Abstract: In accordance with an embodiment, a method for producing an aggregate is disclosed comprising mixing IBA and a second, silicoaluminous material having a calcium content less than the IBA. The method further comprises agglomerating the mixture, such as by pelletizing, and pyroprocessing the agglomerates, such as by sintering or vitrification, to form the aggregate. The second material may be a clay, such as bentonite or kaolin, a mining waste, such as granite sawing residues, waste glass, or furnace bottom ash, for example. The addition of the second material has been found to facilitate production of lightweight and normal weight aggregates. Preferably, the IBA or the mixture of IBA and the second material are wet milled prior to agglomeration. Methods for producing expanded aggregates are also disclosed.

Abstract: In one example of an embodiment of the invention, a method for producing an aggregate is disclosed comprising mixing sewage sludge from a waste water treatment facility with a non-coal combustion ash silicoaluminous waste material, agglomerating the mixture to form an agglomerate, and pyroprocessing the agglomerate to form an aggregate. The waste material may comprise municipal solid waste incinerator bottom ash, incinerator fly ash, incinerator filter dusts, cement kiln dusts, waste glass, blast furnace slag, kiln dusts, and/or granite sawing residues, for example. The method may further comprise milling the waste material prior to mixing. Preferably, the milling is wet milling. Pyroprocessing of the agglomerate may take place in a rotary kiln. The resulting aggregate may be a lightweight or a normal weight, sintered or vitrified aggregate. Aggregates and methods for making aggregates of high and low calcium silicoaluminous materials are also disclosed.

Abstract: In accordance with an embodiment, a method for producing an aggregate is disclosed comprising mixing IBA and a second, silicoaluminous material having a calcium content less than the IBA. The method further comprises agglomerating the mixture, such as by pelletizing, and pyroprocessing the agglomerates, such as by sintering or vitrification, to form the aggregate. The second material may be a clay, such as bentonite or kaolin, a mining waste, such as granite sawing residues, waste glass, or furnace bottom ash, for example. The addition of the second material has been found to facilitate production of lightweight and normal weight aggregates. Preferably, the IBA or the mixture of IBA and the second material are wet milled prior to agglomeration. Methods for producing expanded aggregates are also disclosed.

Abstract: In accordance with an embodiment, a method for producing an aggregate is disclosed comprising mixing IBA and a second, silicoaluminous material having a calcium content less than the IBA. The method further comprises agglomerating the mixture, such as by pelletizing, and pyroprocessing the agglomerates, such as by sintering or vitrification, to form the aggregate. The second material may be a clay, such as bentonite or kaolin, a mining waste, such as granite sawing residues, waste glass, or furnace bottom ash, for example. The addition of the second material has been found to facilitate production of lightweight and normal weight aggregates. Preferably, the IBA or the mixture of IBA and the second material are wet milled prior to agglomeration. A lightweight sintered aggregate comprising IBA and the second material and an aggregate comprising IBA and the second material are also disclosed.

Abstract: In one example of an embodiment of the invention, a method for producing an aggregate is disclosed comprising mixing sewage sludge from a waste water treatment facility with a non-coal combustion ash silicoaluminous waste material, agglomerating the mixture to form an agglomerate, and pyroprocessing the agglomerate to form an aggregate. The waste material may comprise municipal solid waste incinerator bottom ash, incinerator fly ash, incinerator filter dusts, cement kiln dusts, waste glass, blast furnace slag, kiln dusts, and/or granite sawing residues, for example. The method may further comprise milling the waste material prior to mixing. Preferably, the milling is wet milling. Pyroprocessing of the agglomerate may take place in a rotary kiln. The resulting aggregate may be a lightweight or a normal weight, sintered or vitrified aggregate. Aggregates and methods for making aggregates of high and low calcium silicoaluminous materials are also disclosed.

Abstract: In accordance with an embodiment, a method for producing an aggregate is disclosed comprising mixing incinerator bottom ash (“IBA”) from a municipal solid waste incinerator and pulverized fuel ash (“PFA”) from coal combustion. The method further comprises agglomerating the mixture, such as by pelletizing, and pyroprocessing the agglomerates, such as by sintering or vitrification, to form the aggregate. The addition of PFA to IBA has been found to facilitate production of lightweight and normal weight aggregates. Preferably, the IBA or the mixture of IBA and PFA is wet milled prior to agglomerating. A preferred proportion of IBA to PFA is 40%/60%. The agglomerates may be coated with an inorganic material to create a surface layer on the aggregate. Organic material may be included in the mixture to increase the porosity of the aggregate. A lightweight sintered aggregate comprising IBA and PFA and an aggregate comprising IBA and PFA are also disclosed.

Abstract: In one example of an embodiment of the invention, a method for producing an aggregate is disclosed comprising mixing sewage sludge from a waste water treatment facility with a non-coal combustion ash silicoaluminous waste material, agglomerating the mixture to form an agglomerate, and pyroprocessing the agglomerate to form an aggregate. The waste material may comprise municipal solid waste incinerator bottom ash, incinerator fly ash, incinerator filter dusts, cement kiln dusts, waste glass, blast furnace slag, kiln dusts, and/or granite sawing residues, for example. The method may further comprise milling the waste material prior to mixing. Preferably, the milling is wet milling. Pyroprocessing of the agglomerate may take place in a rotary kiln. The resulting aggregate may be a lightweight or a normal weight, sintered or vitrified aggregate. Aggregates and methods for making aggregates of high and low calcium silicoaluminous materials are also disclosed.

Abstract: In one example of an embodiment of the invention, a method for producing an aggregate is disclosed comprising mixing sewage sludge from a waste water treatment facility with a non-coal combustion ash silicoaluminous waste material, agglomerating the mixture to form an agglomerate, and pyroprocessing the agglomerate to form an aggregate. The waste material may comprise municipal solid waste incinerator bottom ash, incinerator fly ash, incinerator filter dusts, cement kiln dusts, waste glass, blast furnace slag, kiln dusts, and/or granite sawing residues, for example. The method may further comprise milling the waste material prior to mixing. Preferably, the milling is wet milling. Pyroprocessing of the agglomerate may take place in a rotary kiln. The resulting aggregate may be a lightweight or a normal weight, sintered or vitrified aggregate. Aggregates and methods for making aggregates of high and low calcium silicoaluminous materials are also disclosed.

Abstract: In accordance with an embodiment, a method for producing an aggregate is disclosed comprising mixing incinerator bottom ash (“IBA”) from a municipal solid waste incinerator and pulverized fuel ash (“PFA”) from coal combustion. The method further comprises agglomerating the mixture, such as by pelletizing, and pyroprocessing the agglomerates, such as by sintering or vitrification, to form the aggregate. The addition of PFA to IBA has been found to facilitate production of lightweight and normal weight aggregates. Preferably, the IBA or the mixture of IBA and PFA is wet milled prior to agglomerating. A preferred proportion of IBA to PFA is 40%/60%. The agglomerates may be coated with an inorganic material to create a surface layer on the aggregate. Organic material may be included in the mixture to increase the porosity of the aggregate. A lightweight sintered aggregate comprising IBA and PFA and an aggregate comprising IBA and PFA are also disclosed.

Abstract: In accordance with an embodiment, a method for producing an aggregate is disclosed comprising mixing IBA and a second, silicoaluminous material having a calcium content less than the IBA. The method further comprises agglomerating the mixture, such as by pelletizing, and pyroprocessing the agglomerates, such as by sintering or vitrification, to form the aggregate. The second material may be a clay, such as bentonite or kaolin, a mining waste, such as granite sawing residues, waste glass, or furnace bottom ash, for example. The addition of the second material has been found to facilitate production of lightweight and normal weight aggregates. Preferably, the IBA or the mixture of IBA and the second material are wet milled prior to agglomeration. A lightweight sintered aggregate comprising IBA and the second material and an aggregate comprising IBA and the second material are also disclosed.