Abstract: A method for making a low-alkali fly ash cement includes forming a mixture of class C fly ash and an aqueous solution and forming low-alkali fly ash cement from the mixture. The aqueous solution has an alkali at a molar concentration between about 0.002 M and about 2 M. A low-alkali fly ash cement includes class C fly ash and an alkali activating agent. The low-alkali fly ash cement contains between about 3×10?4 wt % alkali activating agent and about 2 wt % alkali activating agent. A method for making fly ash cement includes forming a mixture of class C fly ash and water, wet pressing the mixture and forming fly ash cement from the mixture by curing the mixture at a temperature between about 60° C. and about 90° C.

Abstract: Wallboards, as well as other building materials, are produced by methods which use significantly reduced embodied energy, generating far less greenhouse gases when compared with the energy used to fabricate gypsum wallboard. A novel cementitious core, consisting in one embodiment of post-industrial waste such as slag and combined with pH modifiers, provides a controlled exothermic reaction to create a gypsum-wallboard-like core which can be wrapped in a selected material such as recycled paper and manufactured on a conveyor system to appear, weigh and handle similar to gypsum wallboard, but without the large amounts of energy required to make gypsum wallboard. The manufacturing process results in lower greenhouse gas emissions than the processes used to make gypsum wallboard.

Abstract: Chemically bonded ceramics and manufacturing processes are described. In one aspect, a manufacturing process of a chemically bonded ceramic is carried out by: (1) combining an acidic liquid and Fly ash to form a mixture; and (2) curing the mixture to form the chemically bonded ceramic. The Fly ash corresponds to at least a majority by weight of solids combined with the acidic liquid to form the mixture.

Abstract: The description relates to production of fly ash with properties suitable for use in Portland cement. The fly ash compositions will contain coal ash, water-insoluble copper compositions and metallic mercury adsorbed onto ash particles. In one aspect, the coal ash composition will have a total mercury content of from 0.1 to 2.0 ppm and the water-soluble mercury is less than 20% of the total mercury content. The process entails combusting coal to produce hot combustion gases containing fly ash, CO2, chlorine, and mercury, cooling the combustion gases and introducing into the combustion gases at a temperature of less than 1000° F., preferably within the range of from about 250° to about 900° F., a copper-based chloride remediator (CBCR), and collecting the fly ash which comprises insoluble copper compositions and water insoluble mercury compositions.

Abstract: A method to significantly reduce the need for treating bottom ash with a bonding agent, such as lime or concrete, as is typically done by Waste-to-Energy facilities within the United States of America. Furthermore it is a method that will greatly reduce the costs associated with freight, and disposal typically associated with WTE bottom ash by extracting excess water, metallic, and eliminating the need for supplemental additives such as lime or concrete.

Abstract: Methods and compositions are disclosed that comprise cement kiln dust having a mean particle size that has been altered. An embodiment discloses a method of preparing cement kiln dust comprising: providing cement kiln dust having an original particle size; and altering the mean particle size of the cement kiln dust from the original size by grinding, separating, or a combination thereof. Another embodiment discloses a well treatment fluid comprising: cement kiln dust having a mean particle size that has been altered from its original size by grinding, separating, or a combination thereof; and water.

Abstract: A method of producing enhanced coal combustion ash for use in pozzolanic applications or cement manufacture, in which the enhanced combustion ash has lower mercury content. A slurry is formed of the combustion ash and water and is subjected to froth flotation to form a mercury-enriched ash slurry and a mercury-depleted ash slurry. The product mercury-depleted ash slurry is isolated and may optionally be dried. The combustion ash may be pulverized prior to being used to form the slurry, reducing its mean particle size. The mercury-depleted combustion ash product has reduced levels of mercury and ammonia, and reduced particle size.

Abstract: The present invention relates to a method for recycling waste water from a stainless steel slag treatment process wherein stainless steel slag is brought into contact with water, in particular to neutralize the free lime contained therein, thereby producing said waste water. This waste water contains heavy metals, including at least chromium, and has a pH higher than or equal to 11. In accordance with the invention, it is used as production water for manufacturing mortar and/or concrete. In this way, the heavy metals, which are dissolved in the waste water and thus readily available, become bound in the newly formed cement phases so that they are prevented from leaching. Moreover, it has been found that the workability of the fresh mortar or concrete and also the quality of the final mortar or concrete materials is not negatively affected by the use of this alkaline waste water and that an accelerated setting could be achieved during the first hours.

Abstract: A process for the recovery of bottom ash is characterized by shredding and physical separation phases. The bottom ash undergoes an oxidation treatment of the amphoteric metals contained therein. After the process, the treated bottom ash can be employed as mineral additive for concretes or hydraulic bonding agents.

Abstract: A low density annular grout composition for filling voids. The composition may consist of cementitious fly ash, water, set retarder and cellular foam. The composition may have a compressive strength of between 100 and 600 psi at seven days and less than 1500 psi at 28 days. The composition may have a density between 20 and 75 pcf. Also disclosed is a method of filling a void with a low density annular grout composition. The method can include determining the time necessary to fill the void, adding water and set retarder to a cementitious fly ash to make a wet mixture, adding air to the wet mixture, and adding the composition to the void.

Abstract: Methods and compositions for treating a subterranean formation with salt-tolerant cement slurries including treating a salt-containing subterranean formation having sodium salts, potassium salts, magnesium salts, calcium salts, or any combination thereof comprising: providing a salt-tolerant cement slurry comprising: a base fluid, a cementitious material, a pozzolanic material, a salt-tolerant fluid loss additive, a salt additive, and optionally, an elastomer, a weight additive, a fluid loss intensifier, a strengthening agent, a dispersant, or any combination thereof; introducing the salt-tolerant cement slurry into the subterranean formation; and allowing the salt-tolerant cement slurry to set.

Abstract: A process for lowering the carbon content in ash includes introducing the ash having a carbon content of 1 to 20 wt-% into a reactor where the ash is burnt at a temperature between 700 and 1100° C. Fuel is also introduced into the reactor. During combustion, microwave radiation is fed into the reactor. At least part of the energy released during the combustion is recovered.

Abstract: Methods and compositions are provided that utilize pumice and various additives. Embodiments provide pumice-containing remedial compositions. One of the pumice-containing remedial composition embodiments comprises pumice; a calcium activator; and water, wherein the pumice-containing remedial composition has a density of less than about 13.5 pounds per gallon, and wherein the pumice-containing remedial composition is free of Portland cement.

Abstract: Methods and compositions are provided that utilize pumice and various additives. An embodiment provides a method of remedial cementing in a subterranean formation comprising: providing a lightweight settable composition comprising pumice, a calcium activator, and water, wherein the lightweight settable composition has a density of less than about 13.5 pounds per gallon and is free of Portland cement; and using the lightweight settable composition in a remedial cementing method to seal one or more voids in a well bore. Also provided are pumice-containing remedial compositions and systems for remedial cementing.

Abstract: Inorganic polymer compositions and methods for their preparation are described herein. The compositions include the reaction product of a reactive powder, an activator, and optionally a retardant. The reactive powder includes fly ash, calcium sulfoaluminate cement, and less than 10% by weight portland cement. In some examples, the composition is substantially free from alkanolamines. In some examples, the ratio of water to reactive powder is from 0.06:1 to less than 0.2:1. Also described herein are building materials including the compositions.

Abstract: A method of making a rapid setting lightweight homogeneous foamed fly ash based cementitious aggregate composition with improved compressive strength for products such as panels is disclosed. The method mixes fly ash, alkali metal salt of citric acid, foaming agent for entraining air, optional foam stabilizing agent, a calcium sulfate such as stucco or gypsum, and water. Compositions are also disclosed which include mixtures of fly ash, particularly Class C fly ash alone or in mixtures with Class F fly ash, alkali metal salts of citric acid, foaming agents, a calcium sulfate such as calcium sulfate dihydrate or hemihydrate and an optional portland cement.

Abstract: A zinc-oxide based set retardant additive and admixture for use in Portland cement or other hydraulic cement mixtures. The admixture may comprise silica fume, vitreous calcium aluminosilicate, magnesium aluminum silicate hydrate, a cellulose ether derivative, or their equivalents. The zinc-oxide based set retardant may be interground or pre-blended, pre-packaged, or added on the jobsite, as an admixture, additive, or addition. The zinc-based set retardant may be subsequently added or mixed into a ready mix or wet mixture of portland cement or other hydraulic cement, sand and/or aggregate, with or without fillers, and water, with or without other pozzolans or polymers.

Abstract: Low embodied energy wallboards and methods for forming same are disclosed. A wallboard can include at least one industrial material in an amorphous phase and at least one alkali-activating agent. The amorphous phase industrial material can be slag, fly ash, silica fume, and/or lime kiln dust. The alkali-activating agent can be calcium oxide, magnesium oxide, potassium hydroxide, sodium hydroxide, calcium hydroxide, calcium carbonate, potassium carbonate, sodium carbonate, sodium sesquicarbonate, sodium silicate, calcium silicate, magnesium silicate and/or calcium aluminate. Additional wallboard components can include water, a foam filler, paper, industrial material in a crystalline phase, and/or polyethylene fibers, polypropylene fibers, and/or other synthetic fibers.

Abstract: An agglomerate is provided that can include an aluminosilicate (ash) base material and one or more of a binding agent or leach reduction agent. Each of the agglomerate and binding agent can include no more than about 25 wt. % cement.

Abstract: The present description is directed to a cement or cementitious mixture that includes fly ash, zinc oxide and borate. Importantly, the cementitious mixture includes greater than 50% of fly ash by weight, or alternatively greater than 75% by weight of fly ash, or still further alternatively greater than 90% or 95% by weight of fly ash. Zinc oxide is incorporated in the cementitious mixture at levels of 2.5% and greater, or alternatively at the amounts of about 5 to 20% zinc oxide. Finally, a borate compound in needed for use as a set retarder.

Abstract: The present invention relates to a method for accelerating the hardening of hydraulic or latent hydraulic binders, wherein ternesite and an aluminum component are added to the binder, and relates to an additive that increasing early strength for hydraulic or latent hydraulic binders that contain ternesite and a non-hydraulically reactive aluminum component, and relates to the use of an additive comprising ternesite and an aluminum component for the purpose of accelerating the hardening of hydraulic or latent hydraulic binders.

Abstract: The present invention relates to a ternesite calcium sulfoaluminate clinker as well as a ternesite clinker containing 20 to 100% by weight of C5S2$ and less than 15% by weight of C4A3$, as well as the use of ternesite as an additive to calcium sulfoaluminate (ferrite) (belite) (CSA(F)(B)) clinker, calcium sulfoaluminate (ferrite) (belite) cement, and calcium sulfoaluminate (ferrite) (belite) binder containing 10 to 90% by weight of CSA(F)(B) and 90 to 10% by weight of ternesite.

Abstract: The present invention relates to a self-neutralising type of calcium hydroxide (Ca(OH)2) preparation for use in dentistry. More specifically, it relates to a self-neutralising type of calcium hydroxide preparation which is formulated in such a way that it can be used in dentistry by being mixed, in a cement clinker, with an active siliceous substance, bismuth oxide (Bi2O5), silica, sulphur trioxide and aluminum oxide/ferric oxide and the like. One aspect of the present invention provides a self-neutralising type of calcium hydroxide preparation comprising an active siliceous substance and bismuth oxide, and this self-neutralising type of calcium hydroxide preparation is characterized in that it comprises silica, sulphur trioxide and aluminum oxide/ferric oxide.

Abstract: Inorganic polymer compositions and methods for their preparation are described herein. The compositions include the reaction product of a reactive powder, an activator, and optionally a retardant in the presence of water and an aerating agent. The reactive powder includes 85% or greater fly ash. The aerating agent can be a blowing agent, a foaming agent, or a mixture of these. Also described herein are building materials including the compositions.

Abstract: A mix design for a polymer modified cement pavement overlay is disclosed along with a method of making and using the mix on a variety of pavement substrates. The mix includes a specific dry combination of: finely divided Elotex 2311 and 2322 or 2320 polymers; Type 2 or C144 aggregate or equivalent; Type I/II cement; Type F or Type C fly ash; intermediate length polymer microfibers; plasticizer; (optionally) calcium chloride or equivalent; (optionally) quikrete retarder or equivalent; and water. The mixture is combined and applied to the substrate in depths of about ? to about 1 inch in lifts. The mixture is allowed to cure for 3-4 hours before being returned to traffic. The placed mixture exhibits preferred qualities of substrate adhesion, flexibility, tire friction, and wearability.

Abstract: The present invention contemplates a cementitious additive that contains electric-arc furnace dust (EAFD) and a precursor as a replacement for up to about 30% of the cement in concrete. The additive includes about 50% by weight EAFD and about 50 wgt. % of precursor. The precursor includes about 55 wgt. % silica, about 10 to 20 wgt. % lime, about 2 to 5 wgt. % soda, about 5 to 15 wgt. % potash, about 2 to 6 wgt. % alumina and about 1 to 3 wgt. % magnesia. The method also contemplates the step of homogenizing the electric-arc furnace dust (EAFD) and precursor to produce engineered dust (ED) and then replacing up to 30% of the cement with a mixture referred to as ED i.e. homogenized EAFD and precursor.

Abstract: A cementitious mixture for high-volume production of masonry products comprises a hydraulic binder accounting for 20 wt % or more of the cementitious mixture, the hydraulic binder comprising 75 to 100 wt % Class C fly ash with a CaO equivalent content of at least 15% by weight. The cementitious mixture also comprises one or more aggregates, and a set control system.

Abstract: A composition and method for reducing freeze-thaw heave risk over flash-filled voids are disclosed. A composition can include cementitious fly ash, water and cellular foam. The composition can optionally include a filler, e.g., Type F fly ash, or additional desired components. A method can include mixing the desired composition and applying the composition to a void. The method can optionally include determining the desired composition based on various factors.

Abstract: By-product materials are processed to mitigate undesirable effects. In some embodiments, industrial waste by-products are recycled using calcium polysulfide and used in building materials. In certain implementations, toxins are rendered non-viable as human pathogens by reaction with calcium polysulfide to create non-soluble sulfide crystals locked in the material as hydration is completed. The sulfides are not soluble in water and are locked into position within the resulting hydrate material, which mitigates escape of or changes of state in the toxins.

Abstract: The present invention provides combustion products of hydrocarbon fuels and controlled amounts of metal oxide strength enhancing materials. The combustion products are useful as additives to cementitious materials. A hydrocarbon fuel such as coal is introduced into a combustion chamber and selected amounts of materials comprising CaO, SiO2 and Al2O3 are also introduced into and/or downstream from the chamber. The hydrocarbon fuel undergoes combustion while the metal oxide strength enhancing materials react with each other and/or the ash or other reaction products of the hydrocarbon fuel. The combustion products have been found to significantly increase compressive strengths of cements such as Portland cement. A reduction in SO2 emission levels also results from the introduction of the metal oxide strength enhancing materials into the combustion process.

Abstract: A cementitious composition including: a binder containing (a) 60-94%, by weight, of at least one pozzolanic material; (b) at least 0.5% calcium sulfoaluminate (CSA), by weight; (c) 1.2-11% by weight, expressed as SO3, of at least one inorganic sulfate selected from the group of sulfates consisting of a calcium sulfate hemihydrate, an anhydrous calcium sulfate, a calcium sulfate dihydrate, a sodium sulfate, and a sodium calcium sulfate; and (d) a total sulfate content of at least 3%, by weight, expressed as SO3, the cementitious composition including, at most, 3% natural lime, the cementitious composition including, at most, 10% alumina cement, the contents of the composition being calculated on a dry, aggregateless basis.

Abstract: Cement compositions containing biowaste ash and methods of cementing in subterranean formations using such cement compositions. Examples of suitable biowaste ash include agricultural waste ash, municipal waste ash, waste-water treatment waste ash, animal waste ash, non-human-non-animal industrial waste ash, and combinations thereof.

Abstract: The present invention provides a composition and a process for the preparation of chemical activated cold setting fly ash building construction materials. The chemical activator is an alkaline aqueous solution of 11.2 to 13.6 in pH and 1.25 to 1.40 gm/cc in density which contains admixtures of different concentrations of hydroxyl, sulfate, acetate and chloride bearing chemical salts of calcium, magnesium, sodium, potassium and aluminum in water medium. The reaction of chemical activator solution and the mineral constituents of fly ash mix develop binding property. The binding matrix of chemical activated fly ash mix is mostly hydrous silica and silicate group of phases which on setting under atmospheric condition attains strength suitable for building construction application. Utilization of fly ash of any source by weight ranges from 80 to 99% in manufacture of building materials including heat and acid resistance and toxic waste disposal products.

Abstract: A process for treating fly ash to activate the fly ash so that it may be used as a substitute for Portland cement, with the process including the use of a specialized rotary mill having variably sized and shaped media to increase the surface area of one fly ash component by grinding, avoiding milling a second fly ash component, while roughing up the surface of the second component to increase its surface area.

Abstract: Embodiments relate to cementing operations and, more particularly, in certain embodiments, to settable compositions that comprise kiln dust and wollastonite and methods of use in subterranean formations. An embodiment discloses a method of cementing comprising: providing a settable composition comprising kiln dust, wollastonite, and water; and allowing the settable composition to set.

Abstract: A dry cement mix based on a hydraulic binder and a glass aggregate for forming light concretes with low thermal conductivity, characterized in that said glass aggregate comprises a fine fraction consisting of granulated aggregate with a particle size from 0.5 to 2 mm, and a coarse fraction consisting of crushed aggregate with a particle size from 4 to 20 mm, obtaining for said glass aggregate a well-defined overall particle size distribution.

Abstract: A manufactured item for the building industry is disclosed, made mainly of bottom ash and/or debris coming from incineration processes of municipal solid waste or of waste which may be assimilated thereto and/or of RDF and of one or more binders. Such manufactured item may have the shape of small bricks, bricks, blocks, small blocks, curbs, interlocking paving blocks, panels, tiles, prefabricated slabs, beams, elements for walls, modular building elements, indoor and outdoor cladding elements, blocks, rocks, supports. Moreover, a process for the manufacture of an item for the building industry is disclosed, from bottom ash and/or debris coming from incineration processes of municipal solid waste or of waste which may be assimilated thereto and/or of FDR wherein the ash and/or debris undergo an oxidation process of the amphoteric metals and mixed with a binder.

Abstract: The invention relates to a mixture containing an alkali-activated aluminosilicate binder, said mixture, after hardening, containing at least 25% by weight of glass beads, based on the total mass. The hardened product has a surface which has very little tendency to soil and is easy to clean. A process for the preparation of the mixture according to the invention and the use thereof as joint filler are disclosed.

Abstract: Sorbent components containing halogen, calcium, alumina, and silica are used in combination during coal combustion to produce environmental benefits. Sorbents such as calcium bromide are added to the coal ahead of combustion and other components are added into the flame or downstream of the flame, preferably at minimum temperatures to assure complete formation of the refractory structures that result in various advantages of the methods. When used together, the components reduce emissions of elemental and oxidized mercury; increase the level of Hg, As, Pb, and/or Cl in the coal ash; decrease the levels of leachable heavy metals (such as Hg) in the ash, preferably to levels below the detectable limits; and make a highly cementitious ash product.

Abstract: Process for production of acid and high temperature resistant cement composites, where the matrix is alkali activated F fly ash alone, F Fly ash combined with ground slag or ground slag alone. F-fly ash produces lower quality alkali activated cement systems. On the other hand the lack of calcium oxide results in very high resistance to medium and highly concentrated inorganic or organic acids. The high strength and low permeability of pure F-fly ash cement systems is achieved by using in the composition un-densified silica fume, the amorphous silicone dioxide obtained as by products in production of ferro-silicones. Precipitated nano-particle silica made from soluble silicates and nano-particle silica fume produced by burning silicon tetra chloride in the hydrogen stream.

Abstract: A manufacturing method of tiles includes the steps of: preparing mixed powder having a water content of 2 to 7% by mixing 30 to 80 parts by weight of calcium hydroxide powder or dolomite plaster powder, 20 to 70 parts by weight of porous aggregate, 0.1 to 5 parts by weight of a first photocatalyst and water; filling the mixed powder into a mold of a molding machine; forming a formed body by pressurizing the filled mixed powder; curing the formed body in a carbon dioxide atmosphere; and forming a thin layer made of a second photocatalyst on a surface of the formed body.

Abstract: A composition used for high-strength impermeable concrete. The composition contains sand, stone, cement, water reducer, water and reinforced impermeable sand. The reinforced impermeable sand includes aeolian sand and binder covering the surface of the aeolian sand. The reinforced impermeable sand can fill the gap between the sand and the stone, and well combine various components in the composition, and suppress the seepage phenomenon of the molded concrete, thereby greatly improving the strength and impermeability of the concrete.

Abstract: Cement compositions containing biowaste ash and methods of cementing in subterranean formations using such cement compositions. Examples of suitable biowaste ash include agricultural waste ash, municipal waste ash, waste-water treatment waste ash, animal waste ash, non-human-non-animal industrial waste ash, and combinations thereof.

Abstract: A cement manufacturing apparatus capable of increasing quantity of fly ash used in the apparatus while controlling unburned carbon content in cement within a permissible range. The cement manufacturing apparatus comprises a removal means for removing unburned carbon from gypsum, and a grinding means for grinding gypsum from which unburned carbon is removed by the removal means together with clinker to generate cement. With the apparatus, total unburned carbon content in cement can be reduced, and the quantity of fly ash used in the apparatus can be, increased by the reduced amount of unburned carbon. The removal means can remove unburned carbon contained in gypsum as well as unburned carbon contained in fly ash, and the grinding means may grind the fly ash from which unburned carbon is removed together with the gypsum, from which unburned carbon is removed, and clinker.

Abstract: Methods for preparing metakaolin-enhanced industrial minerals. Mixing and heating kaolinite clay with an industrial mineral, such as activated carbon, that is between 750° F. and 1400° F. results in a metakaolin/activated carbon complex that provides good mercury sorbent qualities while producing a fly ash (after use as a sorbent in emissions applications) that has a lower foaming index.

Abstract: A catalyst composition for pozzolan compositions, includes: a) one or more chlorides, selected from the group consisting of: sodium chloride, potassium chloride, magnesium chloride, calcium chloride, strontium chloride, barium chloride and/or ammonium chloride, preferably ammonium chloride; b) aluminum chloride, and c) one or more metal oxides, preferably selected from the group consisting of: oxides from metals from Group II of the Periodic Table, oxides from metals from Group VIII B of the Periodic Table (e.g. iron oxide), more preferably oxides from metals from Group II of the Periodic Table, even more preferably magnesium oxide or calcium oxide, most preferably magnesium oxide. The use of the catalytic composition for addition to cement for oil well cementing, and for lowering the pH of cement, a method for obtaining a composition for reinforcing cement, a binder composition and a construction composition are also described.

Abstract: A cementitious mixture for high-volume production of masonry products comprises a hydraulic binder accounting for 20 wt % or more of the cementitious mixture, the hydraulic binder comprising 75 to 100 wt % Class C fly ash with a CaO equivalent content of at least 15% by weight. The cementitious mixture also comprises one or more aggregates, and a set control system.

Abstract: A cementitious mixture for high-volume production of masonry products comprises a hydraulic binder accounting for 20 wt % or more of the cementitious mixture, the hydraulic binder comprising 75 to 100 wt % Class C fly ash with a CaO equivalent content of at least 15% by weight. The cementitious mixture also comprises one or more aggregates, and a set control system.

Abstract: The present invention relates to an alkali-activated binder which can be used as a binder for replacing cement, and more particularly, to an alkali-activated binder, and to mortar, concrete, concrete products, and wet loess paving material comprising the binder, in which inorganic sodium-free alkaline materials are contained to reduce the total amount of Na2O and K2O in concrete, thus improving the workability and the strength stability and inhibiting the alkali-aggregate reaction.

Abstract: A cement clinker which can be sintered at 1,300 to 1,400° C. which is lower than the conventional sintering temperature and develops excellent strength characteristics such as mortar compression strength. The cement clinker has a total content of C3A and C4AF calculated by Bogue's formulas of 22 mass % or more, a C35 content calculated by Bogue's formula of 60 mass % or more and an iron modulus (I.M.) of 1.3 or less, preferably 1.0 to 1.3. Since the total content of C3A and C4AF is 22 mass % or more, the cement clinker can be sintered at a low temperature and the reduction of strength when a cement composition is cured can be prevented by reducing the iron modulus of the cement clinker.