Ash Containing (e.g., Fly Ash, Volcanic Ash, Coal Ash, Etc.) Patents (Class 106/705)
  • Patent number: 8137453
    Abstract: Fiber reinforced concrete is generated by including fiber in a dispersed manner in a cement matrix including: cement; first pozzolanic reactant particles having a high activity; second pozzolanic reactant particles having an activity lower than the first pozzolanic reactant particles; first aggregate particles having a maximum particle diameter smaller than or equal to 2.5 mm, a mean particle diameter within a range of 0.4 mm to 0.8 mm and a fineness modulus within a range of 1.5 to 3.5; second aggregate particles having a maximum particle diameter smaller than or equal to 0.425 mm, a mean particle diameter within a range of 0.1 mm to 0.3 mm and a fineness modulus within a range of 0.4 to 0.8; at least one type of plasticizer; and water.
    Type: Grant
    Filed: May 12, 2005
    Date of Patent: March 20, 2012
    Assignee: Taisei Corporation
    Inventors: Yoshihiro Tanaka, Jun Sakamoto
  • Patent number: 8133317
    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: Grant
    Filed: October 13, 2006
    Date of Patent: March 13, 2012
    Assignees: Taiheiyo Cement Corporation, DC Co., Ltd.
    Inventors: Hiroshi Hirao, Kazuo Yamada, Kiyoshi Koibuchi, Nobukazu Nito
  • Patent number: 8118927
    Abstract: A cementitious composition is provided that comprises an effective amount of bottom ash and an effective amount of cement. In one embodiment, a structural product formed from mixing the composition with an effective amount of water has a seven-day compressive strength of at least about 2,500 psi and, more preferably, a seven-day compressive strength of at least about 4,000 psi. In another embodiment, a structural product formed from mixing the composition with an effective amount of water has a twenty-eight-day compressive strength of at least about 4,000 psi and, more preferably, a twenty-eight-day compressive strength of at least about 5,000 psi.
    Type: Grant
    Filed: July 25, 2003
    Date of Patent: February 21, 2012
    Inventor: Charles E. Price
  • Publication number: 20120031306
    Abstract: There is provided an apparatus and process for manufacturing a brick or paver with a high content of coal ash (ranging from 60% to 100% coal ash or fly ash) so that a waste product (coal ash, and more particularly Class F coal ash) from a coal-fired power plant is incorporated into a building product (high content fly ash brick or paver). Also provided is a variable firing tray to support the dried, high content coal ash bricks/pavers as the dried products are sent through a tunnel kiln, to improve circulation around the individual bricks/pavers and thereby result in reduced firing time in the kiln.
    Type: Application
    Filed: July 13, 2011
    Publication date: February 9, 2012
    Inventors: Robert Thomas Belden, Michel Cristallo, George W. Ittmann, Robert W. Ittmann
  • Publication number: 20120031307
    Abstract: Techniques are generally described for producing cement clinker that includes forming cement clinker in a kiln, heating waste additives, and applying the heated waste additives to the cement clinker in the kiln. Additionally, examples are generally described that include an apparatus for producing cement clinker that includes a kiln in which cement clinker is formed and a device having an opening positioned inside the kiln which provides heated waste additives to the kiln for application to the cement clinker. An example device for applying waste additives to cement clinker includes an eductor configured to receive waste additives and transport air in which the waste additives are pneumatically entrained, and includes a lance coupled to the eductor and configured to receive the pneumatically entrained waste additives and receive a support gas that reacts with the waste additives and heats the same for application to the cement clinker.
    Type: Application
    Filed: August 6, 2010
    Publication date: February 9, 2012
    Inventor: John Graham Whellock
  • Publication number: 20120032107
    Abstract: A concrete mixture for forming a breathable concrete. The mixture comprises aggregate particles and a paste comprising water, cement or cement substitute, and plasticiser. The plasticiser controls the viscosity of the paste such that the paste forms a substantially uniform layer coating the particles, with the coated particles in contact, whilst allowing spaces to be retained there between. These spaces interconnect forming channels through the concrete, allowing air to permeate there through such that the concrete exhibits good dynamic insulation properties, whist retaining structural strength.
    Type: Application
    Filed: June 23, 2009
    Publication date: February 9, 2012
    Inventors: Mohammed Imbabi, Fredrik Glasser, Jim Min Wong
  • Patent number: 8110039
    Abstract: A method of manufacturing a hydratable cementitious material, which includes: a) providing at least one waste material containing calcium, silica, magnesium, aluminium, and/or iron; b) thermally treating each waste material to a first temperature such that surface water vapour present is substantially removed; and c) blending the treated waste material such that the resultant blend has a reactive oxide chemical/physical composition in the following range, by weight of the blend: Calcium Oxide 7.0 to 76% Alumina 0.1 to 30% Iron Oxide 0.4 to 19% Silica Oxide 1 to 36% Magnesia 0.1 to 2%. The resultant blend from step c) may subsequently be mixed with Portland cement.
    Type: Grant
    Filed: April 29, 2004
    Date of Patent: February 7, 2012
    Assignee: Cenin Limited
    Inventor: Gary Hunt
  • Publication number: 20120012034
    Abstract: Hydraulic cements, such as Portland cements and other cements that include substantial quantities of tricalcium silicate (C3S), dicalcium silicate (C2S), tricalcium aluminate (C3A), and/or tetracalcalcium alumino-ferrite (C4AF), are particle size optimized to have increased reactivity compared to cements of similar chemistry and/or decreased water demand compared to cements of similar fineness. Increasing hydraulic cement reactivity increases early strength development and release of reactive calcium hydroxide, both of which enhance SCM replacement and 1-28 day strengths compared to blends of conventional Portland cement and one or more SCMs, such as coal ash, slag or natural pozzolan. Decreasing the water demand can improve strength by decreasing the water-to-cement ratio for a given workability. The narrow PSD cements are well suited for making blended cements, including binary, ternary and quaternary blends.
    Type: Application
    Filed: July 14, 2011
    Publication date: January 19, 2012
    Inventors: John M. Guynn, Andrew S. Hansen
  • Patent number: 8092593
    Abstract: Compositions for fabricating architectural works wherein the compositions utilize one or more cement materials, additives, fibers and recycled glass. Exemplary cement materials include Portland cement, calcium aluminate, fly ash and/or E glass. Exemplary additives include boric acid, citric acid, lithium, plasticizer and/or methylcellulose ethers. Exemplary fibers include polyvinyl alcohol (PVA) and/or micro-fibers. Crushed recycled glass is used as an aggregate or non-reactive material. Other ingredients may be used including: sodium hydroxide, potassium hydroxide and hydrated lime to alter the PH; ferrous sulfate, mono-potassium phosphate, or manganese carbonate and magnesium sulfate as color enhancements; and/or pozzolans (Vcas) to neutralize the ASR efflorescence.
    Type: Grant
    Filed: June 17, 2010
    Date of Patent: January 10, 2012
    Inventor: Melvin Scott McCombs
  • Publication number: 20120000396
    Abstract: Reduced-carbon footprint concrete compositions, and methods for making and using the same, are provided. Aspects of the reduced-carbon footprint concrete compositions include CO2-sequestering carbonate compounds, which may be present in the hydraulic cement and/or aggregate components of the concrete. The reduced-carbon footprint concrete compositions find use in a variety of applications, including use in a variety of building materials and building applications.
    Type: Application
    Filed: July 19, 2010
    Publication date: January 5, 2012
    Inventors: Brent R. CONSTANTZ, Andrew Youngs, Terence C. Holland
  • Patent number: 8066813
    Abstract: A method of making a cementitious composition comprises (a) selecting at least one pozzolanic particulate material; (b) selecting and grinding at least one feldspar material to a fineness of at least 3000 Blaine; (c) mixing calcium oxide or calcium hydroxide with gypsum; (d) mixing the ground feldspar with the lime-gypsum mixture to produce an activator; (e) conditioning the pozzolanic particulate material with an aqueous solution; (f) adding the activator to the conditioned material to produce a slurry; and (g) curing the slurry in a sealed container. The pozzolanic particulate material can be slag, fly ash, or siliceous rock. A cementitious composition of the invention comprises a pozzolanic particulate material, a ground feldspar material, a lime compound and gypsum, and uses readily available materials, as an economic replacement for Portland cement, fly ash or other materials in filling, backfilling and paving, particularly for backfilling or stabilizing mine sites.
    Type: Grant
    Filed: February 24, 2009
    Date of Patent: November 29, 2011
    Assignee: Her Majesty the Queen in right of Canada, as represented by the Minister of Natural Resources
    Inventor: Allen Pratt
  • Publication number: 20110283922
    Abstract: Cementitious compositions in which the cementitious properties of fly-ash are carefully controlled. The cementitious compositions may be substantially free harsh acids and bases such as citric acids (?pH 2.2) and alkali metal activators including alkali hydroxides (?pH 12-14) and metal carbonates (?pH 11.6). The use of these harsh chemicals creates acid base reactions during use of the products. Instead of these harsh chemicals, a citric salt, for example potassium citrate, may be used as a reaction accelerator. Boric compounds may be used as a retarder in the compositions.
    Type: Application
    Filed: August 3, 2011
    Publication date: November 24, 2011
    Applicant: CeraTech, Inc.
    Inventors: Glenn SCHUMACHER, Rajeshkumar Patel, Paul Sampson, Michael Riley
  • Publication number: 20110287198
    Abstract: The present invention relates to an alkali-activated binder which can be used as a binder for replacing cement, and more particularly, to an alkali-activated binder, and to mortar, concrete, concrete products, and wet loess paving material comprising the binder, in which inorganic sodium-free alkaline materials are contained to reduce the total amount of Na2O and K2O in concrete, thus improving the workability and the strength stability and inhibiting the alkali-aggregate reaction.
    Type: Application
    Filed: January 29, 2010
    Publication date: November 24, 2011
    Applicant: INDUSTRY FOUNDATION OF CHONNAM NATIONAL UNIVERSITY
    Inventors: Jin Kyu Song, Keun Hyeok Yang
  • Patent number: 8062413
    Abstract: Disclosed herein are an asphalt concrete mixture, an asphalt binder composition, and methods of preparing the related compositions. The asphalt binder compositions include heavy oil fly ash that contains more than about 90 wt. % carbon. The compositions are capable of being performance graded. The binder can be used to modify the asphalt and also as a filler in asphaltic concrete compositions.
    Type: Grant
    Filed: November 1, 2010
    Date of Patent: November 22, 2011
    Assignee: Saudi Arabian Oil Company
    Inventors: Mohammed Al-Mehthel, Hamad L Al-Abdul Wahhab, Ibenalwaleed A. Hussein
  • Patent number: 8057594
    Abstract: The various embodiments of the present invention relate generally to high strength foam materials and methods of making the same. More particularly, various embodiments of the present invention relate to high strength foam materials comprising pozzolans, such as cenospheres derived from fly ash. An embodiment of the present invention comprises, a pozzolan foam material comprising a pozzolan, an alkali, a silicate, and an organosilicon compound. Various embodiments of the present invention are directed to strong, lightweight materials that are environmentally-friendly and can be economically manufactured.
    Type: Grant
    Filed: June 19, 2008
    Date of Patent: November 15, 2011
    Assignee: Georgia Tech Research Corporation
    Inventors: Mulalo Doyoyo, Paul Biju-Duval
  • Patent number: 8048219
    Abstract: A method of placing a concrete compositions including a) combining 3-40 volume percent cement, 5-50 volume percent fine aggregate, 5-50 volume percent coarse aggregate, and 10-22 volume percent water; b) adding 1.5-40 volume percent of prepuff particles to form a concrete composition; and c) pumping the concrete composition to a point higher in elevation than the delivery point of the concrete to place the concrete. The concrete composition contains less than 30 volume percent of other light weighting aggregates and the prepuff particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3. The slump value of the placed concrete measured according to ASTM C 143 is greater than 1 inch and the concrete has a density of from about 40 to about 135 lb./ft3.
    Type: Grant
    Filed: September 17, 2008
    Date of Patent: November 1, 2011
    Assignee: NOVA Chemicals Inc.
    Inventors: Daniel Woolfsmith, Michael T. Williams, Rick Hughes, Michael R. Kelley, John K. Madish, Kristen Van Buskirk, Tricia Guevara Ladely
  • Patent number: 8043425
    Abstract: A subject of the invention is a mixture comprising in proportions by mass: from 0.4 to 4%, preferably from 0.8 to 1.7%, of materials in the ultrafine particle size range, constituted by particles with a D90 smaller than 1 ?m and/or with a specific BET surface area greater than 6 m2/g; from 1 to 6%, preferably from 2 to 5%, of Portland cement; from 8 to 25%, preferably from 12 to 21%, of materials in the fine particle size range, constituted by particles the D10 and the D90 of which are comprised between 1 ?m and 100 ?m and with a specific BET surface area of less than 5 m2/g, different from the cement; from 25 to 50%, preferably from 30 to 42%, of materials in the medium particle size range, constituted by particles the D10 and the D90 of which are comprised between 100 ?m and 5 mm; and from 25 to 55%, preferably from 35 to 47%, of materials in the larger particle size range, constituted by particles the D10 of which is greater than 5 mm.
    Type: Grant
    Filed: May 16, 2007
    Date of Patent: October 25, 2011
    Assignee: Lafarge
    Inventor: Emmanuel Garcia
  • Patent number: 8038789
    Abstract: A process for making a pervious concrete comprising a geopolymerized pozzolanic ash. Generally, the process includes mixing a solid aggregate and a geopolymerized pozzolanic ash binder together to form a pervious concrete mixture. Some examples of suitable aggregates comprise recycled carpet, recycled cement, and aggregates of coal-combustion byproducts. The geopolymerized pozzolanic ash binder is made by combining a pozzolanic ash, such as fly ash, with a sufficient amount of an alkaline activator and water to initiate a geopolymerization reaction. The activator solution may contain an alkali metal hydroxide, carbonate, silicate, aluminate, or mixtures thereof. In some aspects, the final concrete forms a solid mass in the form of pavement or a pre-cast concrete shape. The solid mass of concrete may have a void content of between about 5% and about 35%.
    Type: Grant
    Filed: September 3, 2009
    Date of Patent: October 18, 2011
    Assignee: Ceramatec, Inc.
    Inventor: Chett Boxley
  • Patent number: 8016937
    Abstract: Cementitious compositions in which the cementitious properties of fly-ash are carefully controlled. The cementitious compositions may be substantially free harsh acids and bases such as citric acids (?pH 2.2) and alkali metal activators including alkali hydroxides (?pH 12-14) and metal carbonates (?pH 11.6). The use of these harsh chemicals creates acid base reactions during use of the products. Instead of these harsh chemicals, a citric salt, for example potassium citrate, may be used as a reaction accelerator. Boric compounds may be used as a retarder in the compositions.
    Type: Grant
    Filed: January 22, 2008
    Date of Patent: September 13, 2011
    Assignee: Ceratech, Inc.
    Inventors: Glenn Schumacher, Rajeshkumar Patel, Paul Sampson, Michael Riley
  • Patent number: 8007581
    Abstract: Cuttings from drilling through or into natural rock and/or soil can be incorporated into useful, high quality load-bearing structures such as vehicle roads and pads for deep drilling rigs. This process recycles a material previously regarded as valueless at best and often as a pollution hazard. The cuttings, optionally mixed with drilling mud and/or soil, are converted to the useful structures by pozzolanic and/or cementitious reactions after being mixed with suitable other materials and/or are bonded into the useful structures by asphaltic materials.
    Type: Grant
    Filed: October 26, 2009
    Date of Patent: August 30, 2011
    Assignee: Scott Environmental Services, Inc.
    Inventors: Jonathan Blake Scott, Billy Roy Scott, Jeanne McCoy Scott, legal representative, Dallas N. Little
  • Patent number: 7998268
    Abstract: A method of making durable, non-vitrified masonry units comprising fly ash, the method comprising mixing fly ash comprising a minimum of 15% CaO by weight and no more than about 10% loss on ignition, water, and an air entrainment agent to form a fly ash mixture; compacting the fly ash mixture in a shaping device by applying pressure of at least 1000 psi to the fly ash mixture; and curing the compacted fly ash mixture to cause the mixture to harden and gain strength.
    Type: Grant
    Filed: January 19, 2006
    Date of Patent: August 16, 2011
    Assignee: Ecologic Tech Company, Inc.
    Inventor: Henry Liu
  • Publication number: 20110192324
    Abstract: A device is provided for use at temperatures above 1000° C. or in steel melts. The device has a body based on a material selected from at least one of high temperature-resistant hollow balls and high temperature-resistant hollow fibers. The body further contains water glass and a cement.
    Type: Application
    Filed: April 19, 2011
    Publication date: August 11, 2011
    Applicant: HERAEUS ELECTRO-NITE INTERNATIONAL N.V.
    Inventor: Johan KNEVELS
  • Patent number: 7993449
    Abstract: A binder composition includes a) an ash, b) an additive composition, wherein the additive composition includes one or more components from group (b1) and one or more components from group (b2), wherein group (b1) consists of metal chlorides and wherein group (b2) consists of silica, zeolite and apatite, and c) a cement. In addition to that the present application relates to a construction composition including the present binder composition and a basic component, and also to a method for preparing the construction composition and to uses thereof.
    Type: Grant
    Filed: February 12, 2007
    Date of Patent: August 9, 2011
    Assignee: Mega-Tech Holding B.V.
    Inventor: Robin de la Roij
  • Patent number: 7993450
    Abstract: The object is to remove unburned carbon in a fly ash in a stable and economically advantageous manner. A fly ash, water and a trapping agent are mixed together in a hybrid mixer (2), a shearing force is applied to the mixture to prepare a slurry containing surface-modified unburned carbon within a short time, a foaming agent is added to the slurry, and then the unburned carbon is separated by performing flotation separation in a flotator (11).
    Type: Grant
    Filed: December 13, 2006
    Date of Patent: August 9, 2011
    Assignee: Mitsui Engineering & Shipbuilding Co., Ltd.
    Inventors: Kazuo Abe, Takao Suzuki, Hitoshi Koyama, Kazuyoshi Matsuo, Shinichiro Saito
  • Publication number: 20110174196
    Abstract: A CO2 control device and method for capturing CO2 from fluid flow, including: a flow-through apparatus and an CO2 absorbing filter treated with an alkaline material which is housed within the flow-through apparatus. The flow-through apparatus receives fluid flow and the CO2 from the fluid flow is absorbed by the CO2 absorbing filter. The absorbed CO2 is converted into CaCO3 which is combined with volcanic ash to form a useful cement material.
    Type: Application
    Filed: March 30, 2011
    Publication date: July 21, 2011
    Inventors: Kenneth D. MURRAY, Katherine A. Murray
  • Publication number: 20110174194
    Abstract: A pumpable grout mixture includes a first grout stream including a hydraulically active cementitious material suitable for cementing in underground applications and water, and a second grout stream including a pozzalanic material and an inorganic gelling agent wherein the two grout streams are combined into a grout mixture to form a self-supporting load bearing structure.
    Type: Application
    Filed: March 6, 2008
    Publication date: July 21, 2011
    Inventor: Duncan Hird
  • Publication number: 20110168059
    Abstract: A CO2 control device and method for capturing CO2 from fluid flow, including: a flow-through apparatus and an CO2 absorbing filter treated with an alkaline material which is housed within the flow-through apparatus. The flow-through apparatus receives fluid flow and the CO2 from the fluid flow is absorbed by the CO2 absorbing filter. The absorbed CO2 is converted into CaCO3 which is combined with volcanic ash to form a useful cement material.
    Type: Application
    Filed: March 28, 2011
    Publication date: July 14, 2011
    Inventors: Kenneth D. Murray, Katherine A. MURRAY
  • Patent number: 7976625
    Abstract: A compound and method for treating fly ash includes an amphoteric, alkyl polyglycoside, ester, derivative of triglyceride, fatty alcohol, alkoxylated fatty alcohol, alkoxylated polyhydric alcohol, and mixtures thereof, wherein the treated fly ash is incorporated into a cement admixture, and is effective in blocking absorptive carbon. Also, a method is included that reduces the amount of Portland cement by substituting up to 40 by total weight of the cement in a mixture with an equal amount of fly ash treated with an an amphoteric, alkyl polyglycoside, ester, derivative of triglyceride, fatty alcohol, alkoxylated fatty alcohol, alkoxylated polyhdric alcohol, and mixtures thereof.
    Type: Grant
    Filed: January 19, 2007
    Date of Patent: July 12, 2011
    Assignee: Cognis IP Management GmbH
    Inventors: Jianhua Mao, James H. Irvine
  • Patent number: 7976626
    Abstract: The problems to be solved by the invention are to provide a fiber reinforced cement composition for obtaining a fiber reinforced cement product which is inexpensive and economical, and to provide pushing forward disposal of defective products. Namely, the fiber reinforced cement composition comprises a hydraulic inorganic material, a siliceous material, a woody reinforcement, a finely dividing fiber reinforced cement product and/or a finely dividing intermediate of fiber reinforced cement product which is produced by said raw materials.
    Type: Grant
    Filed: September 27, 2006
    Date of Patent: July 12, 2011
    Assignee: Nichiha Corporation
    Inventors: Kazuo Utagaki, Tadashi Sugita, Satoshi Takayama
  • Publication number: 20110162559
    Abstract: Methods of manufacture and use of flowable materials are provided. The flowable fill materials include a cement-based fill material with a cement component and an aggregate component that are mixed with a chemical agent and the like in water. This provides the cement-based material in a flowable state that can be controllably set over time.
    Type: Application
    Filed: March 17, 2011
    Publication date: July 7, 2011
    Applicant: VCNA PRAIRIE IP, INC.
    Inventors: Jeffrey Jerald Krozel, Gary Lee Matney
  • Patent number: 7972432
    Abstract: A high early strength pozzolan cement includes larger sized pozzolan particles blended with smaller sized hydraulic cement particles containing tricalcium silicate and/or dicalcium silicate (e.g., Portland cement). Excess calcium release from the hydraulic cement when mixed with water forms calcium hydroxide available for reaction with the pozzolan. The fineness of the hydraulic cement particles is substantially greater than the fineness of the pozzolan particles (e.g., about 1.25 to about 50 times greater). Reducing or eliminating coarse hydraulic cement particles that cannot fully hydrate but include unreacted cores reduces or eliminates wasted cement normally found in concrete. Replacing some or all of the coarse cement particles with pozzolan particles provides a pozzolan cement composition having significantly lower water demand compared to the hydraulic cement by itself.
    Type: Grant
    Filed: August 2, 2010
    Date of Patent: July 5, 2011
    Assignee: Roman Cement, LLC
    Inventors: John M. Guynn, Andrew S. Hansen
  • Publication number: 20110155020
    Abstract: Integrated cement production systems and methods implementing the systems are disclosed, where the integrated cement production systems include a burnable fuel supply subsystem, a cement raw material supply subsystem, a kiln subsystem and a cement clinker composition storage subsystem. The burnable fuel supply subsystem is adapted to receive one or a plurality of used and/or unused healthcare materials. The burnable fuel supply subsystem can feed the materials directly into the kiln subsystem, can convert the materials into different form and feed the different form to the kiln subsystem or feed a combination of the materials, different forms and optionally conventional fuels to the kiln subsystem.
    Type: Application
    Filed: December 29, 2009
    Publication date: June 30, 2011
    Applicant: SHARPS COMPLIANCE, INC.
    Inventors: Burton J. Kunik, James C. Berns, David G. Gossman
  • Publication number: 20110132233
    Abstract: Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticiser is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.
    Type: Application
    Filed: January 24, 2011
    Publication date: June 9, 2011
    Applicant: UNISEARCH LIMITED
    Inventors: Obada Kayali, Karl John Shaw
  • Patent number: 7955577
    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: Grant
    Filed: June 10, 2010
    Date of Patent: June 7, 2011
    Assignee: NOx II, Ltd
    Inventor: Douglas C. Comrie
  • Publication number: 20110120348
    Abstract: Described and claimed herein is a method of producing enhanced combustion ash for use in pozzolanic applications or cement clinker manufacture. The method employs a primary process in which wet or dry feedstock is pulverized with sonication using one or more grinding media having a maximum component size of about 2 mm. Alternatively, the media may have a true grinding medium volume to chamber volume ratio of at least 0.29. Also disclosed an claimed is an enhanced combustion ash produced by the method, whereby the enhanced combustion ash has one or more qualities that make it particularly suitable in pozzolanic applications or cement clinker manufacture.
    Type: Application
    Filed: June 4, 2009
    Publication date: May 26, 2011
    Applicant: SONOASH LLC
    Inventors: Klaus Oehr, Rod McElroy, Michael Kiktavy
  • 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: 20110088598
    Abstract: Provided are cementitious compositions and related systems and methods. The cementitious compositions, or admixtures, according to the present invention generally comprise gypsum, a first alkaline component and glass. The admixture may further comprise fly ash, which is preferably obtained as a waste by-product from a coal-burning power plant. A method according to the present invention comprises an initial step of analyzing or receiving an analysis of a fly ash sample. Based at least in part on the analysis of the fly ash sample, a mix rate may be selected and an initial admixture can be formulated, which, when added to the fly ash sample, creates an alternative or additive to Portland cement for use in concrete, for example.
    Type: Application
    Filed: October 21, 2009
    Publication date: April 21, 2011
    Inventors: David A. Lisowski, John R. Miglautsch
  • Publication number: 20110083585
    Abstract: An aqueous slurry including a particulate pozzolan, different from silica fume, which pozzolan includes less than 80% silicon dioxide, and, optionally, a particulate substantially inert filler: wherein the dry matter content of the slurry is from 30% to 90% by weight; substantially all of the elementary particles of pozzolan and filler have an elementary particle size less than 100 ?m; and the particles have a mean particle size less than 15 ?m.
    Type: Application
    Filed: July 10, 2009
    Publication date: April 14, 2011
    Applicant: LAFARGE
    Inventors: Philippe Fonollosa, Fabrice Pourcel
  • Patent number: 7914758
    Abstract: A CO2 control device and method for capturing CO2 from fluid flow, including: a flow-through apparatus and an CO2 absorbing filter treated with an alkaline material which is housed within the flow-through apparatus. The flow-through apparatus receives fluid flow and the CO2 from the fluid flow is absorbed by the CO2 absorbing filter. The absorbed CO2 is converted into CaCO3 which is combined with volcanic ash to form a useful cement material.
    Type: Grant
    Filed: November 19, 2009
    Date of Patent: March 29, 2011
    Inventors: Kenneth D. Murray, Katherine A. Murray
  • Publication number: 20110067601
    Abstract: The present invention provides combustion products of hydrocarbon fuels and controlled amounts of metal oxide strength enhancing materials. The combustion products are useful as additives to cementitious materials. A hydrocarbon fuel such as coal is introduced into a combustion chamber and selected amounts of materials comprising CaO, SiO2 and Al2O3 are also introduced into and/or downstream from the chamber. The hydrocarbon fuel undergoes combustion while the metal oxide strength enhancing materials react with each other and/or the ash or other reaction products of the hydrocarbon fuel. The combustion products have been found to significantly increase compressive strengths of cements such as Portland cement. A reduction in SO2 emission levels also results from the introduction of the metal oxide strength enhancing materials into the combustion process.
    Type: Application
    Filed: September 23, 2010
    Publication date: March 24, 2011
    Applicant: Ash Improvement Technology, Inc.
    Inventor: Wayne Fried
  • Patent number: 7905956
    Abstract: A fiber reinforced cement composition having the following raw material composition is provided to manufacture a fiber reinforced cement product which is excellent in bending strength, dimension stability, handling property, flexibility performance, and processability such as nail performance, as well as to provide a process for manufacturing the product. Namely, the fiber reinforced cement composition comprises a hydraulic inorganic material, a siliceous material and a woody reinforcement in a mass ratio of CaO to SiO2 contained in the hydraulic inorganic material and the siliceous material in the raw materials in a range of from 23:77 to 60:40.
    Type: Grant
    Filed: February 15, 2006
    Date of Patent: March 15, 2011
    Assignee: Nichiha Corporation
    Inventors: Kazuo Utagaki, Tadashi Sugita, Satoshi Takayama
  • Patent number: 7901505
    Abstract: A method of producing cementitious mixtures containing fly ash as one of the cementitious components, under air entrainment conditions. The method involves forming a mixture comprising water, cement, fly ash, optionally other cementitious materials, aggregate, conventional chemical admixtures, and an air entrainment agent and agitating the mixture to entrain air therein. Additionally, at least one sacrificial agent is also included in the mixture. The sacrificial agent is a material or mixture of materials that is not required to act as an air entrainment agent but interacts preferentially with components of the fly ash that otherwise neutralize, repress or depress the activity of the air entrainment agent. The invention includes cementitious mixtures and hardened concretes resulting from the method and fly ash treated with sacrificial agent, or air entrainment agent/sacrificial agent combinations, and processes for selecting suitable sacrificial agents.
    Type: Grant
    Filed: February 2, 2009
    Date of Patent: March 8, 2011
    Assignee: Boral Material Technologies Inc.
    Inventors: Russell L. Hill, Carmel R. Jolicoeur, Monique Page, Ioan Spiratos, Thi Cong To
  • Publication number: 20110048285
    Abstract: The present invention relates to the field of settable compositions for general purpose concrete mixes, and more particularly to settable compositions containing pulverized fly ash and/or bottom ash for improved final and early strength. The fly ash and/or bottom ash is pulverized to a Blaine fineness of 4000 cm2/g or more.
    Type: Application
    Filed: December 30, 2009
    Publication date: March 3, 2011
    Inventor: Ronald L. Barbour
  • Patent number: 7892350
    Abstract: A method of producing cementitious mixtures containing fly ash as one of the cementitious components, under air entrainment conditions. The method involves forming a mixture comprising water, cement, fly ash, optionally other cementitious materials, aggregate, conventional chemical admixtures, and an air entrainment agent and agitating the mixture to entrain air therein. Additionally, at least one sacrificial agent is also included in the mixture. The sacrificial agent is a material or mixture of materials that is not required to act as an air entrainment agent but interacts preferentially with components of the fly ash that otherwise neutralize, repress or depress the activity of the air entrainment agent. The invention includes cementitious mixtures and hardened concretes resulting from the method and fly ash treated with sacrificial agent, or air entrainment agent/sacrificial agent combinations, and processes for selecting suitable sacrificial agents.
    Type: Grant
    Filed: February 2, 2009
    Date of Patent: February 22, 2011
    Assignee: Boral Material Technologies Inc.
    Inventors: Russell L. Hill, Carmel R. Jolicoeur, Monique Page, Ioan Spiratos, Thi Cong To
  • Patent number: 7892349
    Abstract: A method of producing cementitious mixtures containing fly ash as one of the cementitious components, under air entrainment conditions. The method involves forming a mixture comprising water, cement, fly ash, optionally other cementitious materials, aggregate, conventional chemical admixtures, and an air entrainment agent and agitating the mixture to entrain air therein. Additionally, at least one sacrificial agent is also included in the mixture. The sacrificial agent is a material or mixture of materials that is not required to act as an air entrainment agent but interacts preferentially with components of the fly ash that otherwise neutralize, repress or depress the activity of the air entrainment agent. The invention includes cementitious mixtures and hardened concretes resulting from the method and fly ash treated with sacrificial agent, or air entrainment agent/sacrificial agent combinations, and processes for selecting suitable sacrificial agents.
    Type: Grant
    Filed: February 2, 2009
    Date of Patent: February 22, 2011
    Assignee: Boral Material Technologies Inc.
    Inventors: Russell L. Hill, Carmel R. Jolicoeur, Monique Page, Ioan Spiratos, Thi Cong To
  • Patent number: 7892479
    Abstract: Methods of forming a shaped article having a matrix that contains sintered fly ash are disclosed that include forming a fly ash dough that includes fly ash and water. In one form a superplasticiser is added in the dough. A green article is formed in a desired shape from the fly ash dough that is subsequently fired so that the shaped article is hardened by sintering its fly ash matrix. In one form, the green article is cured under conditions of moderate heating and high humidity. A building element having a matrix of sintered fly ash is also disclosed.
    Type: Grant
    Filed: August 29, 2007
    Date of Patent: February 22, 2011
    Assignee: Newsouth Innovations Pty Limited
    Inventors: Obada Kayali, Karl John Shaw
  • Publication number: 20110036272
    Abstract: A system and method for treating tailings from a bitumen froth treatment process such as TSRU tailings. The tailings are dewatered and then combusted to convert kaolin in the tailings into metakaolin. Calcined fines and heavy minerals may be recovered from the combustion products, namely from the flue gas and bottom ash.
    Type: Application
    Filed: June 29, 2010
    Publication date: February 17, 2011
    Inventors: Payman Esmaeili, Mainak Ghosh, Brian C. Speirs
  • Patent number: 7883576
    Abstract: An inorganic binder composition has a first constituent which is a poly(sialate) or a poly(sialate-siloxo) admixed with a second constituent which has one or more of: fly ash F, fly ash C, fumed silica, Al2O3, pozzolan, ground slag, nepheline syenite, anhydrous aluminum silicate, hydrous aluminum silicate, hydrous sodium hydroxide, silicic acid, potassium salt, and sodium salt. The binder is used to recycle and reuse revert materials from metal smelting operations.
    Type: Grant
    Filed: January 29, 2007
    Date of Patent: February 8, 2011
    Inventor: Douglas C Comrie
  • Publication number: 20110028607
    Abstract: Methods and compositions that include a method of cementing comprising providing a cement composition comprising water, a hydraulic cement, and an additive comprising at least one additive selected from the group consisting of a stevia retarder and inulin; placing the cement composition in a subterranean formation; and permitting the cement composition to set in the formation.
    Type: Application
    Filed: October 8, 2010
    Publication date: February 3, 2011
    Applicant: HALLIBURTON ENERGY SERVICES, INC.
    Inventors: Ronnie G. Morgan, William J. Caveny, Rickey L. Morgan
  • Patent number: RE43253
    Abstract: A lightweight concrete composition containing from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.03 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 0 to 50 volume percent of aggregate; where the sum of components used does not exceed 100 volume percent, and where after the lightweight concrete composition is set it has a compressive strength of at least 1700 psi as tested according to ASTM C39 after seven days. The concrete composition can be used to make concrete masonry units, construction panels, road beds and other articles.
    Type: Grant
    Filed: April 29, 2010
    Date of Patent: March 20, 2012
    Assignee: NOVA Chemicals Inc.
    Inventors: Tricia Guevara Ladely, Michael T. Williams, David A. Cowan, John K. Madish, Kolapo Adewale, Roger Moore, Mary Margaret Moore, legal representative, Blain Hileman