Abstract: A method to stabilize solid and liquid waste at room temperature is provided comprising combining solid waste with a starter oxide to obtain a powder, contacting the powder with an acid solution to create a slurry, said acid solution containing the liquid waste, shaping the now-mixed slurry into a predetermined form, and allowing the now-formed slurry to set. The invention also provides for a method to encapsulate and stabilize waste containing cesium comprising combining the waste with Zr(OH).sub.4 to create a solid-phase mixture, mixing phosphoric acid with the solid-phase mixture to create a slurry, subjecting the slurry to pressure; and allowing the now pressurized slurry to set. Lastly, the invention provides for a method to stabilize liquid waste, comprising supplying a powder containing magnesium, sodium and phosphate in predetermined proportions, mixing said powder with the liquid waste, such as tritium, and allowing the resulting slurry to set.

Abstract: This invention provides a process wherein hazardous or radioactive wastes in the form of liquids, slurries, or finely divided solids are mixed with finely divided glassformers (silica, alumina, soda, etc.) and injected directly into the plume of a non-transferred arc plasma torch. The extremely high temperatures and heat transfer rates makes it possible to convert the waste-glassformer mixture into a fully vitrified molten glass product in a matter of milliseconds. The molten product may then be collected in a crucible for casting into final wasteform geometry, quenching in water, or further holding time to improve homogeneity and eliminate bubbles.

Abstract: A method of recovering metals and producing a secondary slag from base metal smelter slag produced by a copper or nickel smelter includes mixing the smelter slag with at least one reducing agent selected from the group consisting of carbon and aluminum, said carbon (if present) being from about 1% to about 10% by weight of the slag and said aluminum (if present) being from about 5 to about 30% by weight of the slag, and with from zero to about 60% calcium oxide by weight of the slag. The mixture is heated above the eutectic melting point thereof directly and to ignition temperature aluminothermically (if aluminum is present as reducing agent) to reduce the iron silicate to ferrosilicon containing substantially all the copper, nickel and cobalt which was in the smelter slag and form a secondary slag comprising at least one compound selected from the group consisting of calcium silicate, calcium aluminate and calcium iron aluminum silicate. The ferrosilicon is then separated from the secondary slag.

Abstract: The invention relates to a process of eliminating high chloride-containing incinerator ash and incinerator ash-residue mixtures, without generating excessive heavy metal-containing effluents during the actual vitrification of the ash. The process involves first pretreating the incinerator ash or ash-residue mixture, if needed, whereby the resultant ash contains less than about 3% halogen by weight and less than about 3% C.. Following the pretreatment, the ash is dried and then mixed with any additives needed to make up a vitrifiable batch mixture which will, when subsequently vitrified, form a glass possessing an excellent acid durability. A durability whereby such that the weight loss of the glass in 5% HCl solution at 95.degree. C. is 2.0 mg/cm.sup.2 or less in 24 hours. This durability results in minimal or non-detectable leaching of hazardous heavy metal or non-metallic specie and is sufficient enough durability such that the vitrified glass will easily pass the EPA's test for leachability.

Abstract: Asbestos cement may be converted to a harmless product by melting at a melt temperature of 1400.degree. to 1700.degree. C. a blend of 50 to 85% by weight asbestos cement with 15 to 50% by weight of additives that include naturally occurring silicate material such that the total blend has a CaO content of not more than 50%. The melt is discharged from the furnace, cooled and solidified and may be used as aggregate or, generally after solidification as regular units, may be used as part or all of the charge for producing MMV fibre material. It is of particular value for the production of man made vitreous fibre material that has low alumina content and is soluble in lung fluids.

Abstract: A process for treatment of aluminum dross residue (NMP) having available aluminum nitride (AlN) and/or free aluminum (Al) and/or aluminum chlorides (AlCl.sub.3) having a particle size within the range of 0.3 to 300 microns, i.e., "fines" to produce a high alumina lightweight aggregate is described. The process is characterized in that the NMP is fed into a rotating sealed kiln and heated to a temperature in the range of 2000.degree. to 4000.degree. F. while feeding oxygen or a mixture of oxygen and water into the kiln with less than about 20% of the total heat energy input for heating the NMP to a temperature between 2000.degree. and 4000.degree. F. being supplied from an external source. The process does not require prior agglomerization of the fines.

Abstract: A process for treating a halogen-containing waste material. The process provides a bath of molten glass containing a sacrificial metal oxide capable of reacting with a halogen in the waste material. The sacrificial metal oxide is present in the molten glass in at least a stoichiometric amount with respect to the halogen in the waste material. The waste material is introduced into the bath of molten glass to cause a reaction between the halogen in the waste material and the sacrificial metal oxide to yield a metal halide. The metal halide is a gas at the temperature of the molten glass. The gaseous metal halide is separated from the molten glass and contacted with an aqueous scrubber solution of an alkali metal hydroxide to yield a metal hydroxide or metal oxide-containing precipitate and a soluble alkali metal halide. The precipitate is then separated from the aqueous scrubber solution. The molten glass containing the treated waste material is removed from the bath as a waste glass.

Abstract: The invention comprises a novel type of glass for a cone (3) of a display tube envelope (1), said glass being manufactured by recycling screen glass and cone glass of display tube envelopes. A mixture of screen and cone glasses is supplemented with other glass-forming components to form a novel glass composition which can be used in cone glass applications. The glass is characterized by a relatively high BaO and SrO content. The glass has an x-ray absorption .mu. of at least 65 cm.sup.-1 at 0.6 .ANG..

Abstract: Disclosed is a method for converting spent nuclear fuel and surplus plutonium into a vitreous ceramic final waste form wherein spent nuclear fuel is bound in a crystalline matrix which is in turn bound within glass.

Abstract: The invention is the new material, a ternary compound of cesium, silica, and titania, together with a method of making the ternary compound, cesium titanium silicate pollucite. More specifically, the invention is Cs.sub.2 Ti.sub.2 Si.sub.4 O.sub.13 pollucite which is a new crystalline phase representing a novel class of Ti-containing zeolites. Compositions contain relatively high Cs.sub.2 O and TiO.sub.2 loadings and are durable glass and ceramic materials. The amount of TiO.sub.2 and Cs.sub.2 that can be incorporated into these glasses and crystalline ceramics far exceeds the limits set for the borosilicate high level waste glass.

Abstract: The present invention has disclosed raw materials for producing color ceramic products, which is prepared by using V-bearing titanomagnetite tails obtained after ore dressing as base material with a given proportion of additives and with or without coloring agents. The total content of Fe, Ti, Co, and Ni in said base material is in a range of about 3-45% by weight. The raw materials of the present invention have the advantages of no free iron and soluble vanadium compounds contained therein, thus when they are used to produce ceramic products, they can be sintered in a wide temperature range within shorter time. The products produced therefrom have the advantages of higher strength and hardness, lower water absorption, higher corrosion resistance, and stable tints. Products with a variety of sorts and various colors can be produced by using the raw materials of the present invention.

Abstract: A ceramic kiln-fired product which comprises glass, fly ash, and a clay binder. Further provided is a method for preparing raw material suitable for forming a shaped, kiln-fired, ceramic product. The method comprises mixing glass, fly ash, and a clay binder with from about 10 wt. % to about 15 wt. % water, on a dry weight basis, to form an aqueous mixture, separating the aqueous mixture using a mesh of from about 10 to about 12 screen into first and second portions, the first portion comprising the aqueous mixture which does not pass through the mesh and the second portion comprising the aqueous mixture which passes through the mesh, and drying the second portion until the moisture content of the second portion is less than about 0.5 wt. % to form the raw material. The present invention also provides a tile glazing formulation which may be used with the ceramic product of the present invention, as well as a method of using the formulation. The glazing formulation comprises, on a dry weight basis, about 70 wt.

Abstract: Compositions for refractory materials and methods for providing the compositions are described. A synthetic forsterite-rich refractory sand composition includes a mixture. The mixture includes: a) a carbon bridging agent, the carbon bridging agent being present in the mixture in a proportion of from approximately 5 to approximately 15 percent by weight of the mixture; and b) a synthetic forsterite-rich sand, the synthetic forsterite-rich sand being free-flowing, having a MgO:SiO.sub.2 weight ratio of at least approximately 1.2, a specific gravity of approximately 3 g/cm.sup.3, a void volume of less than approximately 50 percent by volume of the synthetic forsterite-rich sand, and a fusion point of at least approximately 1610.degree. C., wherein i) at least approximately 50 percent by weight of the synthetic forsterite-rich sand is forsterite, and ii) from approximately 3 to approximately 27 percent by weight of the synthetic forsterite-rich sand is maghemite.

Abstract: The present invention relates to a process for forming glass-ceramic tiles. Spent aluminum potliner containing carbonaceous material, fluorine, and glass forming materials is oxidized under conditions effective to combust the carbonaceous material and volatilize partially the fluorine in the glass forming materials. The oxidized glass forming materials are vitrified to form a glass melt. This glass melt is then formed into tiles containing fluorine.

Abstract: The invention is a process for decomposing dried paint sludge to recover the organic and inorganic components of the paint sludge as gaseous, liquid, and composite materials. The process comprises drying the paint sludge to remove water and organic solvents, pyrolizing the dried paint sludge in an inert atmosphere in an elevated temperature of up to about 600.degree. C. to form gaseous and liquid decomposition materials and a solid residue. The process further comprises collecting the gaseous and liquid decomposition materials and subjecting the solid residue to sintering in an elevated temperate of about 900.degree. to 1300.degree. C. in an atmosphere of nitrogen, argon or ammonia to convert the solid residue to composite materials comprising barium nitranate and titanium compounds such as titanium dioxide, titanium nitride, and titanium carbide. The gaseous and liquid materials may be further pyrolyzed to carbon materials.

Abstract: A novel glass batch material produced from materials comprising refractory brick and one or more fluxes and an associated method, and a method of making glass utilizing the novel glass batch material. The present invention provides a method of safely and inexpensively disposing of and utilizing used refractory linings from glass melting furnaces.

Abstract: A method of vitrifying a high-level radioactive liquid waste comprising removing a precipitate composed mainly of Mo and Zr from the high-level liquid waste, mixing the resulting high-level liquid waste with a raw glass material having a chemical composition wherein the B.sub.2 O.sub.3 /SiO.sub.2, ZnO/Li.sub.2 O and Al.sub.2 O.sub.3 /Li.sub.2 O ratios are at least 0.41, at least 1.00 and at least 2.58, respectively, and melt-solidifying the mixture to thereby form a vitrified waste. By using such a raw glass material, there can be obtained a vitrifled waste having the waste content of about 45% by oxide weight in which the same leaching rate as that of a conventional vitrified waste having the waste content of 25% by oxide weight is ensured without suffering from yellow phase separation.

Abstract: A ceramic material made from raw coal fly ash or raw municipal solid waste fly ash and (1) sodium tetraborate or (2) a mixture of sodium tetraborate and a calcium containing material that is triple superphosphate, lime, dolomitic lime, or mixtures thereof.

Abstract: An amorphous ceramic glass composition having a density greater than about 2.1 g/cm.sup.3 comprises: between about 35 and 55% by weight SiO.sub.2 ; between about 18 and 28% by weight Al.sub.2 O.sub.3 ; between about 1 and 5% by weight CaO; between about 7 and 14% by weight MgO; between about 0.5 and 5% by weight TiO.sub.2 ; between about 0.4 and 3% by weight B.sub.2 O.sub.3 ; and greater than 0 and up to about 1% by weight P.sub.2 O.sub.5. A convenient source of raw materials is a mixture of coal ash waste, borax (or boric acid) manufacturing plant waste, and titanium pigment waste. The ceramic glass is formed from an intermediate ceramic mixture which is subjected to a heat treatment. The intermediate ceramic mixture is formed by heating a mixture containing SiO.sub.2, Al.sub.2 O.sub.3, CaO, MgO, TiO.sub.2, B.sub.2 O.sub.3, and Na.sub.4 P.sub.2 O.sub.7 to a temperature between about 1400.degree. and 1600.degree. C.; cooling the mixture at a controlled rate between about 15.degree. C. and about 30.degree. C.

Abstract: A method and apparatus of reclaiming hazardous inorganic wastes to produce an environmentally benign abrasive for use in loose grain processes, as a coated or bonded abrasive, or as a polishing grain. A tough and useful abrasive, with a MOH hardness of 7 to 8, is manufactured from emission control dusts of the aluminum industry or sludges from other industries, and may include small amounts of lead and cadmium oxides as toughening agents. The abrasive particles are sized by air sifting or by water sedimentation separating methods. The process for the manufacture of abrasive material comprises the steps of removing soluble salts from a waste stream by hot water extraction; using a computer matrix to group the waste stream into different batches for mixing with other glass-making materials to form a batch mixture; oxidizing the organic compounds contained in the batched mixture; melting the batch mixture to form a glasseous substance; and fritting the glasseous substance to form the abrasive.

Abstract: A method for treating materials such as wastes for solidification to form a solid, substantially nonleachable product. Addition of reactive silica rather than ordinary silica to the material when bringing the initial molar ratio of its silica constituent to a desired ratio within a preselected range increases the solubility and retention of the materials in the solidified matrix. Materials include hazardous, radioactive, mixed, and heavy metal species. Amounts of other constituents of the material, in addition to its silica content are also added so that the molar ratio of each of these constituents is within the preselected ranges for the final solidified product. The mixture is then solidified by cement solidification or vitrification.

Abstract: An improved method for processing aluminum dross containing fluxing salt to provide a fired inorganic or ceramic product wherein said dross is processed to remove fluxing salts therefrom, and wherein a non-metallic product is recovered. The improved process comprises providing a body of the non-metallic product in an aqueous slurry, a major portion of the body comprised of Al.sub.2 O.sub.3 and minor portions of said body comprised of SiO.sub.2 and MgO. The composition of the slurry is adjusted by adding one of Al.sub.2 O.sub.3 and SiO.sub.2 in an amount sufficient to form the fired inorganic product on heating. The slurry is heated to a temperature sufficiently high to fire the slurry and produce the fired inorganic product.

Abstract: A process for obtaining a synthetic refractory sand for use in steelmaking, said synthetic refractory sand being free-flowing, comprising at least 50% forsterite, having semi-angular and irregularly shaped grains, lenses and flat grains, a specific gravity of approximately 3 g/cm.sup.3, a void volume of less than approximately 50%, a coefficient of thermal expansion of approximately 1.09.times.10.sup.-5 and a fusion point of at least 1610.degree. C. including the steps of: (a) agglomerating a mixture comprising a particulate starting material selected from the group consisting of serpentine-containing asbestos tailings and an enstatite-containing product produced by calcining serpentine-containing asbestos tailings and from 10% to 25%, based on the total weight of mixture, of magnesium oxides or precursors of magnesium oxides with an aqueous binder solution to obtain agglomerates of said mixture; (b) calcining said agglomerates at a temperature of from 1200.degree. C. to 1500.degree. C.

Abstract: The present invention relates to a novel composition which is useful for forming construction blocks and encapsulating hazardous materials, a process for producing blocks and encapsulating the material, and blocks made of the material. This composition is a mixture of pozzoulanic fly ash and bottom ash. The weight ratio of fly ash:bottom ash is preferably in the range 80:20% by weight to 20:80% by weight. The process comprises the steps of (a) blending a dry mixture comprising the ash mixture with water; (b) transferring the blended mixture into a compression zone and (c) compressing the blended mixture in the compression zone to form a brick of the desired size.

Abstract: A ceramic glass composition comprises: between about 35 and 55% by weight SiO.sub.2 ; between about 18 and 28% by weight Al.sub.2 O.sub.3 ; between about 1 and 5% by weight CaO; between about 7 and 14% by weight MgO; between about 0.5 and 5% by weight TiO.sub.2 ; between about 0.4 and 3% by weight B.sub.2 O.sub.3 ; and greater than 0 and up to about 1% by weight P.sub.2 O.sub.5. A convenient source of raw materials is a mixture of coal ash waste, borax (or boric acid) manufacturing plant waste, and titanium pigment waste. The ceramic glass is formed from an intermediate ceramic mixture which is subjected to a heat treatment. The intermediate ceramic mixture is formed by heating a mixture containing SiO.sub.2, Al.sub.2 O.sub.3, CaO, MgO, TiO.sub.2, B.sub.2 O.sub.3, and Na.sub.4 P.sub.2 O.sub.7 to a temperature between about 1400.degree. and 1600.degree. C.; cooling the mixture to solidify it; annealing the mixture at 600.degree. to 670.degree. C.

Abstract: The present invention relates to a novel composition which is useful for forming construction blocks and encapsulating hazardous materials, a process for producing blocks and encapsulating the material, and blocks made of the material. This composition is a mixture of kiln dust or volcanic fly ash and aggregate. The process comprises the steps of (a) blending a dry mixture comprising the kiln dust or volcanic fly ash mixture with water; (b) transferring the blended mixture into a compression zone and (c) compressing the blended mixture in the compression zone to form a brick of the desired size.

Abstract: A method is described for making concrete from an initially dry mixture including Portland cement, a fine aggregate, and a coarse aggregate. The method is effective for curing mixtures which contain rubble, as well as for mixtures which contain primarily virgin aggregate. In the method, substantially dry steam is introduced to the mixture at elevated temperature and pressure. Air injection may be utilized to further increase the pressure. An improved concrete is also described. The concrete exhibits unexpectedly high compressive strength.

Abstract: A method of immobilizing a hazardous waste is provided. The method comprises providing a dry cementitious composition capable of hardening and in the form of finely divided particles of at least one cement binder, placing an amount of the dry cementitious composition into the hazardous waste with or without an additional added volume of water, without any type of physical mixing of the cementitious composition and water other than the mixing which occurs merely by applying the cementitious composition into the water. The major portion of the particles of the cementitious composition have approximately the same drop rate through the volume of water. The water contacts the dry cementitious composition when poured into the volume of water to hydrate the particles of the dry cementitious composition, the particles of cementitious composition dropping through the water to displace excess water and form the hydrated cementitious composition particles in a substantially non-segregated mass.

Abstract: A leach-resistant vitrified composition, particularly suitable for long term encapsulation and disposal of nuclear wastes, comprises a high iron, high potassium aluminosilicate, fired at a temperature of at least 1850.degree. F. for at least 12 h.

Abstract: Lead in coatings on structures can be removed, without creating hazardous waste, by a flame spray process which utilizes a glass composition having high lead solubility, resistance to devitrification, and an expansion coefficient which is substantially different from that of the metal structure. The process comprises flame spraying particles of a glass powder composition onto the lead based coating to form a layer of glass material, permitting the glass layer to cool sufficiently so that it spalls, thereby forming fragments of the glass layer which readily separate from the structure, collecting the glass fragments, and repeating these steps until any organic material in the coating has been pyrolized and removed as part of the fragments, substantially all red lead present in the coating has been reduced to yellow lead, and all of the lead which was in the lead based coating has been removed from the structure by being incorporated into the glass layers.

Abstract: A process for producing brick involves calcining electric arc furnace dust and subsequently mixing the dust with a brick raw material prior to shaping the material into bricks and firing. The precalcination of the EAF dust greatly increases the bulk density of the dust and provides a brick having a much higher compressive strength when compared to bricks incorporating raw dust which has not been precalcined. Volatilized and recondensed heavy metals produced during the calcination process are collected and refined. As a result of the separation and collection of the volatilized heavy metals during the calcination process, substantially no heavy metals are volatilized during the brick firing process.

Abstract: A process for the production of a water-insoluble, abrasion-resistant, synthetic solid article or aggregate, as well as the products produced thereby. Fly ash, lime, water and FGD sludge are mixed intimately and formed at pressures exceeding 1,000 psi, preferably 4000-8000 psi. The product is cured for at least the equivalent of 28 days at 73.degree. F., and crushed and sized to produce a commercial aggregate, for example, for concrete, asphalt, concrete masonry units, etc.

Abstract: The invention relates to ceramic composite articles formed by infiltration of a particulate, permeable bed or permeable preform with a polycrystalline matrix produced as a metal-oxidant reaction product. The bed or preform includes a dross material.

Abstract: A building product comprises slate particles e.g. flakes, slivers, chips, fragments, and/or powdered dust particles bonded together by a fused glassy binder.

Abstract: A waste material which contains chromium and/or lead impurities is treated by mixing the waste material with diatomaceous earth and/or sodium borate and then heating the mixture in a free oxygen containing gas at about 500.degree.-1500.degree. C., preferably in the presence of steam.

Abstract: The invention provides a process for producing a ceramic product for use as a construction material. According to the process of the invention, 2 to 50% by weight, based on the total weight, of sludge ashes containing 0.3 to 0.8 mole of CaO in Seger formula, 0.1 to 0.5 mole of MgO in Seger formula, and 0.2 mole or more of P.sub.2 O.sub.5 in Seger formula is added to a ceramic raw material. A desired percentage can be selected from the range of 2 to 50% to produce a ceramic product with desired properties. Also, according to the invention, a molded body can be fired at a temperature lower than a temperature used to fire a molded body with no sludge ashes to produce a ceramic product which is comparable to a ceramic product produced by firing the latter molded body. That is, according to the invention, a molded body can be fired at a temperature of 900.degree. to 1,200 .degree. C. to produce such a ceramic product.

Abstract: An inorganic based strippable coating is provided for isolating hazardous materials. The coating is formed from a metal alkoxide material which undergoes a sol-gel reaction to form a metal oxide material. While the sol is still in a green state, the sol is applied to the surface to be protected. Any hazardous material such as nuclear contamination present on the surface is trapped within the matrix of the sol. The sol coating may be stripped from the surface while in a green state or may be allowed to harden. Once hardened, the sol forms a metal oxide coating which will deter the future accumulation of contamination.

Abstract: A processing method is presented for treating sludges from municipal and waste materials. The ashes from such sludges, containing SiO.sub.2 as a primary constituent, are treated with additives to tailor the feed material composition. Thermal processing, including melting, rapid cooling and subsequent annealing, produces a crystallized glass microstructure in which needle-shaped shaped crystals of anorthite and .beta.-wollastnite are infiltrated with a vitreous material. Such crystallized glasses having superior mechanical and aesthetic properties are an attractive architectural material which can be utilized for interior finishing, exterior walls, flooring as well as for interior decorations.

Abstract: Material, such as, for example, sealed double bags of asbestos containing waste or ash from infectious waste or toxic material or radioactive waste, is transferred into a glass melt of a furnace. Gas bubbles released into the melt form a gas curtain which causes enhanced mixing of the material to accelerate the dissolution of the components of the added material. The presence of the gas bubbles reduces the cross-section of the molten glass through which current passes, which in turn increases the electrical resistance of the glass melt and therefore increases power generation of the melt or power density at constant current. A highly oxidizing hot region is produced under the location where the material is introduced into the furnace. Drawn off glass is shaped and quenched into at least two sizes of approximate spheres. The spheres are cooled sufficiently fast to be thermally tempered and have a surface compressive strength level above 5000 psi.

Abstract: The process is the type wherein the solid portions of waste materials of all origins are crushed and ground to a granulometry of under 5 mm and then are heated to between 750.degree. C. and 1,350.degree. C. According to the invention, after the addition, if applicable, of liquid waste to obtain a pasty mass, a reagent is added to the latter, in pulverulent form having granules of under 500 microns based with calcium carbonate, silicium oxide and, possibly, aluminum and iron oxides in quantities to produce the following ratio after incineration: ##EQU1## Application to the treatment of all types of waste by combustion.

Abstract: The ceramic tile using sludge slag of the present invention comprises:______________________________________ sludge slag from 5 to 70 wt. %, agalmatolite from 20 to 90 wt. %, clay from 5 to 50 wt. %, and the balance being incidental impurities. ______________________________________The sludge slag is obtained by separating sludge from sewage, burning the thus separated sludge into ash, melting the resultant ash and solidifying the thus melted ash. The sludge slag consists essentially of: ______________________________________ silicon dioxide (SiO.sub.2) from 10 to 50 wt. %, aluminum oxide (Al.sub.2 O.sub.3) from 3 to 20 wt. %, phosphorous pentoxide (P.sub.2 O.sub.5) from 1 to 30 wt. %, calcium oxide (CaO) from 10 to 70 wt. %, magnesium oxide (MgO) from 0.5 to 20 wt. %, and iron oxide (Fe.sub.2 O.sub.3) from 5 to 25 wt. %.

Abstract: A low density aggregate product and method for making the same utilizing coal ash slag resulting from a typical coal gasification system wherein the resulting aggregate product has a lower density than the initial coal ash slag. The coal ash slag is combined with a small amount of a binder and then fired for a predetermined time and temperature to produce the aggregate. Also, by heating the coal ash slag and binder, a gaseous efflux is emitted to form interlaced channels throughout the aggregate which have a characteristic length and diameter.

Abstract: Aluminum electrolysis cell having a refractory lining, said lining being produced by calcining red mud obtained as a byproduct of the Bayer process of producing alumina, grinding the calcined product to form particles of -4 Tyler mesh, mixing the ground product with a binder (e.g. colloidal silica, colloidal alumina, sodium silicate or sodium aluminate) and sufficient water to produce a formable mixture. The mixture is formed into a shaped product, fired and used, for example, as a monolithic lining, to form the internal surface of the aluminum electrolysis production cell.

Abstract: The method of disposal of hydrocarbon sludge (such as petroleum-derived sludge residue from a hydrocracker) comprises mixing the sludge with spent silica-alumina catalyst particulate fines, of particle size not exceeding 50 micrometers, so as to form friable aggregates of the particulate fines in which the individual particles are bound together by the sludge. The resulting formulation is useful, inter alia, for road-making.

Abstract: Production of composite ceramic articles by infiltration of a particulate, permeable bed or permeable preform with a polycrystalline matrix produced as a metal-oxidant reaction product, wherein the bed or preform is comprised of dross.

Abstract: A process for using nitride-containing aluminum dross residues to produce refractory products. The process involves mixing a dross residue which contains AlN, without prior conversion of the aluminum nitride in the dross to aluminum oxide or hydroxide, with a material comprising a metal oxide or a metal oxide precursor, and calcining the resulting mixture at a temperature suitable to produce a refractory product. During the calcination step, the AlN reacts with other components of the mixture. Since the reaction is exothermic, less heat is required for the calcination step than if a dross residue containing no AlN were used. The AlN can also reduce various contaminants (e.g. Fe.sub.2 O.sub.3, silicon and titanium) present in the metal oxide refractories, and so the invention can be used to produce conventional refractory products of improved purity and appearance. The process enables dross residues to be used for useful purposes rather than being discarded.

Abstract: For a complete utilization of used DeNOx catalysts contaminated with fly ash, the catalyst is crushed to a particle size of usually less than 500 microns, admixed with the ash of a molten ash firing chamber of a coal power plant at weight ratio of usually at least 9 parts molten ash to 1 part catalyst where the catalyst is dissolved in the molten ash at a temperature generally above 1460.degree. C. The resulting molten ash chamber granulated material can be utilized in the usual way, for example in the construction industry, since no pollutants, especially no compounds of tungsten, molybdenum, vanadium and arsenic are eluted into the environment.

Abstract: Disclosed is a heat-resistant composition particularly useful to produce heat-resistant boards, tubes, linings or similar articles, capable of resisting to a high temperature for a substantial period of time. The composition comprises from 30 to 70% by weight of a fibrous-like, synthetic forsterite obtained by calcination of chrysotile asbestos fibers at a temperature of from 650.degree. C. to 1450.degree. C., the synthetic forsterite having an MgO: SiO.sub.2 ratio lower than 1.1, a raw loose density of from 3 to 40 pcf, a thermal conductivity "k" factor of from 0.25 to 0.40 BTU. in/hr. .degree.F. ft.sup.2 and a fusion point of from 1600.degree. C. to 1700.degree. C. The composition also comprises colloidal silica as a binder. If desired, the composition may further comprise reinforcing fibers in such an amount as to give sufficient strength to the composition to make it operative depending on the intended use of the article produced therefrom.

Abstract: Chromite by-products having a composition which includes FeCr.sub.2 O.sub.4 as well as iron, aluminum, magnesium, sodium, calcium and silicon oxides are directly mixed with cement mortar and with the aggregates on use, or added to the water, producing the effect of corrosion inhibition of the steel reinforcements.

Abstract: A process for producing a refractory material and to the material so-produced. The process comprises calcining red mud obtained as a by-product of the Bayer process of producing alumina, grinding the calcined product to form particles of -4 Tyler mesh, mixing the ground product with a binder (e.g. colloidal silica, colloidal alumina, sodium silicate or sodium aluminate) and sufficient water to produce a formable mixture. The mixture is then formed into a desired shape and fired, preferably after curing and drying. The resulting fired products have good resistance to high temperatures and to corrosive chemicals such as cryolite. Consequently, the products can be used as refractory linings for aluminium production cells, and in similar applications.