Abstract: A synthetic microsphere having a low alkali metal oxide content and methods of forming the microsphere and its components are provided. The synthetic microsphere is substantially chemically inert and thus a suitable replacement for natural cenospheres, particularly in caustic environments such as cementitious mixtures. The synthetic microsphere can be made from an agglomerate precursor that includes an aluminosilicate material, such as fly ash, a blowing agent such as sugar, carbon black, and silicon carbide, and a binding agent. The synthetic microsphere is produced when the precursor is fired at a pre-determined temperature profile so as to form either solid or hollow synthetic microspheres depending on the processing conditions and/or components used.

Abstract: A building product incorporating synthetic microspheres having a low alkali metal oxide content is provided. The synthetic microspheres are substantially chemically inert and thus a suitable replacement for natural cenospheres, particularly in caustic environments such as cementitious mixtures. The building product can have a cementitious matrix such as a fiber cement product. The synthetic microspheres can be incorporated as a low density additive and/or a filler for the building product and/or the like.

Abstract: A synthetic microsphere having a low alkali metal oxide content and methods of forming the microsphere and its components are provided. The synthetic microsphere is substantially chemically inert and thus a suitable replacement for natural cenospheres, particularly in caustic environments such as cementitious mixtures. The synthetic microsphere can be made from an agglomerate precursor that includes an aluminosilicate material, such as fly ash, a blowing agent such as sugar, carbon black, and silicon carbide, and a binding agent. The synthetic microsphere is produced when the precursor is fired at a pre-determined temperature profile so as to form either solid or hollow synthetic microspheres depending on the processing conditions and/or components used.

Abstract: A building product incorporating synthetic microspheres having a low alkali metal oxide content is provided. The synthetic microspheres are substantially chemically inert and thus a suitable replacement for cenospheres derived from coal combustion, particularly in caustic environments such as cementitious mixtures. The building product can have a cementitious matrix such as a fiber cement product. The synthetic microspheres can be incorporated as a low density additive and/or a filler for the building product and/or the like.

Abstract: Carbides and nitrides are provided containing a controlled amount of pre-determined diluents and methods for their manufacture and use are disclosed. The pre-determined diluents include at least one of the silica, silicon metal, carbon, alumina, boron oxide, alkaline earth oxides such as calcium oxide, magnesium oxide, alkali oxides such as sodium oxide, potassium oxide, iron oxide, titanium oxide, and other components typically present in glass, ceramics, or metals. The carbides and nitrides with pre-determined diluents are formed by optionally pyrolyzing a precursor material to form a carboneous mixture and heat treating the carboneous mixture for a pre-determined time and at an elevated temperature during which carbon and/or nitrogen reacts with silica in the mixture to form carbides and/or nitrides and controlled amounts of pre-determined diluents.

Abstract: Carbides and nitrides are provided containing a controlled amount of pre-determined diluents and methods for their manufacture and use are disclosed. The pre-determined diluents include at least one of the silica, silicon metal, carbon, alumina, boron oxide, alkaline earth oxides such as calcium oxide, magnesium oxide, alkali oxides such as sodium oxide, potassium oxide, iron oxide, titanium oxide, and other components typically present in glass, ceramics, or metals. The carbides and nitrides with pre-determined diluents are formed by optionally pyrolyzing a precursor material to form a carboneous mixture and heat treating the carboneous mixture for a pre-determined time and at an elevated temperature during which carbon and/or nitrogen reacts with silica in the mixture to form carbides and/or nitrides and controlled amounts of pre-determined diluents.

Abstract: A method of preparing a low-density material and precursor for forming a low-density material is provided. An aqueous mixture of inorganic primary component and a blowing agent is formed, the mixture is dried and optionally ground to form an expandable precursor. Such a precursor is then fired with activation of the blowing agent being controlled such that it is activated within a predetermined optimal temperature range. Control of the blowing agent can be accomplished via a variety of means including appropriate distribution throughout the precursor, addition of a control agent into the precursor, or modification of the firing conditions such as oxygen deficient or fuel rich environment, plasma heating etc.

Abstract: A method of preparing a low-density material and precursor for forming a low-density material is provided. An aqueous mixture of inorganic primary component and a blowing agent is formed, the mixture is dried and optionally ground to form an expandable precursor. Such a precursor is then fired with activation of the blowing agent being controlled such that it is activated within a predetermined optimal temperature range. Control of the blowing agent can be accomplished via a variety of means including appropriate distribution throughout the precursor, addition of a control agent into the precursor, or modification of the firing conditions such as oxygen deficient or fuel rich environment, plasma heating etc.

Abstract: A low density material and a method for preparing a low-density material and precursor for forming a low-density material are provided. An aqueous mixture of inorganic primary component and a blowing agent is formed, the mixture is dried and optionally ground to form an expandable precursor. Such a precursor is then fired with activation of the blowing agent being controlled such that it is activated within a predetermined optimal temperature range. The firing conditions are also controlled to provide a low density sphere containing a heterogeneous sphere wall structure comprising a combination of amorphous glass and a crystalline phase or gas phase or both.

Abstract: A bottom-up cocurrent combustion furnace for the production of synthetic microspheres by thermal expansion of glass particles is provided having improved characteristics with regard to anti-fouling, process efficiency, and yield. The disclosed furnace uses preheated combustion air to preheat the feed material and to convey the feed material in a dilute phase transport regime to a burner. The combustion air, fuel, and feed material are premixed prior to being injected though the burner. The feed material rapidly expands as it is ejected through the burner and through a flame and then rapidly cools to solidify the microspheres. Additional features are provided to prevent the furnace from fouling by keeping the feed material away from the furnace walls, removing feed material that adheres to the furnace walls, and collecting feed material that agglomerates or does not expand.

Abstract: Shaped geopolymeric particles, fibers, and articles incorporating at least one geopolymer are provided; the geopolymeric particles, fibers, and articles having a structure that is solid, foamed, hollow or with one or more voids. Geopolymers are formed by alkali activation of an aluminosilicate and/or aluminophosphate material. The end-products are shaped as spheres, flakes, fibers, aggregates thereof or articles. Such products are formed at low temperatures; wherein forming includes processing using techniques such as spray drying, melt spinning, or blowing. The shaped geopolymeric particles and fibers have high chemical durability, high mechanical strength, application-targeted flowability and packing properties, and are specially suited for incorporating into composite materials, articles, and for use in cementitious, polymeric, paint, printing, adhesion and coating applications.

Abstract: The invention relates to an extrusion die having at least one flexible lip element (1, 2) for discharging extruded material from a gap (S) the flow cross-section of which can be modified. The invention is characterized in that at least one flexible lip element (2) can be displaced relative to the other lip element (1) by means of a plurality of jointly actuated lever elements (8).

Abstract: A method of preparing a low-density material and precursor for forming a low-density material is provided. An aqueous mixture of inorganic primary component and a blowing agent is formed, the mixture is dried and optionally ground to form an expandable precursor. Such a precursor is then fired with activation of the blowing agent being controlled such that it is activated within a predetermined optimal temperature range. Control of the blowing agent can be accomplished via a variety of means including appropriate distribution throughout the precursor, addition of a control agent into the precursor, or modification of the firing conditions such as oxygen deficient or fuel rich environment, plasma heating etc.

Abstract: A synthetic microsphere having a low alkali metal oxide content and methods of forming the microsphere and its components are provided. The synthetic microsphere is substantially chemically inert and thus a suitable replacement for natural cenospheres, particularly in caustic environments such as cementitious mixtures. The synthetic microsphere can be made from an agglomerate precursor that includes an aluminosilicate material, such as fly ash, a blowing agent such as sugar, carbon black, and silicon carbide, and a binding agent. The synthetic microsphere is produced when the precursor is fired at a pre-determined temperature profile so as to form either solid or hollow synthetic microspheres depending on the processing conditions and/or components used.

Abstract: A building product incorporating synthetic microspheres having a low alkali metal oxide content is provided. The synthetic microspheres are substantially chemically inert and thus a suitable replacement for natural cenospheres, particularly in caustic environments such as cementitious mixtures. The building product can have a cementitious matrix such as a fiber cement product. The synthetic microspheres can be incorporated as a low density additive and/or a filler for the building product and/or the like.

Abstract: A synthetic microsphere having a low alkali metal oxide content and methods of forming the microsphere and its components are provided. The synthetic microsphere is substantially chemically inert and thus a suitable replacement for natural cenospheres, particularly in caustic environments such as cementitious mixtures. The synthetic microsphere can be made from an agglomerate precursor that includes an aluminosilicate material, such as fly ash, a blowing agent such as sugar, carbon black, and silicon carbide, and a binding agent. The synthetic microsphere is produced when the precursor is fired at a pre-determined temperature profile so as to form either solid or hollow synthetic microspheres depending on the processing conditions and/or components used.