Fly Ash, Coal Ash, Or Bottom Ash Or Derived Therefrom Patents (Class 106/405)
  • Patent number: 9884804
    Abstract: A method of making solid acid catalysts includes the step of sulfonating waste tire pieces in a first sulfonation step. The sulfonated waste tire pieces are pyrolyzed to produce carbon composite pieces having a pore size less than 10 nm. The carbon composite pieces are then ground to produce carbon composite powders having a size less than 50 ?m. The carbon composite particles are sulfonated in a second sulfonation step to produce sulfonated solid acid catalysts. A method of making biofuels and solid acid catalysts are also disclosed.
    Type: Grant
    Filed: May 24, 2016
    Date of Patent: February 6, 2018
    Assignees: UT-BATTELLE, LLC, UNIVERSITY OF TENNESSEE RESEARCH FOUNDATION
    Inventors: Zachary D. Hood, Shiba P. Adhikari, Marcus W. Wright, Abdessadek Lachgar, Yunchao Li, Amit K. Naskar, Mariappan Parans Paranthaman
  • Patent number: 9651497
    Abstract: A method and system for measuring the adsorption potential of fly ash. A sample of the fly ash is mixed with an optically active reagent. The mixture is irradiated with light at a given wavelength and an optical parameter of the irradiated sample, such as intensity of optical absorbance or fluorescence emission is measured by an optical measuring apparatus. The adsorption capacity of the sample is determined as a function of the optical measurement. A controller is provided that communicates with the optical absorption measuring apparatus and controls flow of fly ash and sacrificial agent to a reaction zone or housing wherein the fly ash is contacted by the sacrificial agent.
    Type: Grant
    Filed: October 10, 2014
    Date of Patent: May 16, 2017
    Assignee: Headwaters Incorporated
    Inventors: Rafic Y. Minkara, Jennifer M. Kelley, Crystal A. Dixon, Richard J. Nordman, Michael J. Ponstingl
  • Patent number: 9512038
    Abstract: A fly ash composition including fly ash and a plasticizing agent and being in a powder form is disclosed. The plasticizing agent is capable of binding the fly ash particles in the fly ash composition together on pressing of the fly ash composition. Processes of forming shaped articles containing fly ash may utilize the fly ash composition and/or mixtures containing fly ash and have low water content and may exhibit sufficient green strength to be handled by industrial equipment.
    Type: Grant
    Filed: December 22, 2010
    Date of Patent: December 6, 2016
    Assignees: Newsouth Innovations Pty Limited, Vecor IP Holdings Ltd
    Inventor: Sandor Koszo
  • Patent number: 9388074
    Abstract: Processes and methods of making and preparing, compositions and structural products therefrom are provided, whereby the surface area of alumino-silicate based powders is greatly increased and rendered chemically active so that when the functionalized powders are mixed with water poly-condensation reactions occur between the surfaces binding the powders together to form a structural material with negligible emission of carbon compounds. In another embodiment, the surface functionalized powders can be mixed with an additive; a dry aggregate, such as sand and water to make a slurry that can be poured or cast into any desired shape and rapidly cured to a hardened shape suitable for use as a structural material with the mechanical strength equivalent to Portland-cement based concrete products.
    Type: Grant
    Filed: December 16, 2008
    Date of Patent: July 12, 2016
    Assignee: University of Central Florida Research Foundation, Inc.
    Inventors: Sudipta Seal, Larry L. Hench, Suresh Babu Krishna Moorthy, David Reid, Ajay Karakoti
  • Patent number: 9018278
    Abstract: Provided is a surface treated calcium carbonate filler for resins, which comprises calcium carbonate particles, the surface of which has been treated with at least one surface active agent (A) selected from the group consisting of saturated fatty acids, unsaturated fatty acids, alicyclic carboxylic acids, resin acids, and salts thereof and with at least one compound (B) having the ability to chelate alkaline earth metals, the compound (B) being selected from the group consisting of phosphonic acids, polycarboxylic acids, and salts thereof. The surface treated calcium carbonate filler for resins of the present invention deteriorates little with time, has satisfactory dispersibility in resins, and can give a sheet or film which has a satisfactory balance among durability, weatherability, strength, and thermal stability, and is useful as a battery separator or a light reflector.
    Type: Grant
    Filed: January 29, 2010
    Date of Patent: April 28, 2015
    Assignee: Maruo Calcium Co., Ltd.
    Inventors: Makoto Nagamatsu, Hidemitsu Kasahara, Kouhei Sako, Hisakazu Hojo
  • Publication number: 20150013570
    Abstract: In a method of processing paint sludge, measured portions of the sludge are supplied into a heating chamber for pyrolysis at about 1500° F. to disintegrate into organic and inorganic portions, the organic portion in the form of syngas is then drawn out, cooled, and pressurized to be used in kilns or combustion chambers, whereas the inorganic portion in the form of ash is directed to a calciner, where it is heated at about 1500° F. in a controlled presence of oxygen and cooled to have it ready for the reuse in paint manufacturing.
    Type: Application
    Filed: January 25, 2013
    Publication date: January 15, 2015
    Inventor: Jeffrey J. Bittner
  • Publication number: 20140373752
    Abstract: The present invention relates to a method and an apparatus for producing the raw material (46) used in producing black dye pigment. The invention further relates to a raw material (46) for producing black dye pigment as well as to the use of ash (20,24,26) separated from the raw synthetic gas (12, 14, 18) in the purification of the raw synthetic gas (12, 14, 18) generated in the gasification of a biomass (2, 4, 6) for producing black dye pigment.
    Type: Application
    Filed: February 13, 2012
    Publication date: December 25, 2014
    Applicant: UPM-KYMMENE CORPORATION
    Inventors: Esa HASSINEN, Riikka SILMU, Mauno MIETTINEN, Teuvo LEPPANEN
  • Publication number: 20140371116
    Abstract: A method for manufacturing a plurality of glass microspheres comprises: melting a batch into a first glass melt in a melter system, processing the first glass melt into a second glass, pulverizing the second glass into a plurality of glass fragments, thermally processing the plurality of glass fragments into a plurality of glass microspheres, providing at least one of a plurality of redox reactions and a plurality of events in at least one of the first glass melt and a melt of the second glass, and the plurality of redox reactions and the plurality of events are induced by a plurality of redox active group (RAG) components.
    Type: Application
    Filed: June 12, 2013
    Publication date: December 18, 2014
    Inventors: HAMID HOJAJI, LAURA GABRIELA KOCS
  • Patent number: 8895485
    Abstract: Methods and compositions are disclosed that comprise cement kiln dust having a mean particle size that has been altered. An embodiment discloses a method of preparing cement kiln dust comprising: providing cement kiln dust having an original particle size; and altering the mean particle size of the cement kiln dust from the original size by grinding, separating, or a combination thereof. Another embodiment discloses a well treatment fluid comprising: cement kiln dust having a mean particle size that has been altered from its original size by grinding, separating, or a combination thereof; and water.
    Type: Grant
    Filed: May 22, 2012
    Date of Patent: November 25, 2014
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Craig W. Roddy, Jiten Chatterji, Chad Brenneis, Callie R. Jarratt
  • Patent number: 8894319
    Abstract: A permeable paver and paving slab that have water permeability of on average about 1 inch per hour and compressive strength of an average of about 5000 psi to 8000 psi, the paver and paving slab manufactured by forming a mixture comprising blast-furnace slag, sand, gravel and Portland cement into predetermined sizes, shapes and colors as desired utilizing a hydraulic-type or equivalent compacting block forming machine.
    Type: Grant
    Filed: April 1, 2014
    Date of Patent: November 25, 2014
    Assignee: Pacific Interlock Pavingstone, Inc.
    Inventors: Dean R. Tonder, Glen Tonder, Tim Donovan, Per Jensen
  • Patent number: 8881909
    Abstract: A process for the recovery of bottom ash is characterized by shredding and physical separation phases. The bottom ash undergoes an oxidation treatment of the amphoteric metals contained therein. After the process, the treated bottom ash can be employed as mineral additive for concretes or hydraulic bonding agents.
    Type: Grant
    Filed: September 16, 2008
    Date of Patent: November 11, 2014
    Assignee: PETRACEM S.r.l.
    Inventor: Alessandro Quadrio Curzio
  • Publication number: 20140306369
    Abstract: A method of beneficiating fly ash to produce particulate material for use as a filler/extender in plastics manufacturing. The method includes removal of extraneous surface deposits from surfaces of the particulate material.
    Type: Application
    Filed: October 19, 2012
    Publication date: October 16, 2014
    Inventors: Nigel Peter Smalley, Paul Anthony Shepheard, Philip Michael
  • Publication number: 20140283711
    Abstract: Cement and concrete additives and related methods of making and using such additives are disclosed and described. An additive can include molasses and a carrier. An enhanced Portland cement composition can comprise about 97 wt % to 99.9 wt % of the composition and the above described additive comprises about 0.01 wt % to about 3 wt % of the composition.
    Type: Application
    Filed: October 8, 2012
    Publication date: September 25, 2014
    Inventors: Roberto Augustin Guerra Barrena, Roberto Augustin Guerro Guerrero, Brad Wilson, Dorn Schmidt
  • Publication number: 20140261078
    Abstract: A modified toner based additive is a mixture of a toner powder and a second material selected from a group including a gelling clay, a reactive agent, an elastomer, a functional filler, a handling and agglomerating agent, a compatibilizer and mixtures thereof.
    Type: Application
    Filed: March 12, 2014
    Publication date: September 18, 2014
    Applicant: CLOSE THE LOOP TECHNOLOGIES PTY LTD.
    Inventor: Steve Morriss
  • Publication number: 20140251182
    Abstract: Techniques for disposing of one or more toxic materials, such as coal waste (e.g., fly ash, sludge, etc.), include incorporating the toxic materials into artificial feldspar or forming artificial feldspar from the toxic material(s). The artificial feldspar may be used to form an artificial aggregate, which may be used in a construction material, as road base, as a fill material or for any other suitable purpose. Artificial aggregates that are formed from toxic materials are also disclosed, as are construction materials that include such artificial aggregates.
    Type: Application
    Filed: April 25, 2014
    Publication date: September 11, 2014
    Inventor: Dimitre S. Assenov
  • Publication number: 20140096705
    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.
    Type: Application
    Filed: October 9, 2012
    Publication date: April 10, 2014
    Inventor: Clinton Wesley Pike, SR.
  • Patent number: 8684626
    Abstract: A permeable paver that has water permeability of on average about 1 inch per hour and compressive strength of an average of about 8000 psi, the paver manufactured by forming a mixture comprising blast-furnace slag, sand, gravel and portland cement into predetermined sizes, shapes and colors as desired utilizing a hydraulic-type or equivalent compacting block forming machine.
    Type: Grant
    Filed: April 18, 2011
    Date of Patent: April 1, 2014
    Assignee: Pacific Interlock Pavingstone, Inc.
    Inventors: Dean R. Tonder, Glen Tonder, Tim Donovan, Per Jensen
  • Publication number: 20140033952
    Abstract: A method for recording a volume transmission hologram having angularly multiplexed diffraction fringe patterns that can cooperate to display polychromatic images and can be recorded with a single wavelength exposure source.
    Type: Application
    Filed: August 9, 2012
    Publication date: February 6, 2014
    Applicant: UPM-KYMMENE CORPORATION
    Inventors: Esa Hassinen, Riikka Silmu, Mauno Miettinen, Teuvo Leppänen
  • Patent number: 8609189
    Abstract: The method of forming carbon nanotubes from carbon-rich fly ash is a chemical vapor deposition-based method for forming carbon nanotubes from recycled carbon-rich fly ash. The method includes first ultrasonically treating the carbon-rich fly ash to produce an ultrafine powdered ash, and then reacting the ultrafine powdered ash in a low pressure chemical vapor deposition reactor to form the carbon nanotubes. The ultrasonic treatment of the carbon-rich fly ash includes the steps of dissolving the carbon-rich fly ash in water to form a solution, then sonicating the solution, separating the ultrafine powdered ash from the solution, and finally drying the ultrafine powdered ash. The method provides for total conversion of the carbon-rich fly ash to carbon nanotubes having a variety of differing diameters and lengths, including multi-walled carbon nanotubes with a high degree of wall graphitization and C?C double bonds stretching at 1635 cm?1.
    Type: Grant
    Filed: September 28, 2011
    Date of Patent: December 17, 2013
    Assignee: King Abdulaziz University
    Inventor: Numan Abdullah Salah
  • Patent number: 8603419
    Abstract: The invention concerns a method of treating an alkaline granular carbonatable material which contains aluminium metal and which has in particular a pH of at least 10. The method comprises an oxidation step wherein at least a portion of said aluminium metal is oxidized by contact with moisture. The aluminium should be oxidized to avoid swelling problems when using the granular material as aggregate. In the method according to the invention this oxidation is accelerated by providing at least one oxidizing agent in said moisture, which oxidizing agent has a higher redox potential than the water contained in said moisture. The method further comprises a carbonation step wherein the granular carbonatable material is at least partially carbonated to lower the pH thereof. In this way the formation of ettringite, which may also release aluminium ions which causing further swelling problems, can be avoided in the granular material or any ettringite present therein can be destabilized.
    Type: Grant
    Filed: August 23, 2010
    Date of Patent: December 10, 2013
    Assignee: Recoval Belgium
    Inventors: Philippe Descamps, Isabelle Lecomte, Evelyne Nguyen, Dirk Van Mechelen
  • Publication number: 20130068138
    Abstract: A process for lowering the carbon content in ash includes introducing the ash having a carbon content of 1 to 20 wt.-% into a reactor where the ash is burnt at a temperature between 700 and 1100° C. Fuel is also introduced into the reactor. During combustion, microwave radiation is fed into the reactor. At least part of the energy released during the combustion is recovered.
    Type: Application
    Filed: May 30, 2011
    Publication date: March 21, 2013
    Applicant: OUTOTEC OYJ
    Inventors: Nikola Anastasijevic, Guenter Schneider
  • Publication number: 20120312194
    Abstract: A method for producing a reaction product including at least one synthetic formulation that carbonates sufficiently, said method comprising: providing a first raw material, having a first concentration of M; providing a second raw material, having a second concentration of Me; and mixing the first raw material and the second raw material to produce a reaction product that includes at least one synthetic formulation having the general formula MaMebOc, MaMeb(OH)d, MaMebOc(OH)d or MaMebO(OH)d.(H2O)e, wherein M comprises at least one metal that can react to form a carbonate and Me is at least one element that can form an oxide during the carbonation reaction, wherein the at least one synthetic formulation is capable of undergoing a carbonation reaction, and wherein the at least one synthetic formulation is capable of undergoing volume change during the carbonation reaction.
    Type: Application
    Filed: June 7, 2012
    Publication date: December 13, 2012
    Applicant: RUTGERS, THE STATE UNIVERSITY OF NEW JERSEY
    Inventors: Richard E. RIMAN, Thomas E. NYE, Vahit ATAKAN, Cekdar VAKIFAHMETOGLU, Qinghua LI, Ling TANG
  • Publication number: 20120227631
    Abstract: Methods and compositions are disclosed that comprise cement kiln dust having a mean particle size that has been altered. An embodiment discloses a method of preparing cement kiln dust comprising: providing cement kiln dust having an original particle size; and altering the mean particle size of the cement kiln dust from the original size by grinding, separating, or a combination thereof. Another embodiment discloses a well treatment fluid comprising: cement kiln dust having a mean particle size that has been altered from its original size by grinding, separating, or a combination thereof; and water.
    Type: Application
    Filed: May 22, 2012
    Publication date: September 13, 2012
    Applicant: HALLIBURTON ENERGY SERVICES, INC.
    Inventors: Craig W. Roddy, Jiten Chatterji, Chad Brenneis, Callie R. Jarratt
  • Publication number: 20120216715
    Abstract: A process for treating fly ash to render it highly usable as a concrete additive. A quantity of fly ash is obtained that contains carbon and which is considered unusable fly ash for concrete based upon foam index testing. The fly ash is mixed with a quantity of spray dryer ash (SDA) and water to initiate a geopolymerization reaction and form a geopolymerized fly ash. The geopolymerized fly ash is granulated. The geopolymerized fly ash is considered usable fly ash for concrete according to foam index testing. The geopolymerized fly ash may have a foam index less than 40%, and in some cases less than 20%, of the foam index of the untreated fly ash. An optional alkaline activator may be mixed with the fly ash and SDA to facilitate the geopolymerization reaction. The alkaline activator may contain an alkali metal hydroxide, carbonate, silicate, aluminate, or mixtures thereof.
    Type: Application
    Filed: April 18, 2012
    Publication date: August 30, 2012
    Inventors: Chett Boxley, Akash Akash, Qiang Zhao
  • Publication number: 20120216716
    Abstract: A process for treating fly ash to render it highly usable as a concrete additive. A quantity of fly ash is obtained that contains carbon and which is considered unusable fly ash for concrete based upon foam index testing. The fly ash is mixed with an activator solution sufficient to initiate a geopolymerization reaction and for a geopolymerized fly ash. The geopolymerized fly ash is granulated. The geopolymerized fly ash is considered usable fly ash for concrete according to foam index testing. The geopolymerized fly ash may have a foam index less than 35% of the foam index of the untreated fly ash, and in some cases less than 10% of the foam index of the untreated fly ash. The activator solution may contain an alkali metal hydroxide, carbonate, silicate, aluminate, or mixtures thereof.
    Type: Application
    Filed: April 18, 2012
    Publication date: August 30, 2012
    Inventors: Chett Boxley, Akash Akash, Qiang Zhao
  • Publication number: 20120174825
    Abstract: The invention concerns a method for beneficiation of fly ash particles comprising: determining the heat value of the fly ash particles; comparing the determined heat value of the fly ash particles with a minimum heat value K; feeding an inlet of a combustor (5) with a feed material comprising the fly ash particles and, in case the determined heat value is lower than the minimum heat value K, fuel in sufficient quantity to assure that the heat value of the raw material is greater than or equal to the minimum heat value K; supplying an upstream airflow to the combustor (5) so as to carry the feed material in suspension from the inlet to an outlet of the combustor; operating the combustor (5) at a temperature of at least 700° C.; collecting beneficiated fly ash particles from the airflow at the outlet of the combustor (5). The invention also concerns an installation for implementation of the said method.
    Type: Application
    Filed: July 8, 2009
    Publication date: July 12, 2012
    Inventors: Javier Vazquez Favela, Maria Claudia Ramirez Carrero, César Alberto Sosa Blanco, Hugo Bolio Arceo
  • Publication number: 20120048147
    Abstract: The invention relates to mixtures containing alkali-activatable aluminosilicate binders, characterized in that the mixture contains vegetable oils and/or fats, and furthermore to the use of the vegetable fats and/or oils for reducing shrinkage and for imparting water repellency in alkali-activatable aluminosilicate binders. The invention also relates to grouts, levelling compounds or coatings in which the mixtures according to the invention are present.
    Type: Application
    Filed: March 30, 2010
    Publication date: March 1, 2012
    Inventors: Uwe Gehrig, Florian Ellenrieder
  • Publication number: 20120024196
    Abstract: A geopolymer composite binder is provided herein, the composite binder including (i) at least one fly ash material having less than or equal to 15 wt % of calcium oxide; (ii) at least one gelation enhancer; and (iii) at least one hardening enhancer having a different composition from a composition of the at least one fly ash material.
    Type: Application
    Filed: January 21, 2010
    Publication date: February 2, 2012
    Inventors: Weiliang Gong, Werner Lutze, Jan Pegg
  • Publication number: 20110314884
    Abstract: Mineral Lime is a composition having from about 85% to about 95% by volume of fly ash and from about 5% to about 15% by volume of kiln dust. A composition for Mineral Lime can also have from about 85% to about 95% by volume of Class C fly ash; and from about 5% to about 15% by volume of lime kiln dust. A process for producing a composition of Mineral Lime including fly ash and kiln dust, includes the steps of feeding fly ash to a blender; feeding kiln dust to the blender; and blending the fly ash and kiln dust in the blender.
    Type: Application
    Filed: June 24, 2011
    Publication date: December 29, 2011
    Inventors: William B. Spence, Chris A. Forsha
  • Publication number: 20110174193
    Abstract: A pyrolysis process is provided. The process includes the steps of: depositing a quantity of waste into a porous container, the porous container adapted to allow a convective stream of substantially anaerobic gas to flow therethrough; inserting the porous container into a pyrolysis thermal processor; sealing the thermal processor; circulating the convective stream of gas through the pyrolysis thermal processor; heating the waste according to a first time-temperature profile to pyrolyze the waste and form a carbonaceous char; and cooling the carbonaceous char by circulating the convective stream of gas through a cooler. An oil product and a gaseous hydrocarbon product are produced during the pyrolysis. The carbonaceous char is further processed to form a carbon black product and a recyclable metal product.
    Type: Application
    Filed: March 28, 2011
    Publication date: July 21, 2011
    Inventors: Kenneth Wesley Hamby, James Brian Kelly, Timothy Joseph Kuhn
  • Patent number: 7947229
    Abstract: When fly ash is added to a cement kiln to materialize it after being desalinated by washing, scale is prevented from growing in a dissolution reaction apparatus depositing calcium-containing compounds dissolved in slurry, and the fly ash is effectively used as a cement material. A dissolution reaction apparatus according to the invention comprises: a dissolution tub 3 for dissolving powder material, a wet dust collector 5 for collecting powder material and mist while reacting slurry S in the dissolution tub 3 with gas G and returning the collected powder material and mist to the dissolution tub 3. A second wet dust collector 7 can be provided for collecting powder material and the like accompanying to the gas G discharged from the wet dust collector 5, and both the wet dust collectors 5, 7 can be vertical type and mounted independently with each other on the dissolution tub 3.
    Type: Grant
    Filed: August 26, 2006
    Date of Patent: May 24, 2011
    Assignee: Taiheiyo Cement Corporation
    Inventors: Yukinori Sakamoto, Shinichiro Saito, Toshiaki Hirose
  • Publication number: 20110100260
    Abstract: A process for the recovery of bottom ash is characterised by shredding and physical separation phases. The bottom ash undergoes an oxidation treatment of the amphoteric metals contained therein. After the process, the treated bottom ash can be employed as mineral additive for concretes or hydraulic bonding agents.
    Type: Application
    Filed: September 16, 2008
    Publication date: May 5, 2011
    Applicant: PETRACEM S.R.L.
    Inventor: Alessandro Quadrio Curzio
  • Publication number: 20110036271
    Abstract: To reduce cost of chemical by reducing quantity of foaming agent used when removing unburned carbon in fly ash with wet floatation and to prevent decrease in activity index of the fly ash. In wet decarburization of fly ash, the solution comprising the steps of: adding water to fly ash to generate slurry; adding hydrophobizing agent and foaming agent to the slurry and agitating them to generate bubbles; and adhering unburned carbon in the fly ash to the bubbles to float them to remove the unburned carbon in the fly ash, when sedimentation component at wet floatation separation is solid-liquid separated and liquid phase obtained by solid-liquid separation is reused for another floatation separation for new fly ash, the quantity of foaming agent added to the slurry is adjusted such that concentration of the foaming agent in liquid phase is in a predetermined range.
    Type: Application
    Filed: March 17, 2009
    Publication date: February 17, 2011
    Inventors: Tomomichi Nakamura, Takao Suzuki, Kazuyoshi Matsuo
  • Patent number: 7879144
    Abstract: The present invention is a fly ash filler or filler blend having a particle size distribution with at least three modes that can be combined with a polymer at higher filler loadings to produce a filled polymer for polymer composites that, in many cases, can produce improved mechanical properties for the polymer composites over polymer composites using conventional fillers. As a result, superior polymer composites (e.g. those used in carpet backing) can be produced at a lower cost than conventional polymer composites. The present invention also includes a method for producing a polymer composite, comprising the steps of combining a polymer with a fly ash filler or a filler blend having a particle size distribution with at least three modes to produce a filled polymer and producing a polymer composite with the resulting filled polymer. The present invention further includes a method of determining what fly ashes can be used as fillers for polymer composites.
    Type: Grant
    Filed: July 3, 2007
    Date of Patent: February 1, 2011
    Assignee: Boral Material Technologies Inc.
    Inventors: Raymond T. Hemmings, Russell L. Hill, Bruce J. Cornelius
  • Publication number: 20100330288
    Abstract: Disclosed are methods for reclaiming inorganic material from waste carpeting. The method comprises providing a waste carpeting composition comprising an inorganic filler component and an organic component. The waste carpeting is heat treated under conditions effective to separate at least a portion of the organic component from the waste carpeting composition and to provide a reclaimed inorganic filler composition at least substantially free of the organic component. Also disclosed are carpets comprising the reclaimed inorganic material reclaimed by the methods disclosed herein.
    Type: Application
    Filed: May 10, 2010
    Publication date: December 30, 2010
    Inventors: Jeffery Segars, Jeffrey J. Wright, James Jarrett
  • Publication number: 20100319581
    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.
    Type: Application
    Filed: August 23, 2010
    Publication date: December 23, 2010
    Inventor: Sophia Bethani
  • Publication number: 20100282595
    Abstract: A system and method for treating unmarketable fly ash and improve its properties as an additive for concrete is disclosed. The method includes the steps of providing a gas stream containing ionized air (34), and an amount of fly ash (10) containing carbon having an adsorption capacity. The fly ash (10) is then exposed to the gas stream (34) to expose the carbon to the ionized air to promote the attachment of the ions to the carbon to reduce the adsorption capacity of the carbon.
    Type: Application
    Filed: October 17, 2007
    Publication date: November 11, 2010
    Applicant: Matrix LLC
    Inventor: John G. Whellock
  • Publication number: 20100251938
    Abstract: Sorbent components containing calcium, alumina, and silica are used in combination during coal combustion to produce environmental benefits. Sorbents are added to the coal ahead of combustion and/or are added into the flame or downstream of the flame, preferably at minimum temperatures to assure complete formation of the refractory structures that result in various advantages of the methods. When used together, the components reduce emissions of elemental and oxidized mercury; increase the level of Hg, As, Pb, and/or Cl in the coal ash; decrease the levels of leachable heavy metals (such as Hg) in the ash, preferably to levels below the detectable limits; and make a highly cementitious ash product.
    Type: Application
    Filed: June 10, 2010
    Publication date: October 7, 2010
    Applicant: NOX II, LTD.
    Inventor: Douglas C. Comrie
  • Patent number: 7772163
    Abstract: Well treating composites are composed of an organic lightweight material and a weight modifying agent. The organic lightweight material preferably forms the continuous phase and the weight modifying agent forms the discontinuous phase. The apparent specific gravity (ASG) of the organic lightweight material is less than the ASG of the well treating composite. The composite of the invention is particularly useful in hydraulic fracturing fluids as lightweight proppants as well as in sand control methods, such as gravel packing and frac packing A subterranean formation may be treated by injecting the well treating composite into the formation in order to increase fracture conductivity, reduce the generation of fines, reduced unwanted water production and/or reduce particulate production.
    Type: Grant
    Filed: January 9, 2008
    Date of Patent: August 10, 2010
    Assignee: BJ Services Company LLC
    Inventors: Harold Dean Brannon, Allan Ray Rickards, Christopher John Stephenson
  • Publication number: 20100193986
    Abstract: A manufacturing method for producing building material is provided. More particularly, a processing method for a waste residue produced by burning and desulfurizing oil dregs in oil refining is provided. The main raw material in the method is waste residue produced by burning and desulfurizing oil dregs, including fly ash and bottom dregs. Dilute sulfuric acid solution is added to the main raw material as the additive. The amount of additive is dependent upon the content of CaO in the main raw material and the concentration of the dilute sulfuric acid solution. The post-reaction materials can be used to produce bricks and brickwork. Therefore, the method provides for recovery of excess process materials, i.e., oil dregs, by utilizing the process materials to form building materials which process material would otherwise be placed in a landfill.
    Type: Application
    Filed: July 31, 2008
    Publication date: August 5, 2010
    Inventor: Teng Shaobo
  • Publication number: 20100144949
    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.
    Type: Application
    Filed: February 2, 2010
    Publication date: June 10, 2010
    Inventor: Sophia Bethani
  • Publication number: 20100006008
    Abstract: When fly ash is added to a cement kiln to materialize it after being desalinated by washing, scale is prevented from growing in a dissolution reaction apparatus depositing calcium-containing compounds dissolved in slurry, and the fly ash is effectively used as a cement material. A dissolution reaction apparatus according to the invention comprises: a dissolution tub 3 for dissolving powder material, a wet dust collector 5 for collecting powder material and mist while reacting slurry S in the dissolution tub 3 with gas G and returning the collected powder material and mist to the dissolution tub 3. A second wet dust collector 7 can be provided for collecting powder material and the like accompanying to the gas G discharged from the wet dust collector 5, and both the wet dust collectors 5, 7 can be vertical type and mounted independently with each other on the dissolution tub 3.
    Type: Application
    Filed: August 26, 2006
    Publication date: January 14, 2010
    Applicant: STETINA BRUNDA GARRED & BRUCKER
    Inventors: Yukinori Sakamoto, Shinichiro Saito, Toshiaki Hirose
  • Patent number: 7641878
    Abstract: A system and method for beneficiation of fly ash particles which at least partially reduces sulfur emissions includes at least one mixing reactor with a chamber and at least one exhaust, at least one fly ash source connected to provide fly ash particles to the chamber, at least one sorbent source, and at least one fluid supply system. The sorbent source provides at least one type of sorbent particles to be mixed with the fly ash particles to reduce sulfur emissions. A mass of the fly ash particles in the chamber is greater than a mass of the sorbent particles in the chamber. The fluid supply system provides at least one fluid to the chamber during a beneficiation of at least a portion of the fly ash particles in the chamber.
    Type: Grant
    Filed: February 21, 2006
    Date of Patent: January 5, 2010
    Assignee: PMI Ash Technologies, LLC
    Inventors: Joseph W. Cochran, S. Frank Kirkconnell
  • Publication number: 20090314185
    Abstract: Treated carbon-containing fly ash with reduced surfactant-adsorbing capacity is prepared by processing involving contacting the fly ash with ionized gas prepared from a humid gas feed, such as humid air. Treated fly ash with reduced ammonia content is prepared by processing involving contacting the fly ash with ionized gas prepared from a humid gas feed, such as humid air, or exposing the fly ash to microwave radiation or ultraviolet radiation.
    Type: Application
    Filed: April 21, 2009
    Publication date: December 24, 2009
    Applicant: MATRIX LLC
    Inventor: John G. Whellock
  • Publication number: 20090217844
    Abstract: The present invention concerns the development of a simple, multipurpose, low cost, environmental friendly and safe binder formulation and related process, based on high volumes of alkaline activated class F fly ash residue (>760%) without ordinary Portland cement and related products, offering a wide scope of applications. More specifically, the universal binder is based on a very limited number of components (fly ash type F, Blast Furnace Slag and a mixture of alkali silicates and carbonates). The binder allows developing considerable strength at the early stage (at room temperature) and very high resistances at 28 days. The binder applies to pastes, mortars concretes and pre-cast with the same flexibility of an Ordinary Portland Cement.
    Type: Application
    Filed: February 24, 2006
    Publication date: September 3, 2009
    Applicant: Cmex Research Group AG
    Inventors: Luis Miguel Ordonez, Thierry Sperisen, Javier Vasquez-Favela, Hugo Bolio-Arceo
  • Publication number: 20090151604
    Abstract: A cement additive contains industrial waste and has the effect of inhibiting formation of monosulfate in a hardened cementitious material. The cement additive contains specifically calcium carbonate, gypsum and coal ash and/or blast-furnace slag powder. This enables efficient use of industrial waste, allows inhibiting monosulfate formation in the hardened cementitious material, and allows producing a hardened cementitious material having good durability (sulfate resistance).
    Type: Application
    Filed: October 13, 2006
    Publication date: June 18, 2009
    Inventors: Hiroshi Hirao, Kazuo Yamada, Kiyoshi Koibuchi, Nobukazu Nito
  • Publication number: 20090156725
    Abstract: The present invention provides a manufactured aggregate material that converts waste materials and/or recyclable materials into construction material. By mixing waste materials with an acid solution and a metal oxide solution, any harmful contaminates in the waste materials are encapsulated and rendered into hard pellets that are suitable for use in conglomerates or composites such as concrete. The manufactured aggregate material may be adjusted for moisture content, density, heat capacity, and other parameters.
    Type: Application
    Filed: December 9, 2008
    Publication date: June 18, 2009
    Applicant: ENVIROPRODUCTS INTERNATIONAL LLC
    Inventor: Jonathan E. Hampton
  • Publication number: 20090071379
    Abstract: A process for treating fly ash to render it highly usable as a concrete additive. A quantity of fly ash is obtained that contains carbon and which is considered unusable fly ash for concrete based upon foam index testing. The fly ash is mixed with a quantity of spray dryer ash (SDA) and water to initiate a geopolymerization reaction and form a geopolymerized fly ash. The geopolymerized fly ash is granulated. The geopolymerized fly ash is considered usable fly ash for concrete according to foam index testing. The geopolymerized fly ash may have a foam index less than 40%, and in some cases less than 20%, of the foam index of the untreated fly ash. An optional alkaline activator may be mixed with the fly ash and SDA to facilitate the geopolymerization reaction. The alkaline activator may contain an alkali metal hydroxide, carbonate, silicate, aluminate, or mixtures thereof.
    Type: Application
    Filed: November 21, 2008
    Publication date: March 19, 2009
    Inventor: Chett Boxley
  • Publication number: 20080271641
    Abstract: In an alkali activated hydraulic binder containing slags and aluminium silicates slag, in particular furnace slag in amounts from ?20% (w/w), aluminium silicates different from furnace slag such as for example flue-ash and natural aluminium silicates, such as for example basalt, clays, marl, andesite or zeolite, in amounts from 5 to 75% (w/w) and an alkali activator in an amount, which corresponds to a Na2O equivalent defined as (Na2O+0.658 K2O) (ASTM C 150) between 0.7 and 4% (w/w), respectively related to the entire mixture are present in the mixture as constitutive components.
    Type: Application
    Filed: April 5, 2005
    Publication date: November 6, 2008
    Applicant: Holcim Ltd.
    Inventors: Suz-chung Ko, Peter Kruspan, Juraj Gebauer
  • Publication number: 20080173217
    Abstract: A method and system for reclaiming and beneficiating fly ash particles includes recovering at least a portion of fly ash particles from reclaimed feed and supplying at least a portion of the recovered fly ash particles to at least one mixing reactor with a chamber where at least a portion of the supplied fly ash particles are thermally beneficiated.
    Type: Application
    Filed: January 19, 2007
    Publication date: July 24, 2008
    Applicant: Progress Materials, Inc.
    Inventor: Joseph W. Cochran