhanced whiteness and purity, qualities that are highly valued in industries like paper and paints.

Faster, Scalable Processing

Water-free processes are often designed for continuous operation, ensuring quick and efficient turnaround times.

  • Higher Throughput Rates: The streamlined nature of dry beneficiation means manufacturers can process larger quantities of material in less time.
  • Easy Integration: Thanks to their modular design, water-free beneficiation systems can be seamlessly incorporated into existing production lines, minimizing disruptions and downtime.

How STET Transforms the Process

ST Equipment & Technology (STET) has revolutionized water-free mineral processing with our patented electrostatic separator. This cutting-edge technology offers an efficient, sustainable solution for manufacturers seeking to modernize their calcium carbonate beneficiation processes.

What is Triboel ectrostatic Separation?

The electrostatic separator utilizes an innovative dry process designed to efficiently separate fine particles based on their electrical charge. This advanced technology works by applying an electrostatic field to materials, causing particles with different charges to move in distinct directions.

Why Choose STET’s Separator?

  • STET’s electrostatic separator delivers high-precision impurity removal for superior calcium carbonate products while eliminating water use and environmental challenges. Backed by more than 30 years of expertise, it offers versatile processing and full support for sustainable, competitive manufacturing.

Take the Next Step

ST Equipment & Technology’s electrostatic separator allows manufacturers to refine their processes, reduce costs, and produce higher-quality products, highlighting the benefits of calcium carbonate beneficiation using dry methods.

Contact us today to learn more about STET’s electrostatic separator and begin your transition to a more efficient, sustainable future.

benefits of calcium carbonate

Fly Ash

Minerals

Animal Feed

Human Food

Jose Rivera Ortiz

Production and Development Manager

Jose Rivera-Ortiz joined the company in 2004 as a Manufacturing Mechanical Technician. Over the years he took on many roles and responsibilities in the research and development and service and engineering departments. Jose is now the Manager of Production and Development as well as the Field Service Manager, and is responsible for manufacturing and production, field service, and product development. He holds many patents for STET belt development and equipment upgrades. Previous to joining STET Jose lived in Puerto Rico and worked as a chemical technician.

Lewis Baker

Service Manager

Lewis Baker provides engineering support to STET's fleet of processing plants throughout Europe and Asia and handles technical aspects of business development. He joined ST in 2004, initially as Plant Manager for STET's fly ash processing facility at Didcot Power Station in the UK, before moving to a broader role in technical support. After graduating from the University of Wales with a master’s degree in chemical engineering, Lewis held a number of roles in plant design and commissioning, process engineering, and plant management.

Kamal Ghazi

Senior Project Manager

Kamal Ghazi is a Project Manager with experience in mineral processing and industrial project implementation. He also collaborates closely with clients to ensure the successful integration of the STET Separator into their operations. Kamal joined STET in July 2015 as a Process Engineer and participated in designing and establishing the first-ever landfilled fly ash processing plant for Titan America in 2020. A mineral engineer by education, he earned a master’s degree from Tehran University and a bachelor’s degree from Kerman University.

Scott Mechler

Senior Mechanical Engineer

Scott Mechler is responsible for mechanical design work on STET’s electrostatic separator machines, focused primarily on research and development of new generations of separators. He joined the company in 2024 after a decade of experience in designing large high-tech industrial equipment in highly regulated design environments. Scott received a bachelor’s degree in mechanical engineering, with a minor in biomechanical engineering, from Northeastern University.

Traci Geer

Office Manager

Traci Geer is responsible for the daily operations of the STET office, facility management, marketing, special events, and safety. She also provides support to the leadership team, staff, and human resources. She joined the company in 2017 after having worked as an executive assistant to the Superintendent of a virtual public school. Earlier, she spent a decade as an IT system analyst. Traci earned a bachelor’s degree in computer information systems and an associate’s degree in management from Bentley University.

Tim Choi

Electrical and Controls Engineering Manager

Tim Choi is the Electrical and Controls Engineering Manager at STET. He joined the company in 2017 as a Senior Electrical and Controls Engineer. Since then, he has contributed to developing control systems for separators, commissioning various balance of plant systems, and working on equipment development at the Needham facility. Tim has been in a managerial role since 2021. He holds a bachelor’s degree in electrical engineering from Hanyang University in Korea and a master’s degree in electrical engineering from the University of Texas at Arlington.

Richard Lane

Pilot Plant and Laboratory Technician

Richard Lane, who has been with STET for more than 13 years, is responsible for analyzing daily pilot plant run samples in the lab. He also helps prepare, mill, condition, and organize samples to be run in the pilot plant. After so many years working with STET technology in the pilot plant, Rich has gained an intimate knowledge of the machines along with vast experience with the separation processes. He received an associate’s degree in applied science from Massasoit.

Kristin Cappello

Operations Manager

Kristin Cappello joined the company in 2014 as a Purchasing and Accounting manager, added Materials Manager to her role, and became the Operations Manager in 2022. She is responsible for supply chain management, inventory and purchasing, customer relations, and operation planning. Previous to 2014, Kristin worked as an Office Manager and Executive Assistant in a corporate/family law firm and as a part-time Real Estate Agent. She received her bachelor’s degree in political science/pre-law from Northeastern University.

Kelsie Garretson

Lead Chemist

Kelsie Garretson is responsible for the daily operations of the STET lab, including testing, instrument maintenance and upkeep, and data collection. Some of the instruments she manages include protein analyzers, near-infrared (NIR) spectrometers, and X-ray fluorescent (XFR) analyzers.

She joined STET in 2021 after graduating from Boston University with a bachelor’s degree in earth and environmental science, with a minor in marine science. She is currently pursuing a master’s degree in natural resources and environmental science from the University of Illinois at Urbana-Champaign.

Tom Newman

Process Engineer

Tom Newman joined STET in 2022, handling the day-to-day operation of minerals testing. He designs experiments, analyzes data, optimizes results, and writes reports to provide insights to customers. Tom often travels with STET’s containerized unit to provide on-site support for mineral enrichment projects. He also works on research and development projects to find new ways to improve and understand the triboelectrostatic process. He received a bachelor’s degree in chemical engineering from the University of Pittsburgh. As part of his role at STET, he attends conferences to share his research findings with peers in the mineral processing industry.

Natsuki Barber

Senior Food Technologist

Natsuki Barber is responsible for human food and animal feed customer projects as well as R&D in those areas, especially managing research collaboration. Before joining STET in 2019, Natsuki worked as a food scientist with the Northern Crop Institute, where she developed deep understanding of crop physiology, functionality, application, processing, and nutrition. She worked especially closely with the development and application of plant protein ingredients.. She holds a bachelor’s degree in food science and a master’s degree in cereal science, both from North Dakota State University.

Abhishek Gupta

Director of Process Engineering

Abhishek Gupta leads bench and pilot-scale test programs to develop novel applications of STET electrostatic separation technology. He also manages auxiliary equipment selection, process design, separator installation, and optimization for commercialized applications. Abhishek joined STET in 2014 as a process engineer. Before that, he worked at QD Vision, a nanotechnology company working with semiconductor crystals called Quantum Dots, to develop display and lighting products. He is a chemical engineer by education with a bachelor’s degree in chemical engineering from the Indian Institute of Technology (IIT) and a master’s degree in chemical engineering from Penn State University.

Tomasz Wolak

Director, Business Development

 Tomasz Wolak is working to introduce STET technology for animal feed and human food industries outside the United States and for fly ash and minerals industries in Europe. Tomasz originally joined STET in 2019 as a Business Development Manager for Europe, focusing on human food and animal feed applications. He has worked in the food and feed industries in both engineering and operational roles, gaining insight on design, engineering, and manufacturing as well as operating and optimizing processing plants. Tomasz earned a master’s degree in mechanical engineering from the University of Science and Technology in Cracov and an executive MBA from Apsley Business School in London, and he participated in an advanced management and leadership program at Rotterdam School of Management.

Kyle Flynn

Director, Business Development
Kyle Flynn is responsible for STET business activities in North America, as well as providing technical support to business development activities worldwide. He joined STET in 2008 as a member of the process engineering group. He has worked closely with customers and the pilot plant to develop projects worldwide for the processing of food and feed materials, industrial minerals, and fly ash using the patented dry STET technology. Kyle has assisted in commissioning multiple industrial mineral and fly ash separators, as well as research and development, process design and process optimization. Beginning in 2018, Kyle joined the business development team. Kyle received a bachelor’s degree in chemical engineering from Worcester Polytechnic Institute (WPI) and a master’s degree in chemical engineering from North Carolina State University.

Hervé Guicherd

Vice President, Business Development

Since 2018, Hervé Guicherd has served as Vice President of Business Development for STET, responsible for building, animating, and supporting the business development team. He has assumed many roles during his more than quarter century with the company, including International Business Development Director in charge of introducing STET products in new applications (e.g., mining) and new territories outside the Americas (e.g., India, East Asia); European Business Development Manager (based in Greece); and positions in supply chain and marketing. After an early career as a Navy Officer, Hervé held several positions in marketing and sales during his long involvement with technology-related companies. He received a business degree from the University of Bordeaux; a master’s degree in electrical engineering from the Institute Polytechnique of Bordeaux; and an MBA from the Darden Graduate School of Business at the University of Virginia.

Lou Comis

Controller
Lou Comis has been responsible for all aspects of financial analysis for STET since joining the company in 2017. Previously, Lou held controller positions at Siemens Medical, for the PLM R&D division, and at Draeger Medical. Immediately before joining STET he was a consultant working with companies migrating from Oracle’s Enterprise to Hyperion Financial Management. He began his career as a financial analyst and finance manager for companies including WR Grace, Polaroid, and Siemens Healthcare. Lou earned an MBA with a concentration in finance from Bentley University’s Elkin B. McCallum Graduate School of Business.

David Schaefer

Vice President of Engineering and Manufacturing
David Schaefer is responsible for the manufacturing division and the design and build of STET’s patented electrostatic separation equipment. He works closely with the company’s commercial and processing teams to enhance STET’s customer experience and help drive innovation. David has more than 30 years of engineering and manufacturing leadership experience in technology and product development in everything from multifunction printers to self-driving vehicle technology. Additionally, he has consulted for several startup operations and founded an energy technology development company, eWindSolutions. Earlier in his career, he was director of mechanical engineering and chief new product architect at Xerox and a staff engineer in product development at IBM. His deep experience with innovation-driven technology and leading end-to-end engineering programs helps drive the entrepreneurial spirit of STET. David earned a bachelor’s degree in mechanical engineering from Rochester Institute of Technology. He holds multiple patents in the areas of product performance improvement, cost reductions, and usability improvements

Frank Hrach

Chief Technology Officer
As Chief Technology Officer for STET, Frank Hrach is responsible for STET process technology development for fly ash and industrial minerals, and design, construction, and commissioning of new processing facilities. He joined STET in 1995, bringing over 25 years of experience in research & development, design & construction, and operation of specialty chemical, material handling, and high temperature combustion processes. Before becoming CTO, he served as Director of Process Engineering. Frank received a bachelor’s degree in chemical engineering and a master’s degree in chemical engineering practice from the Massachusetts Institute of Technology.

Tom Cerullo

President
“Leading a unique mix of technology and business development individuals, my job is to help customers gain more value from their processes and products. Notably, our niche is to create value from waste and by-product streams. Sustainability is in our DNA, viewing near-zero waste as a reality within our reach. “While our separation technology is recognized for delivering products of high value in cement, minerals, and protein for humans and animals, entering new markets requires addressing the needs of many stakeholders and achieving buy-in from private and public organizations. This demands a comfort level with the big picture and opening minds to new endeavors. Projects take vision and commitment to bring to fruition, and that’s why our staying power, backed by Titan Cement, an international cement and technology leader, is necessary for continuous success.” Tom Cerullo’s leadership roles at STET began in operations, sales, and business development. At the start of his career, he managed STET’s early commercial installations, the first of which was commissioned in 1995. He has helped drive the growth and evolution of the business from startup to the viable commercial business it is today. Tom is a graduate of the Massachusetts Maritime Academy, which provides a unique education for professionals entering the merchant marine, the military services, and the global marketplace. Before joining STET, he spent more than 4 ½ years as a marine engineer with Military Sealift Command. Adds Tom, “A rigorous academic program, combined with a regimented lifestyle at a young age, gave me a foundation for taking responsibility, having the discipline to endure long-term challenges, and persevering  through complex challenges.”