Abstract: The invention relates to a hydraulic binder containing, in percentage by weight: from 1.1 to 9% of tricalcium aluminate from 1.5 to 13.5% of tetracalcium ferroaluminate from 0.5 to 1.5% of dodecacalcium heptaaluminate from 0.5 to 1.5% of tetracalcium trialuminate sulphate from 0 to 0.8% of dicalcium silicoaluminate from 5 to 70% of pozzolanic material(s) from 0 to 6% of calcium sulphate the remainder being composed of the non-aluminous constituents of at least one Portland-type clinker. It also relates to concretes or mortars prepared using a binder of this type.

Abstract: The present invention provides settable compositions that comprise water and cement kiln dust. The settable compositions optionally may comprise an additive that comprises at least one of the following group: fly ash; shale; slag cement; zeolite; metakaolin; and combinations thereof. The settable compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the settable composition; introducing the settable composition into a location to be cemented; and allowing the settable composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Abstract: The present invention provides cement compositions that comprise water, high alumina cement, a soluble phosphate, and cement kiln dust. The cement compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the cement composition; introducing the cement composition into a location to be cemented; and allowing the cement composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Abstract: Sorbent components containing calcium, alumina, silica, and halogen 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 mercury and sulfur; ? reduce emissions of elemental and oxidized mercury; ? increase the efficiency of the coal burning process through de-slagging of boiler tubes; ? 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.

Abstract: The present invention provides settable compositions that comprise water and cement kiln dust. The settable compositions optionally may comprise an additive that comprises at least one of the following group: fly ash; shale; slag cement; zeolite; metakaolin; and combinations thereof. The settable compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the settable composition; introducing the settable composition into a location to be cemented; and allowing the settable composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Abstract: A cement mix suitable for blocking or plugging an abandoned pipeline or back filling a mine shaft, tunnel or excavations contains Portland cement or a cement blend of two components selected from Portland cement, fly ash, pozzolan, slag, silica fume and gypsum; diatomaceous earth; zeolite and an inorganic salt accelerator. The cement mix may further contain an alkali metasilicate and/or alkali silicate. A cementitious slurry, formulated from the cement mix, may have a density less than or equal to 1500 kg/m3, and exhibits good compressive strength.

Abstract: The present invention provides cement compositions that comprise water, high alumina cement, a soluble phosphate, and cement kiln dust. The cement compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the cement composition; introducing the cement composition into a location to be cemented; and allowing the cement composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Abstract: Settable compositions that comprise water, CKD, and microspheres, wherein the lightweight settable composition has a density less than about 13 pounds per gallon. Methods of cementing that comprise providing a lightweight settable composition having a density less than about 13 pounds per gallon, the lightweight settable composition comprising water, CKD, and microspheres, introducing the lightweight settable composition into a location to be cemented and allowing the lightweight settable composition to set therein.

Abstract: Cementitious materials including slag and geopolymer can be added to conventional cement compositions, such as Portland cement, as a partial or total replacement for conventional cement materials. The slag may comprise silicates and/or oxides of calcium, silicon, magnesium, iron, aluminum, manganese, titanium, sulfur, chromium and/or nickel. The geopolymer may comprise aluminum silicate and/or magnesium silicate. In a preferred embodiment, curing of concrete materials by the action of water on the cementitious materials is enhanced with the addition of an activator component selected from calcium bromide, calcium nitrate, calcium nitrite, calcium chloride, calcium oxide, and sodium bromide.

Abstract: The present invention provides a process for the preparation of self glazed geopolymer tile using fly ash and granulated blast furnace slag. In the process of the present invention, the granulated blast furnace slag is fine grounded and/or mechanically activated in conventional grinding mills or high-energy mills. The fly ash, which is found in powder form and fine powder of granulated blast furnace slag, is thoroughly mixed to make a homogenous mixture. The alkaline solution is added into the mixture to initiate the geopolymerization. The ratio of water to powder is optimised to obtain a consistent paste to be used for vibration casting. During the casting, the consistent paste flows inside the mould and the particles settles at mirror finished surface of mould, giving rise to dense and smooth surface.

Abstract: A method of preparing a building material is provided. An aggregate material, water, a hydraulic binder material, and one or more hydraulic activators are mixed. The hydraulic binder material comprises slag material. The mixture is allowed to harden. A building material is also provided. The building material includes a slag material, and one or more hydraulic activators.

Abstract: Settable drilling fluids comprising an aqueous-based drilling fluid and cement kiln dust. Methods of cementing in a subterranean formation comprising: providing a settable drilling fluid comprising an aqueous-based drilling fluid and cement kiln dust, introducing the settable drilling fluid into a subterranean formation, and allowing the settable drilling fluid to set in the subterranean formation. Methods of converting an aqueous-based drilling fluid to a settable drilling fluid comprising: providing the aqueous-based drilling fluid, and adding cement kiln dust to the aqueous-based drilling fluid to form the settable drilling fluid. Methods of drilling a well bore and cementing a well bore comprising: drilling a well bore, circulating an aqueous-based drilling fluid in the well bore during the step of drilling the well bore, adding cement kiln dust to the aqueous-based drilling fluid to form a settable drilling fluid, and allowing the settable drilling fluid to set in the well bore.

Abstract: The present invention provides settable compositions that comprise water and cement kiln dust. The settable compositions optionally may comprise an additive that comprises at least one of the following group: fly ash; shale; slag cement; zeolite; metakaolin; and combinations thereof. The settable compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the settable composition; introducing the settable composition into a location to be cemented; and allowing the settable composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Abstract: Provided herein are settable spotting compositions that comprise cement kiln dust and associated methods of use. Also provided are methods that comprise providing a settable spotting composition comprising cement kiln dust; introducing the settable spotting composition into a well bore that penetrates the subterranean formation so as to displace at least a portion of a second fluid from the well bore.

Abstract: Cementitious materials including stainless steel slag and geopolymer can be added to conventional cement compositions, such as Portland cement, as a partial or total replacement for conventional cement materials. The stainless steel slag may comprise silicates and/or oxides of calcium, silicon, magnesium, iron, aluminum, manganese, titanium, sulfur, chromium and/or nickel. The geopolymer may comprise aluminum silicate and/or magnesium silicate. In a preferred embodiment, curing of concrete materials by the action of water on the cementitious materials is enhanced with the addition of an activator component selected from calcium bromide, calcium nitrate, calcium nitrite, calcium chloride, calcium oxide, and sodium bromide.

Abstract: The present invention provides settable compositions that comprise water and cement kiln dust. The settable compositions optionally may comprise an additive that comprises at least one of the following group: fly ash; shale; slag cement; zeolite; metakaolin; and combinations thereof. The settable compositions optionally may be foamed with a gas. Methods of cementing also are provided that comprise: providing the settable composition; introducing the settable composition into a location to be cemented; and allowing the settable composition to set therein. The location to be cemented may be above ground or in a subterranean formation.

Abstract: Dry mixes for hydraulic cement coatings for masonry, above ground concrete structures and below ground concrete structures. Hydraulic cement, sand and particular aggregates are combined to form the dry mix, which is combined with a controlled quantity of a water base emulsion binder and water to form the hydraulic cement coating. The water base emulsion binder may be replaced with a redispersible polymer binder and a quantity of water.

Abstract: Cementicious materials including stainless steel slag and geopolymer can be added to conventional cement compositions, such as Portland cement, as a partial or total replacement for conventional cement materials. The stainless steel slag may comprise silicates and/or oxides of calcium, silicon, magnesium, iron, aluminum, manganese, titanium, sulfur, chromium and/or nickel. The geopolymer may comprise aluminum silicate and/or magnesium silicate.

Abstract: Compositions are provided for increasing the electrical conductivity of concrete or controlled low-strength materials (flowable fill). One composition sets to produce a concrete and includes from 1% to 30% by weight of portland cement; from 1% to 30% by weight of fly ash having a carbon content as measured by loss on ignition of greater than 12%; from 40% to 90% by weight of an aggregate; from 0.1% to 20% by weight of carbon fibers; and water in a sufficient amount such that the composition sets to a concrete. Another composition is a self-compacting, cementitious flowable fill composition that includes from 1% to 30% by weight of portland cement; from 5% to 85% by weight of fly ash; from 0.1% to 20% by weight of carbon fibers; and water in a sufficient amount such that the composition sets to a material having a compressive strength of 8.3 MPa or less.

Abstract: The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and sodium chloride (NaCl) as a substantial replacement for Portland cement conventionally used in such compositions. The sodium chloride is an additive for improved high early strength and accelerated setting times, thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Abstract: A synthetic slag is produced by a high temperature combustion reaction between coal ash having a high carbon content, and a source of lime such as cement kiln dust. The carbon content of the coal ash is oxidized by oxygen gas, which typically is derived from air or an air/oxygen combination in an exothermic reaction and the heat generated is exploited in the melting process. In this way the gaseous products will typically comprise nitrogen, unreacted oxygen and carbon dioxide, and heat energy can be readily recovered from the hot off gas products evolving during the combustion reaction. The synthetic slag may be pelletized and employed as lightweight mineral aggregate or milled to cement fineness to provide slag cement.

Abstract: The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and calcium chloride (CaCl2) as a substantial replacement for Portland cement conventionally used in such compositions. The calcium chloride is an additive for improved high early strength and accelerated setting times, thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Abstract: The present invention provides methods, lightweight well cement compositions and additives for the well cement compositions. The methods of the invention for sealing pipe in a well bore penetrating a zone or formation which readily fractures at low hydrostatic pressure is basically comprised of the steps of providing a lightweight cement composition comprised of a hydraulic cement, water and an additive comprising a suspension of microspheres in water gelled with sodium bentonite, placing the cement composition in the annulus between the pipe and the well bore and allowing the cement composition to set.

Abstract: The present invention relates to settable compositions for general purpose concrete construction containing Class-F fly ash, Class-C fly ash or slag, and cement kiln dust (CKD) as a substantial replacement for Portland cement conventionally used in such compositions. The compositions of the present invention provide high early strength thereby allowing the concrete structure to be put into service sooner, reducing labor cost, and allowing precast concrete and concrete masonry manufacturers to achieve rapid form and mold turnover.

Abstract: A rapid setting cementitious composition useful for making cement boards employs an insoluble form of anhydrous calcium sulfate (anhydrite) to accelerate setting and to permit reducing the amount of high alumina cement usage.

Abstract: A hydratable cementitious composition which includes a blend of; (i) cement and/or; (ii) ground granulated blast furnace slag; and (iii) wastepaper sludge ash which is produced by heating wastepaper sludge to a combustion temperature in the range 850° C. to 1200° C. for a dwell time in the range 1 to 60 seconds.

Abstract: A synthetic slag is produced by a high temperature combustion reaction between coal ash having a high carbon content, and a source of lime such as cement kiln dust. The carbon content of the coal ash is oxidized by oxygen gas, which typically is derived from air or an air/oxygen combination in an exothermic reaction and the heat generated is exploited in the melting process. In this way the gaseous products will typically comprise nitrogen, unreacted oxygen and carbon dioxide, and heat energy can be readily recovered from the hot off gas products evolving during the combustion reaction. The synthetic slag may be pelletized and employed as lightweight mineral aggregate or milled to cement fineness to provide slag cement.

Abstract: A masonry cement composition is provided which contains a blend of fly ash, Portland cement, a retarding agent, and an air entrainment agent. The masonry cement composition may be formed into a mortar having a high air content which exhibits good compressive strength and does not exhibit efflorescence.

Abstract: Cementitious compositions and methods for making the compositions wherein the compositions include high volume of mineral admixtures such as fly ash and blast-furnace slag in combination with rice hull ash. In one embodiment, the cementitious composition is a blend of hydraulic cement, rice hull ash and a mineral addition selected from fly ash and blast-furnace slag. The cementitious compositions can advantageously have high early and 28-day compressive strength and a very low permeability rating.

Abstract: The invention describes an activated supersulphated aluminosilicate binder containing aluminosilicates, calcium sulphate and an activator containing alkali metal salts, wherein the aluminosilicates are selected from the group consisting of blast furnace slag, clay, marl and industrial by-products such as fly ash with the proviso that the Al2O3 content is greater than 5% by weight, wherein blast furnace slag is present in an amount exceeding 35% by weight and clay, marl and/or fly ash is present in an amount exceeding 5% per weight and wherein cement kiln dust in an amount of from 3 to 10% by weight is added to the mixture as an activator and calcium sulphate is used in an amount exceeding 5% by weight.

Abstract: A roadway base comprises oily sludge, steelmaking slag fines, and an additive selected from the group consisting of cement, fly ash, asphaltic emulsion, and mixtures thereof

Abstract: Cementitious compositions and methods for making the compositions wherein the compositions include high volume of mineral admixtures such as fly ash and blast-furnace slag in combination with rice hull ash. In one embodiment, the cementitious composition is a blend of hydraulic cement, rice hull ash and a mineral addition selected from fly ash and blast-furnace slag. The cementitious compositions can advantageously have high early and 28-day compressive strength and a very low permeability rating.

Abstract: Composite materials having fly ash as a constituent is manufactured into a sulfur-less gypsum-like material, a portland cement-like material and a lightweight aggregate. Methods for making such composite materials include combining precipitated calcium carbonate and either Class C-fly ash, Class F-fly ash and/or bottom ash in particular ratios by adding water to dry material and subsequently allowing the material to dry to create the above-described products. Methods for forming and using such composites include the use of a single piece gatefold form for casting manifold surfaces, a panel system for forming concrete walls and a system for creating retaining walls.

Abstract: This invention provides improved cement composition and biodegradable dispersants therefor. The biodegradable dispersants are basically comprised of a high molecular weight, phenolic hydroxy group blocked, alkali metal lignosulfonate.

Abstract: A wood-cement board is manufactured by a method comprising mixing 30 to 40% by weight of cement material, 20 to 27% by weight of wood flake, and 30 to 40% by weight of fly ash to prepare a raw material mixture, strewing said raw material mixture on a mold panel to form a mat, pressing and pre-curing said mat with moisture, and main-curing said pre-cured mat in an autoclave. Preferably the particle size of said fly ash is selected so that less than 10% by weight of fly ash may remain on the sieve whose opening size is 150 .mu.m and said main-curing process is carried out at a temperature of the saturated aqueous vapor in a range between 140 to 165.degree. C. for 7 to 10 hours.

Abstract: The present invention is directed to blended hydraulic cement compositions which are formed with subbituminous fly ash. In one embodiment, the cement composition comprises from about 0.1 wt. % to about 7 wt. % of a retarding agent; from about 0.1 wt. % to about 4 wt. % potassium carbonate; from about 0.1 wt. % to about 4 wt. % citric acid; from about 0.1 wt. % to about 5 wt. % lithium carbonate; and from about 85 wt. % to about 99.7 wt. % of a subbituminous fly ash. In another embodiment, the cement composition comprises from about 0.1 wt. % to about 7 wt % of a retarding agent; from about 0.1 wt. % to about 6 wt. % of an alkali source selected from the group consisting of potassium carbonate, potassium hydroxide and blends thereof; from about 0.1 wt. % to about 4 wt. % citric acid; from about 0.1 wt. % to about 5 wt. % lithium carbonate; from about 25 wt. % to about 91.7 wt. % of a first subbituminous fly ash having a lime content; and from about 8 wt. % to about 60 wt.

Abstract: Undried blast furnace slag, for example, granulated blast furnace slag having a water content of 3 to 20, generally 5 to 15%, by weight, is introduced to hot clinker in a cooler downstream of a cement kiln; the water is volatilized or evaporated in the cooler to provide a cement clinker having an effective content of dried blast furnace slag free of water; this permits use of blast furnace slag in a blended cement without the need for separate special steps for drying the slag.

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: A lightweight, cementitious composition and method which includes a noncementitious filler, Portland cement, bentonite, diatamaceous earth and lime. The noncementitious filler may be sawdust, rubber chips, flyash or combinations of two or more of these ingredients. Once mixed with water and air, the composition can be molded to form a variety of structures, including electrically nonconductive posts, and can be used to absorb and contain liquid contaminants in a vessel.

Abstract: Novel cementitious systems comprised of gypsum, calcined clay, and clinker consisting essentially of hydraulic calcium silicates are disclosed which have the following properties: (1) a water demand of less than about 33% nc; (2) one-day strengths of at least about 1000 psi; and (3) low alkali functionality. By increasing the amount of calcined clay, the resulting cementitious system will sequentially gain the following properties: (1) alkali non-reactiveness; (2) alkali resistance; and (3) low chloride permeability. Novel methods of preparing the novel cementitious systems of this invention are also disclosed. The novel methods not only reduce production costs by decreasing fuel and raw material consumption, but they also allow the cement producer to proactively address significant environmental concerns related to the manufacturing process.

Abstract: A cellular drainage structure is formed of a predetermined volume of a settable, water permeable, cellular concrete product. A concrete mix is formed of a uniformly graded aggregate in the size range from 1/16 inch to two inches and in a quantity corresponding to the predetermined volume; a cementitious component in the quantity range from 141 to 658 pounds per cubic yard of product; water in quantity sufficient to create a water-to-cement ratio in the approximate range from 0.30 to 0.55 and sufficient to wet the aggregate, establishing a cementitious-component-and-water matrix of determinable volume; a pre-formed surfactant foam, generated from an aqueous surfactant mixture at a dilution of from approximately 3 to 25 grams per liter of surfactant in water, wherein the pre-formed foam is in the density range of from 2.0 to 3.0 pcf, and the foam is added in the quantity range of 5% to 30% of the volume of the cementitious-component-and-water matrix.

Abstract: Storing, transporting and dispensing of silica fume containing pozzolanic compositions can be improved by mixing an amount of water in the range of 2 to 25% with the silica fume containing composition so that a uniform humidified powder is obtained. The treated silica fume containing composition has higher bulk gravity and better flow characteristics.

Abstract: The present invention is directed to processes for making blended hydraulic cement compositions. In one embodiment, the process includes the steps of: providing from about 85 wt. % to about 99.7 wt. % of the total composition of a subbituminous fly ash; separating out about a 10% portion of the fly ash; adding from about 0.1 wt. % to about 7 wt. % of the total composition of a retarding agent, from about 0.1 wt. % to about 4 wt. % of the total composition of citric acid, and from about 0.1 wt. % to about 4 wt. % of the total composition of potassium carbonate to the 10% portion; and blending the remainder of the ash with the 10% portion to create a blended hydraulic cement composition.

Abstract: The present invention is directed to blended hydraulic cement compositions which are formed with subbituminous fly ash. In a first embodiment, the cement composition comprises from about 0.1 wt. % to about 7 wt. % of a retarding agent; from about 0.1 wt. % to about 4 wt. % of the total composition of potassium carbonate; from about 0.1 wt. % to about 4 wt. % of the total composition of citric acid; and from about 85 wt. % to about 99.7 wt. % of the total composition of a subbituminous fly ash. In a second embodiment, the cement composition comprises from about 0.1 wt. % to about 7 wt % of the total composition of a retarding agent; from about 0.1 wt. % to about 6 wt. % of the total composition of an alkali source selected from the group consisting of potassium carbonate, potassium hydroxide and blends thereof; from about 0.1 wt. % to about 4 wt. % of the total composition of citric acid; from about 25 wt. % to about 91.7 wt.

Abstract: A method for solidification and stabilization of soils contaminated with vy metals and organic compounds removable by activated carbon includes the steps of placing a selected weight of the contaminated soil in a vessel, adding water to the contaminated soil in the vessel, mixing the soil and the water in the vessel, adding activated carbon to the mixture of soil and water in the vessel, mixing the soil, water and carbon in the vessel, adding cement and fly ash to the mixture of soil, water and carbon in the vessel, mixing the soil, water, carbon, cement and fly ash in the vessel and pouring the mixture of soil, water, carbon, cement and fly ash into a mold and curing the mixture therein.

Abstract: The present disclosure concerns a soil or ground quality stabilizer comprising a mixture formed by mixing a burned sewage sludge ash the main contents of which are CaO, SiO.sub.2 and Al.sub.2 O.sub.3 with a lime of calcium hydroxide to reduce hydraulicity and a fine Fe oxides mixture powder byproduced in steel production the main content of which is iron oxide. The soil or ground quality stabilizer is added into a pavement material containing crushed stones, natural soil, etc. to improve the strength and viscoelasticity of the natural soil and can give a desired CBR strength to the soil having an increased moisture content. The preferable adding ratio of the fine Fe oxides mixture powder into the mixture of the burned sewage sludge ash and the lime of calcium hydroxide is within the range of 15-35 weight %.

Abstract: Novel cementitious systems comprised of gypsum, calcined clay, and clinker consisting essentially of hydraulic calcium silicates are disclosed which have the following properties: (1) a water demand of less than about 33% nc; (2) one-day strengths of at least about 1000 psi; and (3) low alkali functionality. By increasing the amount of calcined clay, the resulting cementitious system will sequentially gain the following properties: (1) alkali non-reactiveness; (2) alkali resistance; and (3) low chloride permeability. Novel methods of preparing the novel cementitious systems of this invention are also disclosed. The novel methods not only reduce production costs by decreasing fuel and raw material consumption, but they also allow the cement producer to proactively address significant environmental concerns related to the manufacturing process.

Abstract: A method for stabilizing wet, oily petroleum refinery wastes and other similar wastes without the need for Portland cement. The waste is combined with at least 5 weight percent of a novel cementitious reagent composition comprised of Powder River Basin fly ash and circulating fluid bed combustion ash in weight ratios ranging from 1:9 to 9:1.

Abstract: A method of immobilizing toxic waste material slurries is disclosed wherein aggregates are formed containing the toxic waste and the aggregates admixed with and embedded in a sulfur cement to form a concrete shape.

Abstract: Class C fly ash may be activated with strong alkali to yield a novel, dense, quick-setting cement having unexpected properties. The setting time of the cement decreased as the pH of the activating solution increased. The microstructure and phase assemblage of the novel cement depended on the pH. Ettringite was absent beyond pH 14.30 (2.0N); a hexagonal plate-like crystalline form (stratlingite (gehlenite hydrate, C.sub.2 ASH.sub.8) and other compounds) became more abundant at higher pH. At higher pH the microstructure was characterized by high amounts of the plate-like crystalline phase and a dense matrix, due to higher reactivity of the glassy phase in fly ash. The novel cement will have uses in a number of areas, including fixation of hazardous wastes such as radioactive wastes, applications where rapid setting is desired, and formation of concrete in hot environments where ordinary Portland cements may tend to crack due to their heat of hydration.