Abstract: A method of manufacturing a cushion and a cushion structure are disclosed. The manufacturing method includes employing a first sheet structure that is the cross-linked foamed polyethylene (PE) or cross-linked foamed polypropylene (PP) in material with the first sheet structure serving as an inner layer and an outer layer of the cushion structure. The method further includes crushing PU foam and adding an adhesive to the crushed PU foam before compressing the crushed PU foam and the adhesive to a second sheet structure, which is called “synthetic foam” functioning as an intermediate layer of the cushion structure. The multi-layer cushion structure may be prepared after having the outer layer, the intermediate layer and the inner layer integrated together using laminating, before being placed in an oven for heating until the inner layer and the outer layer are tendered and in a shape-mold of a molding machine for pressurizing.

Abstract: A sensor chip has a supporting structure layer and a micro-inductor layer formed on the supporting structure layer and having an inductance. The micro-inductor layer comprises an insulating layer, at least one magnetic layer, and a micro-coil layer. When an external physical quantity is applied on sensor chip, the micro-inductor layer can deform correspondingly to generate a variation of the inductance. The variation of the inductance can be measured by an inductance measurement circuit. The inductance measurement circuit can be an external circuit or be integrated into the sensor chip.

Abstract: In accordance with an example embodiment of this disclosure, a micro-electro-mechanical system (MEMS) device comprises a substrate, a CMOS die, and a MEMS die, each of which comprises a top side and a bottom side. The bottom side of the CMOS die is coupled to the top side of the substrate, and the MEMS die is coupled to the top side of the CMOS die, and there is a cavity positioned between the CMOS die and the substrate. The cavity may be sealed by a sealing substance, and may be filled with a filler substance (e.g., an adhesive) that is different than the sealing substance (e.g., a gaseous or non-gaseous substance). The cavity may be fully or partially surrounded by one or more downward-protruding portions of the CMOS die and/or one or more upward-protruding portions of the substrate.

Abstract: A device comprising a substrate comprising at least one microelectronic and/or nanoelectronic structure comprising at least one sensitive portion and one fluid channel (2) defined between said substrate and a cap (6), where said fluid channel (2) comprises at least two apertures to provide a flow in said channel, where said microelectronic and/or nanoelectronic structure is located within the fluid channel, where said cap is assembled with the substrate at an assembly interface, where said device comprises electrical connections between said microelectronic and/or nanoelectronic structure and the exterior of the fluid channel (2), where said electrical connections (8) are formed by vias made through the substrate (4) directly below the microelectronic and/or nanoelectronic structure, and in electrical contact with said microelectronic and/or nanoelectronic structure.

Abstract: Techniques herein enable executing directed self-assembly of block copolymer patterning processes that result in patterns having no defects or a negligibly low occurrence of defects to have a high yield of functional patterns and devices. Methods include executing a same DSA patterning sequence two or more times such that any defects in from a phase-separated first block copolymer film are corrected with a phase-separated second block copolymer film as any defect in the second block copolymer film would only temporarily cover a feature already created and/or transferred from first block copolymer film.

Abstract: Embodiments of a method for forming a suspended membrane include depositing a first electrically conductive material above a sacrificial layer and within a boundary trench. The first electrically conductive material forms a corner transition portion above the boundary trench. The method further includes removing a portion of the first electrically conductive material that removes at least a portion of uneven topography of the first electrically conductive material. The method further includes depositing a second electrically conductive material. The second electrically conductive material extends beyond the boundary trench. The method further includes removing the sacrificial layer through etch openings and forming a cavity below the second electrically conductive material. The first electrically conductive material defines a portion of a sidewall boundary of the cavity.

Abstract: A MEMS acoustic transducer, for example, a microphone, includes a substrate provided with a cavity, a supporting structure, fixed to the substrate, a membrane having a perimetral edge and a centroid, suspended above the cavity and fixed to the substrate the membrane configured to oscillate via the supporting structure. The supporting structure includes a plurality of anchorage elements fixed to the membrane, and each anchorage element is coupled to a respective portion of the membrane between the centroid and the perimetral edge of the membrane.

Abstract: An integrated pressure sensing device and method of fabrication thereof are disclosed. The method can include providing a substrate member having a surface region and forming a CMOS IC layer overlying the substrate and forming an oxide layer overlying the CMOS IC layer. A portion of the oxide layer can be removed to form a cavity region. A single crystalline silicon wafer can be bonded overlying the oxide surface region to seal the cavity region. The bonding process can include a fusion bonding or eutectic bonding process. The wafer can be thinned to a desired thickness and portions can be removed and filled with metal materials to form via structures. A pressure sensor device can be formed from the wafer, and can be co-fabricated with another sensor from the wafer. The pressure sensor and the other sensor can share a cavity pressure or have separate cavity pressures.

Abstract: A MEMS device is formed with facing surfaces of a contoured substrate and a layer of material having complementary contours. In one fabrication approach, a first photoresist layer is formed over a substrate. Selected regions of the first photoresist layer are exposed using a patterning mask. The exposed regions of the first photoresist layer are thermally shrunk to pattern the first photoresist layer with a contour. A layer of material is formed over the contoured first photoresist layer.

Abstract: A linker polynucleotide for attaching a nanomaterial to a polynucleotidic platform and related nanoassemblies, arrangements, structures, methods and systems.

Abstract: Systems and methods that facilitate magnetic collection and/or manipulation of individual micropallets are provided. The embodiments provided herein are directed to a new method for collecting micropallets once released from a substrate. It is accomplished by endowing the micropallets with magnetic properties by incorporating ferromagnetic or superparamagnetic nanoparticles into the photoresist material or otherwise incorporating magnetically responsive material into the micropallet structure. The magnetic particles, which posses magnetic qualities, e.g., ferromagnetism, ferrimagnetism, paramagnetism, and are composed of iron, nickel, and/or other magnetic materials, are mixed into the bulk photoresist prior to its use in the fabrication of microstructures. Also covered are other methods of incorporating magnetically-attractable material into the micropallet structure, such as plating of the micropallets with a material that is magnetically responsive, such as nickel.

Abstract: A method for dispersing nanotubes, comprising contacting the nanotubes with an electronic liquid comprising a metal and an amine solvent, a solution of dispersed nanotubes, comprising individual nanotubes at a concentration of greater than about 0.01 mgml?1 and a solvent and a nanotube crystal comprising a close packed array of nanotubes, wherein the crystal has a thickness of 100 nm or more are described.

Abstract: Disclosed is a method and related system of regenerating a raw material for a hydrogen supply system of a fuel cell. The method includes reacting aluminum and a metal hydroxide to produce hydrogen in the hydrogen supply system of a fuel cell; and recovering an aluminum compound produced simultaneously with the hydrogen in the reaction. An aluminum hydroxide is obtained from the aluminum compound. The aluminum hydroxide is heat-treated to obtain an aluminum oxide. The aluminum oxide is reduced to obtain aluminum. The obtained aluminum is re-supplied as a raw material for producing the hydrogen.

Abstract: A reactor comprising a first zone comprising a dehydrogenation catalyst and a second zone separated from said first zone by a proton conducting membrane comprising a mixed metal oxide of formula (I) LnaWbO12?y wherein Ln is Y or an element numbered 57 to 71; the molar ratio of a:b is 4.8 to 6, preferably 5.3 to 6; and y is a number such that formula (I) is uncharged, e.g. y is 0?y?1.8.

Abstract: A hydrogen supply system for supplying hydrogen comprises a reaction unit for producing a hydrogen-containing gas by a dehydrogenation reaction of a starting material, a heat supply unit for supplying heat to the reaction unit, a removal unit for removing through membrane separation a dehydrogenation product from the hydrogen-containing gas produced by the reaction unit, and a first off-gas line for supplying a part or whole of an off-gas from the removal unit to the reaction unit.

Abstract: Process for the continuous production of chlorine dioxide comprising generating chlorine dioxide in an aqueous reaction medium in a reaction vessel (1) maintained at sub-atmospheric pressure, bringing gaseous chlorine dioxide from said reaction vessel to an absorption tower (7) and contacting it therein with a flow of water to form an aqueous solution containing chlorine dioxide, bringing said aqueous solution containing chlorine dioxide to a stripper (12), blowing a gas through said aqueous solution of chlorine dioxide in the stripper to strip off from 10 to 100% of the chlorine dioxide entering the stripper and form a gaseous chlorine dioxide product.

Abstract: A catalyst effective for the direct reaction of hydrogen and oxygen to form hydrogen peroxide includes particles of gold, palladium or, preferably, gold and palladium deposited upon an acid-washed support. High selectivity to and production of hydrogen peroxide is observed, with low hydrogen peroxide decomposition. The catalysts have extended lifespan.

Abstract: A catalyst structure suitable for use in an ammonia oxidation process is described including a plurality of shaped catalyst units supported on one or more members in a spaced relationship that allows the structure to flex.

Abstract: The present invention relates to compositions comprising esterified lignin and poly(lactic acid). In various embodiments, the present invention provides fibers comprising the esterified lignin and poly(lactic acid) blend, carbon fibers made therefrom, and methods of making the fiber and the carbon fibers.

Abstract: The present disclosure relates to reactive modified lignin, methods of preparing such modified lignin, and materials, such as polymer systems, incorporating the modified lignin. More specifically, the lignin can be modified by selectively masking reactive functional groups such that the material has a modulated reactivity and is thus better suited for incorporation into and/or formation of further materials, such as carbon fibers.

Abstract: Provided is a method for preparing a carbon material based on an organic nanofilm using thermal evaporation, including: depositing a liquid polymer or polymer solution containing a polymer and a solvent onto a substrate, thereby forming an organic nanofilm; stabilizing the organic nanofilm so that the carbon atoms in the organic nanofilm have a cyclic arrangement; and carbonizing the stabilized organic nanofilm, thereby forming a carbon material, wherein the organic nanofilm is formed from the liquid polymer or polymer solution through a thermal evaporation process. The method provides a carbon material with a thickness, sheet resistance and surface roughness suitable for various applications and allows control thereof. In addition, the method uses a relatively inexpensive starting material, pitch, thereby reducing the overall production cost, and avoids a need for a complicated additional patterning operation, so that the carbon material is applied directly to electronic devices.

Abstract: The present application relates to a method of increasing density of aligned carbon nanotubes. Firstly, aligned carbon nanotubes grown on a substrate is transferred to a stretched retractable film. The retractable film is then shrunk along a direction which is perpendicular to the alignment direction of the carbon nanotubes to obtain high density carbon nanotubes. The array of aligned carbon nanotubes is finally transferred from the retractable film to a target substrate. The disclosed method can efficiently obtain high-density high-quality aligned carbon nanotubes at low cost.

Abstract: A preparation method for graphitized carbon material is disclosed. The method may include placing a water-cooled copper mold having a water-cooling equipment at a bottom thereof in a vacuum arc melting furnace, wherein the water-cooled copper mold has disposed thereon a graphite crucible with carbon material therein and the graphite crucible has a tungsten rod placed thereon, with a lower terminal of the tungsten rod and the carbon material within the graphite crucible aligning. The method may further include flowing a gas after placing the vacuum arc melting furnace in a vacuum environment before heating the vacuum arc melting furnace to at least 3200 degrees Celsius to graphitize the carbon material and to form a fully graphitized carbon material after cooling.

Abstract: A method of producing graphene comprises forming a composition comprising magnesium and carbon, and isolating graphene from the composition. The isolated graphene is crystalline.

Abstract: A method of producing inorganic compound particles is provided. It includes a step of impregnating a melt liquid of second raw particles into first raw particles by heating a raw material including them at a temperature, which equals to or higher than an eutectic temperature between a region-II (solid-liquid phase range) and a region-I (solid phase range) in a phase diagram and lower than the melting temperature of the inorganic compound. The first raw particles contain an element with a melting point equals to or higher than a melting point of the inorganic compound. The second raw particles contain an element with a melting point lower than the inciting point of the inorganic compound. The method also includes a step of synthesizing inorganic compound particles by a synthetic reaction in the first raw particles between the elements contained in the first and second raw particles.

Abstract: Magnesium aluminate spinels are made by hydrothermally aging an aqueous slurry of a spinel precursor which can be (a) a mixture of boehmite alumina and a magnesium precursor, (b) an aluminum magnesium oxide or hydroxide, and (c) mixtures thereof. At least one of the aged slurries is dried to remove water and produce at least one dried spinel precursor. The dried spinel precursor is then calcined to produce the magnesium aluminate spinel.

Abstract: A method of making a titanium oxide-containing coating composition comprises attaching an initiator to a pretreated titanium oxide to form an initiator/pretreated titanium oxide complex. The pretreated titanium oxide includes a plurality of pretreated titanium oxide particles which are titanium oxide particles that are pretreated with at least one metal oxide. The initiator/pretreated titanium oxide complex is contacted with a polymerizable unsaturated monomer such that a polymeric encapsulate forms on the initiator/pretreated titanium oxide particles to form polymeric encapsulated titanium oxide particles.

Abstract: Nickel is recovered from pickling acid solutions of crude ore using boric acid as catalyst by ultrasound assisted electrolysis.

Abstract: An acoustic standing wave is utilized to separate components from a multi-component fluid, such as oil from an oil-water mixture, in a fluid flow scheme with an acoustophoresis device. For example, the flow scheme and device allows for trapping of the oil as the oil coalesces, agglomerates, and becomes more buoyant than the water.

Abstract: There is disclosed an electrochemical cell for treating water comprising at least one water chamber configured to hold water to be treated; at least one redox electrode comprising reactants capable of accepting and having a reversible redox reaction with at least one negative ion in the water; at least one intercalation electrode capable of accommodating and intercalating at least one positive ion in the water, wherein the intercalation electrode is immersed in the water chamber or separated from the water chamber by an optional porous separator; and an anion exchange membrane separating the redox electrode from the water chamber. The cell can be used to desalinate water having a wide range of salinities, including sea water, and brackish water. The cell can also be used to collect salt, which can subsequently used to concentrate industrial brine. Methods for using the electrochemical cell to treat water, such as desalinate saline solutions are disclosed.

Abstract: An electrodialysis unit 8 comprises a cathode 68, an anode 70, a membrane 71 between the cathode 68 and the anode 70, a cathode flow path 72 for water flow along the membrane 71 on the cathode side, an anode flow path 74 for water flow along the membrane 71 on the anode side, and a reaction zone formed between the membrane 71 and the cathode 68 where the cathode 68 faces the anode 70, wherein the cathode flow path 72 is arranged for laminar flow in the reaction zone and wherein the electrodialysis unit 8 comprises flow conditioning elements 64 arranged to promote laminar flow in the incoming water flow to the cathode flow path 72.

Abstract: Disclosed are systems and methods for dissolving gases into a fluid that is passing through a force-main and gravity sewer system. The system includes a dissolution tank having a pressure vessel for containing a liquid and for providing a regulated gas head space above the liquid, an inlet that permits passage of wastewater into the gas head space, and an outlet that permits passage of treated wastewater out of the pressure vessel. The system also includes a gas source in communication with the pressure vessel; a pump for supplying wastewater from a force-main or sewer system sump into the pressure vessel under conditions effective to dissolve oxygen gas in the wastewater; and a discharge device in communication with the outlet of the dissolution tank assembly for discharging treated wastewater.

Abstract: A reactor and control method thereof for nitrogen removal in wastewater treatment achieves a measured control of maintaining high ammonia oxidizing bacteria (AOB) oxidation rates while achieving nitrite oxidizing bacteria (NOB) repression, using various control strategies, including: 1) ammonia and the use of ammonia setpoints, 2) operational DO and the proper use of DO setpoints, 3) bioaugmentation of a lighter flocculant AOB fraction, and 4) proper implementation of transient anoxia within a wide range of reactor configurations and operating conditions.

Abstract: The invention relates to a method for the treatment of process water which is obtained in a plant for the hydrothermal carbonization of renewable raw materials and organic residual materials by an evaporation of process water, a condensation of the washed process steam, and a biological treatment of the process steam condensate as partial quantity or possibly as total quantity of the amount of waste water discharged from an HTC plant.

Abstract: The present invention provides a system for treating wastewater in which the majority of solids and biological oxygen demand compounds are separated from the wastewater feed using a primary separation process, to produce a solids phase and a water phase. The solids phase is irradiated to reduce the level of pathogens such that it is safe to use as a soil substitute and/or additive so that the solids can thus be disposed of in an environmentally-friendly manner. In additional embodiments, the solids that have been disinfected by radiation are mixed with a suitable inert filler material to produce a soil substitute, fertilizer, compost, or other soil additive. The liquid phase is treated in a substantially smaller system than would be required for treating the full-strength wastewater that can include a suspended media biological regeneration reactor system.

Abstract: A method and an apparatus for hydrolyzing an organic solid are described. The method includes mixing an organic solid and a nanobubble water having a plurality of nanobubbles, to form an organic liquid, in which the nanobubbles contain a combustible gas; and applying an ultrasonic wave on the organic liquid, such that the nanobubbles generate an additional cavitation effect. A preprocessor is applicable to an organic solid processing system having an anaerobic digestion tank, in which the anaerobic digestion tank has anaerobic microbes for generating a combustible gas. The preprocessor includes a nanobubble water generator, a digestion tank, and an ultrasonic wave generator. With the method and the structure, the nanobubbles are used to increase the probability of generation of the additional cavitation effect, and the combustible gas is used to improve an impact force of bursts produced by the cavitation effect.

Abstract: Surface modification layers and associated heat treatments, that may be provided on a sheet, a carrier, or both, to control both room-temperature van der Waals (and/or hydrogen) bonding and high temperature covalent bonding between the thin sheet and carrier. The room-temperature bonding is controlled so as to be sufficient to hold the thin sheet and carrier together during vacuum processing, wet processing, and/or ultrasonic cleaning processing, for example. And at the same time, the high temperature covalent bonding is controlled so as to prevent a permanent bond between the thin sheet and carrier during high temperature processing, as well as maintain a sufficient bond to prevent delamination during high temperature processing.

Abstract: A method includes (1) a thermal diffusion process for using an alkali metal salt raw material having an average particle size of 1 mm or less in diameter, supplying a vapor of the alkali metal salt produced by heating the alkali metal salt raw material together with a carrier gas to the inside of a silica-based glass pipe from one end side of the glass pipe, and heating the glass pipe using a heat source which relatively moves in a longitudinal direction of the glass pipe to cause an oxidation reaction of an alkali metal and thermally diffuse the alkali metal into an inner side of the glass pipe, (2) a collapsing process for collapsing the glass pipe after the thermal diffusion process to prepare a core rod; and (3) a cladding portion addition process for adding a cladding portion around the core rod prepared in the collapsing process.

Abstract: Optical fibers with previously unattainable characteristics and the method of producing the same are disclosed and claimed herein. Specifically, the application discloses and claims a method to produce ZBLAN, Indium Fluoride, Germanate and Chalcogenide optical fibers and other similar optical fibers in a microgravity environment. The resulting optical fibers have unique molecular structures not attainable when optical fibers with the identical chemical composition are produced in a standard 1 gravity environment. The method of the invention requires a novel draw tower and modified preform, which are specifically designed to operate in microgravity environments. A lead wire is inserted into the preform that, when wound onto a spool in the draw tower, causes a fiber to form. The pull rate of the lead wire controls the diameter of the fiber.

Abstract: A refractive index device and method of making it include obtaining a glass structure comprising a plurality of nucleation sites. The glass structure is formed from a glass composition that comprises a first chemical component and a second chemical component. A crystal of the second chemical component has a different second refractive index from a first refractive index of the first chemical component. Each nucleation site defines where a crystal of the second chemical component can be grown. The method includes causing crystals of the second chemical component to grow in situ at a set of the plurality of nucleation sites in order to produce a spatial gradient of a refractive index in the glass structure.

Abstract: The embodiments described herein relate to chemically and mechanically durable glass compositions and pharmaceutical packaging formed from the same. According to one embodiment, a glass for pharmaceutical packaging includes from about 70 mol. % to about 80 mol. % SiO2; from about 4 mol. % to about 8 mol. % alkaline earth oxide, the alkaline earth oxide comprising MgO and CaO; X mol. % Al2O3, wherein X is from about 4 to about 8; and Y mol. % alkali oxide comprising non-zero amounts of Na2O and K2O, wherein Y is about 9-15 mol. % and a ratio of Y:X is greater than 1.

Abstract: A method of producing a substrate having a frosted appearance, an article having a frosted appearance and frost-imparting compositions are disclosed. The method includes applying a frost-imparting composition onto a ceramic substrate and firing the coated substrate above 400° C. to impart the frost appearance. The frost-imparting composition comprises a liquid vehicle, 20% to 90% by weight of glass frit particles and less than 10% by weight of at least one gas-releasing material, inactive below an activation temperature of at least 400° C. The gas releasing material may include carbonate, nitrate, iodate, bromate, chlorate, fluoride, manganate, dimanganate and sulfate compounds. The firing temperature is chosen to be above the activation temperature of the gas-releasing material, above which the gas-releasing material yields gas bubbles and above a temperature that causes the glass frit particles to behave as a viscous liquid.

Abstract: Ceramic frit compositions including a cathode ray tube (CRT) glass component and methods for their manufacture are provided. Also provided are coating compositions including these ceramic frit compositions.

Abstract: An etching method for selective introduction of structures into surfaces of different substrates, such as glass or glass ceramic substrates, is provided. The method provides for surface structuring using an etch mask. The etchmask allows for the production of very fine structures on the substrate surfaces using liquid etching media. In this method the etch mask is produced on the substrate.

Abstract: Methods for machining glass structures may be performed on fusion-drawn glass laminates having a core layer interposed between a first cladding layer and a second cladding layer. The core layer may be formed from a core glass composition having a core photosensitivity, the first cladding layer may be formed from a glass composition having a photosensitivity different from the core photosensitivity, and the second cladding layer may be formed from a glass composition having a photosensitivity different from the core photosensitivity. At least one of the core layer, the first cladding layer, and the second cladding layer is a photomachinable layer. The methods may include exposing a selected region of a photomachinable layer in the fusion-drawn laminate to ultraviolet radiation; heating the glass structure until the selected region crystallizes; and removing the crystallized material selectively from the photomachinable layer.

Abstract: A coated article includes a low-E coating having an absorbing layer located over a functional layer (IR reflecting layer) and designed to cause the coating to have an increased outside reflectance (e.g., in an IG window unit) and good selectivity. In certain embodiments, the absorbing layer is metallic, or substantially metallic, and is provided directly over and contacting a lower of two IR reflecting layers. In certain example embodiments, a nitride based layer (e.g., silicon nitride or the like) may be located directly over and contacting the absorbing layer in order to reduce or prevent oxidation thereof during heat treatment (e.g., thermal tempering, heat bending, and/or heat strengthening) thereby permitting predictable coloration, high outside reflectance values, and/or good selectivity to be achieved.

Abstract: This transparent glass substrate has at least one face which is provided with a texturing formed by a plurality of geometric features in relief relative to a general plane of the face, this texturing being adapted in order to ensure a transmission of radiation through the substrate greater than the transmission of radiation through a substrate that is identical but lacks texturing. The face of the substrate is also provided with an antireflection layer having a refractive index between the refractive index of air and the refractive index of the glass. The antireflection layer is an etched out superficial portion of the glass substrate on the side of the face, which comprises a structure based on silica and voids having a characteristic dimension between 0.5 nanometers and 50 nanometers.

Abstract: Methods are described for activating a glass fiber or flake to participate in polymerizing a resin. The methods may include sizing the glass fiber or flake with a sizing composition that includes a solution containing a polymerization initiator, and activating the polymerization initiator by forming a free radical moiety on the polymerization initiator that can initiate the polymerization of the resin. Additional methods of making a glass reinforced composite are described. The methods may include sizing glass fibers or flakes with a sizing composition that includes a solution containing a polymerization initiator, forming a free radical moiety on the polymerization initiator to make activated glass fibers or flakes, and contacting the activated glass fibers or flakes with a polymer resin. The activated glass fibers or flakes initiate the polymerization of the resin around the glass fibers or flakes to form the glass reinforced composite.

Abstract: A method for the production of hard plaster, a calcining plant, and a retrofit reactor for calcining plants. The method includes feeding plaster material, predominantly including beta-hemihydrate plaster, to a postreactor. The temperature is set to at least a calcining temperature of 95° C. during this step. The plaster material is retreated in the postreactor to form hard plaster, the beta-hemihydrate plaster being converted directly into alpha-hemihydrate plaster at a temperature above 95° C. The hard plaster can then be discharged out of the postreactor and cooled. Conversion can be carried out in the postreactor during continuous operation, and conversion of the beta-hemihydrate plaster can occur with a dwell time in the postreactor of less than 30 minutes. Steam can be externally supplied to the postreactor and the temperature and pressure in the postreactor can be regulated so that the temperature is at least 95° C. and an over pressure prevails.

Abstract: The process using multiple waste streams to manufacture synthetic lightweight aggregate includes providing a mixture of aggregate wash and at least one of another waste stream, such as waste lube oil or sewage sludge. The mixture is formed into pellets and subjected to various firing stages and temperatures in which the calcination and subsequent bloating occurs. The mixture can also be added to natural clays to form corresponding pellets. The bloating promotes formation of porous cavities, and once cooled, the pellets form lightweight, low density synthetic aggregates suitable for use as building materials, thermal insulators, and the like.