Abstract: Methods of recovering coal combustion products (CCPs) and/or dry bottom furnace slag (DBFS) from coal combustion byproducts are disclosed. The methods include compiling coal combustion byproducts (e.g., from combustion of lignite coal and/or bituminous coal), grinding the coal combustion byproducts to form ground coal combustion byproducts with a maximum particle size of 40 microns, and separating CCPs from the ground coal combustion byproducts using an electrostatic precipitator. The following CCPs can be separated from the coal combustion byproducts using the presently disclosed methods: fly ash, bottom ash (e.g., containing pyrites), scrubber materials (e.g., calcium sulfate and calcium sulfite), and raw coal.

Abstract: Methods of recovering coal combustion products (CCPs) from coal combination byproducts are disclosed. The methods include compiling coal combustion byproducts (e.g., lignite coal and/or bituminous coal), grinding the coal combustion byproducts to form ground coal combustion byproducts with a maximum particle size of 40 microns, and separating the ground coal combustion byproducts to yield CCPs using an electrostatic precipitator. The following CCPs can be separated from the coal combination byproducts using the presently disclosed methods: fly ash, bottom ash, scrubber materials, and raw coal.

Abstract: A method for accelerating the strength of cement involves providing an activated fly ash processed to increase the surface area of the fly ash and reacting the activated fly ash with a polycarboxylate heteropolymer that acts as a catalyst to produce a pozzolanic cementitious material having as much as a 28% increase in strength (e.g., compressive strength). In one embodiment, the heteropolymer includes hydrophilic and hydrophobic components that assist in providing an optimal equilibrium for the formation of cementitious structures. The increase in strength permits reducing the amount of Portland cement mixed with the pozzolanic cementitious material to as little as 30% by weight, thus achieving a significant cost reduction.

Abstract: A method of producing high-strength cementitious product from raw fly ash by mixing the raw fly ash with a lithium compound, whereby milling of the raw fly ash to achieve requisite strength is unnecessary. It has now been found that by adding as little as 0.1% of lithium chloride to raw untreated Class C fly ash, one can achieve improved seven-day and twenty-eight-day compressive strength. At the very least, raw lithium treated Class C fly ash may be used at lower total cementitious content per yard of concrete as opposed to Ordinary Portland Cement (OPC) for improved compressive strength.

Abstract: A method for accelerating the strength of cement involves providing an activated fly ash processed to increase the surface area of the fly ash and reacting the activated fly ash with a polycarboxylate heteropolymer that acts as a catalyst to produce a pozzolanic cementitious material having as much as a 28% increase in strength (e.g., compressive strength). In one embodiment, the heteropolymer includes hydrophilic and hydrophobic components that assist in providing an optimal equilibrium for the formation of cementitious structures. The increase in strength permits reducing the amount of Portland Cement mixed with the pozzolanic cementitious material to as little as 30%, thus achieving a significant cost reduction.

Abstract: A process is provided for treating raw fly ash used in cementitious material so as to increase the strength of the cementitious material while at the same time providing a near linear strength increase for the material as it cures by processing the raw fly ash, as by milling, and by mixing the processed fly ash with a catalyst such as lithium, with the lithium concentration in the fly ash being between 0.05% and 0.25% by weight. The process applies to Class C fly ash and Class F fly ash when mixed with Class C fly ash. All of the above processes include the use of polycarboxylates.

Abstract: A method of producing high strength cementitious product from raw fly ash by mixing the raw fly ash with a lithium compound, whereby milling of the raw fly ash to achieve requisite strength is unnecessary. It has now been found that by adding as little as 0.1% of lithium chloride to raw untreated Class C fly ash one can achieve improved seven day and twenty-eight day compressive strength. At the very least, raw lithium treated Class C fly ash may be used at lower total cementitious content per yard of concrete as opposed to ordinary Portland Cement for improved compressive strength.

Abstract: A method for accelerating the strength of cement involves providing an activated fly ash processed to increase the surface area of the fly ash and reacting the activated fly ash with a polycarboxylate heteropolymer that acts as a catalyst to produce a pozzolanic cementitious material having as much as a 28% increase in strength. In one embodiment, the heteropolymer includes hydrophilic and hydrophobic components that assist in providing an optimal equilibrium for the formation of cementitious structures. The increase in strength permits reducing the amount of Portland Cement mixed with the pozzolanic cementitious material to as little as 30%, thus to achieve a significant cost reduction.

Abstract: A method for remediating alkali silica reactions prevents the reaction from starting by mixing a micro silica additive to an ozonated cement mix, with the micro silica constituting a micro sand that has no more than a 15-18 micron mean particle size and a top size of around 30-40 microns. In one embodiment the micro silica mixed at 8% results in a reduction in mortar expansion on average greater than 96% when used with ozonated Class C fly ash.

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: A dry mix for a composite cement is described. The dry mix includes a calcium-containing material, an aluminum-containing material, a lithium-containing accelerant, a retarder, and a pozzolanic additive that contains a soluble sulfur salt. The pozzolanic additive preferably includes a soluble sulfur salt at a fraction greater than approximately 0.2% by weight. The pozzolanic additive may be a fly ash, and is preferably a class C fly ash. A powdered additive for use with a pre-prepared dry mix for a calcium aluminate cement is also described. The powdered additive includes a lithium-containing accelerant, a retarder, and a pozzolanic additive that contains a soluble sulfur salt.

Abstract: Fly ash contaminated with activated carbon is treated to neutralize the activated carbon by placing the contaminated fly ash in a rotary mill and introducing ozone. The result is that entrained air in concrete made from activated fly ash will contain greater than 4 percent entrained air.

Abstract: Fly ash contaminated with activated carbon is treated to neutralize the activated carbon by placing the contaminated fly ash in a rotary mill and introducing ozone. The result is that entrained air in concrete made from activated fly ash will contain greater than 4 percent entrained air.

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: Increased surface area for a milled product is provided by modifying a standard vibrating media mill for a bottom feedstock feed instead of a top feed, and by replacing the front discharge grate with a solid disk having a slot or slots in the upper region thereof to increase dwell time. In one embodiment, ceramic media replaces the traditional depleted metal ball media.