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.

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.

Abstract: There is provided a process for converting wet fly ash into a useful product such as cement replacement or industrial filler. A first amount of wet fly ash is provided. The wet fly ash is fed into a mixing chamber. An amount of aggregate, such as stone, is provided. The aggregate is also fed into the mixing chamber where the wet fly ash is mixed with the aggregate. The mixed wet fly ash and aggregate is fed into a drying chamber where the mixture is heated, thereby drying the fly ash and heating the aggregate. The heated aggregate is separated from the fly ash. The heated aggregate is fed back into the mixing chamber. A second amount of wet fly ash is added to the mixing chamber where is it mixed with the heated aggregate. The heated aggregate assists in drying the second amount of wet fly ash. Once in cycle, the process is continuous.

Abstract: Carbon-containing fly ash has been treated with optimum amounts of ozone. There is homogenous treatment of the fly ash with ozone and over saturation with ozone is avoided. In a further embodiment of the invention carbon, from various sources is oxygenated to be incorporated into concrete. The preferred oxygenating agent is ozone.

Abstract: A color effect material is described as composed of a plurality of encapsulated substrate platelets in which each platelet is encapsulated with a highly reflective layer which acts as a reflector to light directed thereon and a spacer pigment layer which is selectively transparent to light directed thereon.

Abstract: The present invention relates generally to a method of forming a lightweight fly ash aggregate together with the resultant fly ash aggregate. The invention further relates to various aspects of the method of forming the lightweight fly ash aggregate including methods of forming fly ash slurry, briquettes, or lightweight fly ash particles. The general steps involved in forming a lightweight fly ash aggregate are as follows: I. blending fly ash together with a plasticiser and a reduced quantity of water; II. compacting or compressing the resultant fly ash slurry or dough; III. cutting or otherwise forming the dough into briquettes; IV. heating the briquettes to effectively cure the dough; V. firing the briquettes to sinter the fly ash; VI. crushing the sintered briquettes and sizing, preferably screening, the resultant fly ash particles to provide the lightweight fly ash aggregate of a predetermined size range.

Abstract: The present invention relates to concrete, mortar and other hardenable mixtures comprising cement and fly ash for use in construction. The invention relates to hardenable mixtures comprising cement and fly ash which can achieve greater compressive strength than hardenable mixtures containing only concrete over the time period relevant for construction. In a specific example, processing fly ash by grinding to the desired size distribution range gives a 100% yield of fly ash for utilization in high quality concrete and mortar. Such materials can thus significantly reduce construction costs, as well as provide a useful outlet for material that is generally regarded as a pollutant and a nuisance.

Abstract: Concrete's durability to freeze-thaw cycles is dependent on its level of air entrainment, the appropriate level of which is achieved with the aid of surface active or air entraining agents. These agents promote the fragmentation of large air voids into smaller ones and stabilize air voids in the concrete. The carbon matter found in fly ash when used as a pozzolanic component of concrete, adsorbs the air entraining agents, reduces the air voids and concrete's ability to withstand many freeze-thaw cycles. This invention teaches a process for a partial removal of the carbon from the coal ash, used in concrete, through a partial combustion of only a fine carbon fraction of the carbon residue of the coal ash responsible for adsorbing the air entraining agents, in a reactor with a controlled ignition system. The process of the invention thus limits the adsorption of the air entraining agents and improves the freeze-thaw properties of the concrete produced.

Abstract: Concrete's durability to freeze-thaw cycles is dependent on its level of air entrainment, the appropriate level of which is achieved with the aid of surface active or air entraining agents. These agents promote the fragmentation of large air voids into smaller ones and stabilize air voids in the concrete. The carbon matter found in fly ash when used as a pozzolanic component of concrete, adsorbs the air entraining agents, reduces the air voids and concrete's ability to withstand many freeze-thaw cycles. This invention teaches a process for a partial removal of the carbon from the coal ash, used in concrete, through a partial combustion of only a fine carbon fraction of the carbon residue of the coal ash responsible for adsorbing the air entraining agents, in a reactor with a controlled ignition system. The process of the invention thus limits the adsorption of the air entraining agents and improves the freeze-thaw properties of the concrete produced.

Abstract: A composition used in making wallboard is provided. The composition requires at least fly ash, water and a first binder. The composition is located between two members that together form the wallboard. In one embodiment, at least the first binder is part of a foamable solution and part of a binder solution. In this embodiment, the fly ash, foamable solution and binder solution are combined in a mixer. The output of the mixer can be regulated based on detection of a magnitude related to viscosity of the composition. During the process for making the wallboard, the composition is sandwiched between the two members and subject to both preheating and subsequent heating stages. During the preheating, a sufficient number of bubbles associated with the binder are maintained in order to achieve a predetermined density based on the closed cells that are formed after the water evaporates.

Abstract: The present invention is a fly ash filler or filler blend having a particle size distribution with at least three modes that when combined with asphalt produces asphalt composites such as roofing shingles with improved mechanical properties at a lower cost than asphalt shingles produced using conventional calcium carbonate fillers. The present invention also includes a method for producing an asphalt composite, comprising the steps of combining asphalt with a fly ash filler or a filler blend having a particle size distribution with at least three modes and producing an asphalt composite with the resulting filled asphalt. The present invention further includes a method of determining what fly ashes can be used as fillers for asphalt composites such as roofing shingles.

Abstract: The present invention is directed at a synthetic lightweight aggregate composition comprising fly ash and a mixture of two or more polymer components. More specifically, the present invention is also directed at a lightweight concrete which cures to a hardened cementious composite comprising Portland cement, water in a weight ratio of between about 0.2 and 0.7 of the water to the Portland cement, synthetic lightweight aggregate in a weight ratio of between about 0.1 and 0.5 of the synthetic lightweight aggregate to the cement, wherein the synthetic lightweight aggregate comprises fly ash and two or more polymer components.

Abstract: A manufactured granular substrate composition suitable for use as a carrier for active chemical agents. The composition includes one or more mineral components having a bulk density greater than about 70 pounds per cubic foot. The composition also contains about one or more light weight additives and one or more water soluble binders. The resulting manufactured granular substrate has a bulk density of less than about 55 pounds per cubic foot with a size guide number of about 75 to about 300.

Abstract: The present invention provides a process for producing ultrafine particulate complex oxide containing titanium oxide, including vapor-phase producing a complex oxide containing titanium oxide having a BET specific surface area of about 5 to about 200 m2/g, where a starting material gas containing titanium tetrachloride and an oxidizing gas are preheated to about 700° C. or more, and are reacted with a solution or a slurry of a salt containing a metallic element. The present invention also provides an ultrafine particulate complex oxide containing titanium oxide obtained by the process, and use of the oxide.

Abstract: Systems and methods of making and using fine particle materials in pigment blends and for using the aforementioned pigment blends in paint, coating, or coloring compositions are provided. This invention further provides systems and methods of enhancing the visual appearance of a variety of substrates by introducing a paint, coating, or coloring composition to the substrate. The fine particle materials of the present invention have a substantially random geometric shape, a particle size less than about 100 microns, and help provide both functional and visual enhancing properties to compositions and substrates containing these fine particle materials.

Abstract: Construction material from granular material reclaimed from the ash of a municipal waste combustor wherein the ash is subjected to sorting and separating recovered metals, the granular material including particles having a maximum particle diameter of 5 to 40 mm, a U-coefficient of 10 or more, and ignition loss of 10% or less in weight and being subjected to at least one heavy metal immobilization agent, preferably phosphoric acid; and a second heavy metal immobilization agent consisting of ferrous sulfate. The ash is further subjected to drying before subjecting the ash to the at least one heavy metal immobilization agent. The ash is further subjected to mulling the material after subjecting the ash to the at least one heavy metal immobilization agent.

Abstract: Silk clothes for protecting affected parts (incised wound, burn, tumor, bedsore, etc.) which also contribute to the prevention of suppurating. These clothes are composed of a knitted woven silk fabric or non-woven silk fabric (silk floss, etc.) containing either Sasa veitchii or a parabenzoic acid ester or both of the same and being adhered to a non-woven fabric made of cellulose, etc.

Abstract: The present invention relates generally to a method of forming a lightweight fly ash aggregate together with the resultant fly ash aggregate. The invention further relates to various aspects of the method of forming the lightweight fly ash aggregate including methods of forming fly ash slurry, briquettes, or lightweight fly ash particles.

Abstract: Carbon-containing fly ash has been treated with optimum amounts of ozone. There is homogenous treatment of the fly ash with ozone and oversaturation with ozone is avoided.

Abstract: There is disclosed a method of reducing carbon levels in fly ash. The method comprises the steps of: (a) placing the fly ash in a microwave reactor; (b) exposing said fly ash to microwave radiation in the presence of carbon-free material so as to raise its temperature to at least 600° C. while agitating the fly ash in the presence of oxygen; and; (c) terminating exposure of said fly ash to said microwave radiation when the carbon content of the fly ash has fallen below a predetermined value.

Abstract: Systems and methods of making and using fine particle materials in pigment blends and for using the aforementioned pigment blends in paint, coating, or coloring compositions are provided. This invention further provides systems and methods of enhancing the visual appearance of a variety of substrates by introducing a paint, coating, or coloring composition to the substrate. The fine particle materials of the present invention have a substantially random geometric shape, a particle size less than about 100 microns, and help provide both functional and visual enhancing properties to compositions and substrates containing these fine particle materials.

Abstract: A low density ash particle separation and collection method and device for separating low density particles, primarily frothy-solid particles with internal and external porosity and thick walled hollow particles, from the overall mixture of higher density particles including raw fly ash as produced by coal fired power plants. Specifically, the invention relates to a device and method for separating and collecting the low density fly ash fraction composed of thick walled hollow fly ash particles and frothy generally solid particles with both internal and external porosity and a relatively small amount of cenospheres from the overall mixture of ash particles composing raw ash as produced by coal fired power plants by de-energizing one or more fields of large electrostatic precipitators during electrostatic precipitation of the ash resulting in the dropping out of the lower density particles in the hoppers located below the de-energized field(s) of the electrostatic precipitator.

Abstract: A method for producing a mineral filler and pozzolan product from fly ash is provided in which fly ash is dry processed in an air classifier to obtain a fine fraction having an average particle size of from about 0.1 to 5 microns and a coarse fraction having an average particle size of from about 6 to 20 microns. The fine fraction is then preferably passed through a magnetic separator to remove ferrous iron oxides and may optionally be treated with a surface modifier to form a mineral filler. The coarse fraction is preferably passed through a 100 mesh screen to form a pozzolan product.

Abstract: A manufactured granular substrate composition suitable for use as a carrier for active chemical agents. The composition includes about 65 wt % or more of one or more mineral components having a bulk density greater than about 70 pounds per cubic foot. The composition also contains about 5 wt % to about 25 wt % of one or more light weight additives and up to 20 wt % of one or more water soluble binders. The resulting manufactured granular substrate is readily dispersable in water and has a bulk density of less than about 55 pounds per cubic foot with a size guide number of about 100 to about 230.

Abstract: A method for producing a mineral filler from fly ash is provided in which fly ash is dry processed in an air classifier to obtain a fine fraction having an average particle size of from about 0.1 to 5 microns. The fine fraction is then preferably passed through a magnetic separator to remove ferrous iron oxides and may optionally be treated with a surface modifier. The resulting processed fly ash may be used in a wide variety of filler applications.

Abstract: An apparatus and method for improving the properties of carbon-containing fly ash through ozonation is described. The apparatus includes a chamber for containing the fly ash and an ozonator that generates an ozone-containing gas. The ozonator supplies the ozone-containing gas such that it enters the chamber with the fly ash and deactivates carbon within the fly ash. Afterwards, the fly ash will have decreased surfactant adsorptivity so that it can be effectively mixed with cement or whatever other materials may require fly ash with passivated carbon.

Abstract: Processes for treating fly ash to enhance the fly ash as a pozzolan for portland cement mixes and to separate therefrom a substantial carbon compound and/or to increase the fineness of the fly ash include the treatment of a fly ash slurry with ultrasonic energy using ultrasonic horns immersed in a slurry of fly ash and water and imparting to said slurry such ultrasonic energy as to cause microscopic cavities to form and implode with high localized energy to break up fly ash agglomerations along cleavage lines and to break up carbon particles and matrices which have entrapped fly ash microspheres therein to release the microspheres into the slurry. A conditioner agent may be added at or during ultrasonic treatment to enhance the flotation of the carbon compound.

Abstract: Metal matrix composites comprising of a solid preform comprising of a filler phase containing fly ash and a binding material having a binder to water ratio of 1:1 to 1:9, wherein the preform contains a metal homogeneously distributed within the preform.

Abstract: Spherical agglomerates of finely divided material such as inorganic oxides are prepared by admixing a slurry of finely divided material with a solution of a partially neutralised carboxylic acid.

Abstract: A method of reducing the carbon content of a dry bi-modal fly ash includes subjecting the bi-modal fly ash to dry vibrating screen separation into a carbon rich component and a carbon depleted fly ash component with the carbon depleted fly ash component being created with a carbon content less than about 4 percent by weight and at least 50 weight percent of the fly ash component of the bi-modal fly ash. The dry vibrating screen separation is preferably a single step process with no prior substantial concentration of the carbon component of the bi-modal fly ash. It is preferred to employ bi-modal fly ash produced as a result of combustion of coal. A method of making a concrete mixture employing the carbon depleted component is also provided.

Abstract: Processes for treating fly ash to enhance the fly ash as a pozzolan for portland cement mixes and to separate therefrom a substantial carbon compound and/or to increase the fineness of the fly ash include the treatment of a fly ash slurry with ultrasonic energy using ultrasonic horns immersed in a slurry of fly ash and water and imparting to said slurry such ultrasonic energy as to cause microscopic cavities to form and implode with high localized energy to break up fly ash agglomerations along cleavage lines and to break up carbon particles and matrices which have entrapped fly ash microspheres therein to release the microspheres into the slurry. A conditioner agent may be added at or during ultrasonic treatment to enhance the flotation of the carbon compound.

Abstract: A method for improving the pozzolanic character of fly ash includes the steps of first hydraulically classifying and then flotation separating the fly ash in order to reduce particle size distribution and remove carbon. The method also includes the steps of spiral concentrating separated coarse particles to recover iron, pyrite and marcasite and screening the fly ash to remove ultra-light carbon and plant debris.

Abstract: A method for producing fly ash granules, which comprises mixing 100 parts by weight of fly ash, from 0.001 to 1 part by weight of a water-soluble polymer having from 2 to 80 mol %, based on the total repeating units, of repeating units having carboxyl groups, and from 40 to 100 parts by weight of water, for granulation.

Abstract: A method for preheating particles of carbonaceous fly ash prior to injecting the particles of fly ash into a combustor. In the method, the particles of fly ash are introduced into a preheating vessel. The particles of fly ash are heated in the preheating vessel to a temperature at least approximately equal to their autoignition temperature to form preheated particles of fly ash. The preheated particles of fly ash are then injected into the combustor. The heating of the particles of fly ash in the preheating vessel decreases the amount of time the particles of fly ash are in the combustor below the autoignition temperature and thereby increases the amount of carbon in the particles of fly ash oxidized within the combustor. An apparatus is provided for performing the method of the invention.

Abstract: A method for making synthetic aggregate. Fly ash is combined with water to form a soil-like mixture. The mixture is then compacted into slabs and allowed to set. After setting, the material is crushed to appropriate size. Since fly ash and water mixtures set quickly, and since compaction should take place prior to setting of the mixture, a set sequestering admixture may be used to facilitate the process.

Abstract: A method for beneficiating particles of fly ash containing carbon which includes the following steps. The particles of fly ash are introduced into a dry bubbling fluid bed and air is supplied thereto. The fluid bed is operated at a temperature ranging from approximately 800.degree. to 1300.degree. F., during which the air intimately mixes with the particles of fly ash and oxidizes the carbon therein. The beneficiated particles of fly ash are then removed from the fluid bed. The carbon reduction in the particles of fly ash permits these particles to be used as pozzolan to replace a portion of the cement in concrete. An apparatus is provided for performing the method of the invention.

Abstract: A process for making high-strength aggregates including hydrating calcium oxide containing coal combustion ash for a sufficient period of time to convert a high percentage of the calcium oxide to calcium hydroxide prior to forming the aggregates and curing the aggregates in high humidity. The moisture of the hydrated material is monitored to vary the hydration moisture to the desired set point. Further, the process involves producing high-strength aggregates from calcium hydroxide containing FGD ashes such as generated from duct sorbent injection and spray dryer processes.

Abstract: A method is shown for producing a lightweight aggregate by treating flyash and sewage sludge. The flyash and sewage sludge are mixed together and then agglomerated into pellets, with or without the use of a binder. The pellets may be coated and then are dried. The dried pellets are introduced into a rotary kiln in a direction that is co-current with the flow of fuel and air through the kiln. The pellets in the kiln will be indurated and will experience complete calcination as well as varying degrees of pyrolizing and sintering. The product of the kiln is a nodular material having a low density but with a hard and porous structure. The product of the kiln is feed to a cooler. The flyash sewage sludge mixture has a significant fuel value that is usable in the kiln. Furthermore, the fuel value available in the kiln off-gases may be used for drying the materials.

Abstract: Commercially available fly ash is prepared and charged in a vessel. A halogen gas is supplied to the vessel and is brought into contact with the fly ash in the vessel.

Abstract: Articles and methods for forming optically variable thin film flakes and replicated coatings having preselected optical properties. The articles generally comprise a flexible web of material and an optically variable thin film coating formed on one surface of the web. The optically variable coating is separated from the web to form optically variable thin film flakes. The flakes are disposed in ink and paint vehicles to provide optically variable inks, paints and the like.

Abstract: Bottom ash arising from solid waste combustion has lead (Pb) sufficient quantity to sometimes fail the EPA TCLP test. Addition of water-soluble phosphate, especially phosphoric acid, increases the immobilization of lead (Pb) so as to make such residues in compliance with the toxicity tests over a substantially broader pH range, particularly with respect to the more stringent TCLP extraction test. The bottom ash may be wet or dry when contracted with the water-soluble phosphate. The contacting is preferably preformed in an enclosed environment to avoid bottom ash contact with or exposure to the ambient atmospheres prior to treatment.

Abstract: A wet process for the beneficiation of a fly ash by-product has the following steps: a) forming a slurry mixture of a fly ash material and a liquid; b) gravitationally separating and collecting a first material fraction of the fly ash having a density less than the liquid by skimming off floating slurry material; c) separating a first magnetic fraction from the slurry by subjecting the slurry to a magnetic field of from about 300 gauss to about 10 kilogauss; d) separating the unburned carbon from the remaining slurry components by adding an effective amount of an oil having a carbon chain greater than octane, and a frothing agent whereby the oil coats the unburned carbon forming hydrophobic carbon materials and inducing air into the system for frothing the slurry mixture wherein the hydrophobic unburned carbon froths to the surface and is removed by skimming off the frothing layer; and e) collecting the remaining fraction of silicate spheres and silicates.

Abstract: Articles and methods for forming optically variable thin film flakes and replicated coatings having preselected optical properties. The articles generally comprise a flexible web of material and an optically variable thin film coating formed on one surface of the web. The optically variable coating is separated from the web to form optically variable thin film flakes. The flakes are disposed in ink and paint vehicles to provide optically variable inks, paints and the like.

Abstract: System and method for low temperature treatment of organic wastes containing potentially toxic concentrations of metals is described which comprises forming the waste material into pellets of preselected size, mixing the pellets with inert material, incrementally heating the mixture in air from about 200.degree. C. to about 600.degree. C. in order to oxidize the pellets to the corresponding ash containing the metals, collecting the ash, and combining the ash with inert material and binder to form a solidified compact for disposal.

Abstract: This invention relates to an apparatus, method and product wherein fine particles of fly ash containing carbon are oxidized in a dry, bubbling fluid bed of previously introduced fine particles of the same fly ash so that the subsequently removed particles have reduced carbon content and are useful as pozzolan, suitable for use, without further processing, to replace a portion of the cement in concrete. The preferred conditions are a temperature of about 1300.degree. to 1800.degree. F., air velocity of between at least about 0.5, but not more than about 3 ft./sec., residence time of at least about 2 minutes but up to 100 minutes, volume ratio of air to fly ash of between about 1,000 and 1500, and an excess of oxygen between about 5% and 15%.

Abstract: Described is the process for forming a hardenable mixture of a coal ash comprising free CaO and free CaSO.sub.4.0 H.sub.2 O.In order to remove all free CaO the coal ash is mixed with a fly-ash comprising essentially no free CaO and no free CaSO.sub.4.0 H.sub.2 O and water and subsequently subjected to a heat treatment.By removal of free CaO it is found that the strength of hardened granules formed from such ash mixture does not deteriorate as is the case from granules formed with a coal ash comprising free CaO.Also a process for forming hardened granules and a building component formed with use of a hardenable mixture according to the invention are described.

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

Abstract: A wet process for the beneficiation of a fly ash by-product has the following steps: a) forming a slurry mixture of a fly ash material and a liquid; b) gravitationally separating and collecting a first material fraction of the fly ash having a density less than the liquid by skimming off floating slurry material; c) separating a first magnetic fraction from the slurry by subjecting the slurry to a magnetic field of from about 300 gauss to about 10 kilogauss; d) separating the unburned carbon from the remaining slurry components by adding an effective amount of an oil having a carbon chain greater than octane, and a frothing agent whereby the oil coats the unburned carbon forming hydrophobic carbon materials and inducing air into the system for frothing the slurry mixture wherein the hydrophobic unburned carbon froths to the surface and is removed by skimming off the frothing layer; and e) collecting the remaining fraction of silicate spheres and silicates.

Abstract: Described is the process for forming a hardenable mixture of a coal ash comprising free CaO and free CaSO.sub.4 .OH.sub.2 O.In order to remove all free CaO the coal ash is mixed with a fly-ash comprising essentially no free CaO and no free CaSO.sub.4.OH.sub.2 O and water and subsequently subjected to a heat treatment.by removal of free CaO it is found that the strength of hardened granules formed from such as mixture does not deteriorate as is the case form granules formed with a coal ash comprising free CaO.Also a process for forming hardened granules and a building component formed with use of a hardenable mixture according to the invention are described.