Abstract: A dual-purpose railway hopper car is constructed so that it is capable of holding, handling and hauling both coal and fly ash on different trips by virtue of having a plurality of quick opening hopper doors which are sealed to prevent leakage of fly ash when closed, highly sloping active walls, a covered top with a wide longitudinal hatch for loading coal, which wide hatch carries a smaller circular hatch for pneumatically loading fly ash. The coal hatch is operated by air cylinders from a quick connect coupling at ground level. A center sill covers the hopper door operating linkage.

Abstract: Ash from a fluidized bed combustor in which limestone particles are suspended in the presence of carbonaceous fuel being burned is pelletized. Lime-containing bed ash ("FBCR") is produced in the combustor, and fly ash ("FBC fly ash") is generated as a by-product of the combustion process. FBCR and FBC fly ash generated during the combustion process are obtained. Water is added to the FBCR so as to convert a substantial portion of the lime to hydrated lime. Water is added to the FBC fly ash and pellets are formed from the FBC fly ash. The FBC fly ash pellets are coated with the hydrated FBCR. The coated FBC fly ash pellets are cured in a curing silo for a minimum of 6-10 hours, preferably by nesting them in a bed of hydrated FBCR. The cured pellets then are separated from the bed of hydrated FBCR. New pellets are formed by mixing the separated, hydrated FBCR with FBC fly ash and water.