Abstract: The present invention is directed to a hardening composition characterized by comprising (A) a slag composition containing 0 to 37 wt. % of CaO, 23 to 90 wt. % of SiO.sub.2, and 0 to 40 wt. % of Al.sub.2 O.sub.3 and 0.1 to 50 wt. % of one or more compounds selected from the group consisting of iron oxide, alkali components, phosphorous components, titanium dioxide, manganese oxide, and magnesium oxide, and/or 0.1 to 10 wt. % of a halogen; and (B) an alkaline activator. The invention is also directed to a hardened product obtained by mixing the hardening composition with water. The properties of the hardened product are suitable for use as various concrete materials, and therefore, refuse-incinerated ashes sewage sludge, etc. are effectively utilized and recycled as a resource.

Abstract: Cement is made from base metal smelter slag produced by a nickel, copper, lead or zinc smelter. The slag is ground to a size within the range of from about -250 to about 425 mesh to produce ground slag cement, and the ground slag cement is mixed with Type 3 high early strength Portland cement in a ratio of at least about 0.5:1 by weight to produce a blended cement.

Abstract: A cement mix based on an inorganic hydraulic cement, for example, Portland Cement, an air-cooled blast furnace slag and silica fume produces concretes having strength characteristics superior to those achieved by the cement alone; furthermore this cement mix is superior to a corresponding mix based on the inorganic hydraulic cement, and the air-cooled slag without the silica fume, and to a corresponding mix based on the cement and silica fume without the slag; additionally a cost saving in the expensive Portland Cement is achieved by use of the air-cooled slag which is a waste material and cheaper than granulated or pelletized slag.

Abstract: The present invention provides lightweight, fast setting cement compositions and methods which can be utilized in performing a variety of well cementing operations. The cement compositions are basically comprised of slag cement, water sufficient to form a pumpable slurry, a gas sufficient to foam the slurry and a foaming agent.

Abstract: A method of recovering metals and producing a secondary slag from base metal smelter slag produced by a copper or nickel smelter includes mixing the smelter slag with at least one reducing agent selected from the group consisting of carbon and aluminum, said carbon (if present) being from about 1% to about 10% by weight of the slag and said aluminum (if present) being from about 5 to about 30% by weight of the slag, and with from zero to about 60% calcium oxide by weight of the slag. The mixture is heated above the eutectic melting point thereof directly and to ignition temperature aluminothermically (if aluminum is present as reducing agent) to reduce the iron silicate to ferrosilicon containing substantially all the copper, nickel and cobalt which was in the smelter slag and form a secondary slag comprising at least one compound selected from the group consisting of calcium silicate, calcium aluminate and calcium iron aluminum silicate. The ferrosilicon is then separated from the secondary slag.

Abstract: The invention pertains to a cementious composition of a strong, light, foamed silicate binder or concrete made from ground, calcium-rich glassy silicates that are the major component of blast-furnace slag. The other materials used to create the material are sodium peroxide and water. The cementious mixture can include a volume modification foaming agent that substitutes a part of the mixture. These agents include sodium hydroxide, potassium hydroxide and hydrogen peroxide.

Abstract: A method of making concrete from base metal smelter slag includes grinding the slag to a size within the range of from about -250 to about 425 mesh to produce ground slag cement, mixing the ground slag cement with Type 3 high early strength Portland cement in a ratio of at least about 0.5:1 by weight, and adding sand and stone to produce a concrete.

Abstract: A cementitious slurry is prepared from drilling fluid, blast furnace slag and an emulsion comprising an oil external phase and an aqueous internal phase having therein a additive for said cementitious slurry. In a preferred embodiment the additive is an accelerator for the blast furnace slag such as sodium hydroxide. This allows mixing the additive with the drilling fluid and blast furnace slag without immediate contact between the additive and the other ingredients. After the cementitious slurry has been mixed and pumped into position in a wellbore, the emulsion breaks and the additives are released.

Abstract: A method of recovering steel plant waste revert materials including blast furnace flue dust and sludges involves mixing the revert materials with water to provide a total moisture content of about 14-20% by weight, then adding Portland cement as a sole binder, mixing, and, when the water content is limited to about 18 to 20%, casting the mixture onto the ground in the form of a slab or, when the water content is limited to about 14 to 16% and an accelerator for curing the cement is used, casting the mixture onto a conveyor in the form of preformed streams, curing the cast mixture and breaking it up to provide 1/2 inch to 5 inch agglomerate particles that can be recycled to the blast furnace.

Abstract: Compositions for low heat cements developed especially for massive concrete works and which exhibit a compressive strength/heat of hydration ratio of at least 7.0 at the age of 13 weeks. One of two inventions provides a powder prepared by mixing CaO, SiO.sub.2, and Al.sub.2 O.sub.3 materials, melting the mixture, quenching the melt, and grinding the quenched matter, the powder being composed mainly of amorphous substances and chemically having a CaO/SiO.sub.2 (molar ratio) of 0.8-1.5 and an Al.sub.2 O.sub.3 content of no more than 10 wt. %. The other invention provides a mixed powder comprising no less than 70 wt. % of a powder and no more than 30 wt. % of an addition (portland cement or the like), the powder being the same as that of the first invention in both predominance of amorphous substances and CaO/SiO.sub.2 (molar ratio) excepting the Al.sub.2 O.sub.3 content which is less than 12 wt. % in the second invention.

Abstract: A concrete product which uses 100% of the melt slags and pulverizes the melt slags into aggregates and fine powders, grinds the aggregates so that the percentage of absolute volume of the aggregates is over 60%, mixes the aggregates, fine powders, water and cement, and forms the mixture into the concrete product by vibration or press molding.

Abstract: High-strength, high-hardness concrete, mortar, or grout is prepared by blending portland cement, water, and aggregate with a source of reactive silica, pouring the concrete mixture into a form, allowing the concrete to cure until it reaches its conventional 28-day strength, and immersing the cured concrete in a solution of alkali metal hydroxide and aluminum nitrate at 60.degree.-110.degree. C. for 3-14 days. Alternatively, the cured concrete may be sprayed with the solution and maintained at 60.degree.-110.degree. C. for 3-14 days. A dense, hard surface layer of alkali metal aluminum silicate is formed, the compressive strength and surface hardness of the concrete is increased, and the water infiltration rate into the concrete is decreased.

Abstract: In a process for the preparation of cement from metallurgical slags, in which liquid slags from reduction processes and steelworks processes, e.g. blast furnace and converter slag, are mixed together and mixed with lime the procedure is such that in a first cooling phase at temperatures above 1000.degree. C., and preferably above 1200.degree. C., the cooling is slower than in a subsequent second cooling phase and that the solidified product obtained is granulated and/or ground in order to obtain directly cement with improved hydraulic properties, in particular increased final strength.

Abstract: A blended hydraulic cement binder, is disclosed, consisting of water, fly ash, Type III portland cement, Type I portland cement, slag cement, ground silica, boric acid, borax, citric acid and an alkali metal activator. The cement binder and sequences for mixing the composition, is particularly useful because it provides: time to mix all components adequately, unrestricted transporting time that can be terminated, at will, followed by alterable placement and finishing times. The cement binder can be used as a neat cement or it can be extended with fillers, such as sand and gravel, to make mortar or concrete, that rapidly gains very high structural strengths.

Abstract: A process is disclosed for producing a hydraulic cement binder for both general and special applications, consisting of water, cementitious materials, boric acid, borax, citric acid, an alkali metal activator, and with or without ground silica. This cement making process with sequences for mixing the composition, is particularly useful because it provides: time to mix all components adequately, unrestricted transporting time that can be terminated, at will, followed by alterable placement and finishing times. The process provides the means for creating a hydraulic cement binder that can be used as a neat cement or it can be extended with fillers, such as sand and gravel, to make mortar or concrete, that rapidly gains very high structural strengths.

Abstract: The invention relates to a porous granulated steel slag having a weight per unit volume of less than 1 kg/dm.sup.3 in the loosely dumped state and of 0.99 kg/dm.sup.3 in the compacted dumped state, having a free calcium oxide content of at most 1/10 of the content in the non-granulated slag. The present steel slags are obtained by spraying a molten stream of steel slag with a sprayed pressurized stream of water. After comminuting, for example by grinding, and removal of iron, the porous granulated steel slag can be separated into a ferrite-richer fraction, which can serve as raw material for steel production, and a lower-ferrite fraction, which can serve as raw material for an inorganic binder. Granulated steel slag is also used as aggregate in building materials, as raw material in road building materials and for embankment materials, and as cement replacement material.

Abstract: The invention concerns a raw material briquette for mineral wool production containing a mineral raw material as well as a binder therefor. The invention is characterized in that the briquette, as the binder, contains slag which has been activated with an alkaline agent, such as with an alkalimetal compound. The invention also concerns a process for the preparation of the briquette as well as a process for the preparation of mineral fibres using the briquette according to the invention.

Abstract: A suspension-type grouting liquid for injection into a ground having excellent penetration properties, e.g. low viscosity and long gelation time, and having comparatively high strength after consolidation. The suspension-type grouting liquid for injection into a ground consists essentially of slag, or a combination of slag and cement, alkali metal aluminates, and water. The slag is a fine grain having specific surface area of 5000 cm.sup.2 /g or more, and the alkali metal aluminates have a mole ratio of ({Me.sub.2 O}/{Al.sub.2 O.sub.3 }) of 2.8 or more, in which Me means alkali metal, {Me.sub.2 } and {Al.sub.2 O.sub.3 } represent, respectively, molar concentration of Me.sub.2, and Al.sub.2 O.sub.3.

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.

Abstract: By the addition of wollastonite to slag based cements, such as those formed when converting drilling fluids to cementitious materials in oil and gas well applications, the flexural strength of the cementitious material is improved. The method involves forming a pumpable slurry of drilling fluid, blast furnace slag and the fibrous mineral, wollastonite. The slurry is then activated by the addition of such activators as sodium hydroxide and soda ash and is pumped into the well bore to a desired location and is allowed to solidify.

Abstract: The invention relates to a method for preparing a hydraulically settable cement base material starting from steel slags formed in a steel-making process, which method comprises the formation, in steel slags in the liquid state, of a ferrite gradient by adding a ferrite-precipitating compound, the separation, if required, of the high-ferrite fraction formed, the separation of at least the low-ferrite fraction formed, the cooling and the comminution thereof to obtain a hydraulically settable material. The ferrite-precipitating compound used has preferably acid components, and can expediently generate silicic acid. At least before the cooling of the low-ferrite fraction, the aluminum content of the liquid slag material is regulated by the addition of an aluminate-containing material, such as bauxite. The high-ferrite fraction separated can be returned to the steel-making process to reduce or remove the addition of a flux in the production of steel.

Abstract: The invention relates to a cement composition which can be hardened hydraulically and which consists of ground cement clinker material, granulated blast furnace slags and comminuted steel slags. The comminution of the steel slags is preferably carried out by grinding, in particular to a particle size of at most 0.2 mm and expediently to 0.09 mm. The ground steel slags have a Blaine value of at least 400 m.sup.2 /kg, expediently 473 m.sup.2 /kg, and a weight per unit volume of 2,800-4,000 kg/m.sup.3. The steel slags are chosen from air-cooled steel slags, foamed steel slags, granulated steel slags or a combination thereof. A method is also described for the preparation of a cement composition which can be hardened hydraulically, in which method cement clinker material and ground, granulated blast furnace slags are mixed with ground steel slags at normal or elevated temperature and pressure, the obtained mixture is cooled if desired, and comminuted to obtain a hydraulically hardenable cement composition.

Abstract: A water-in-oil emulsion drilling fluid can be converted into an oil mud-cement slurry for use in oil well cementing procedures. Also, a universal fluid can be prepared using the water-in-oil emulsion drilling fluid by treating with an hydraulic material so that it will lay down a filter cake during drilling which can be triggered to set into a hard cement and bond to the formation after the above oil mud-cement slurry has been placed in the borehole at the conclusion of drilling.

Abstract: Drilling fluid is solidified by the incorporation therein of low grade blast furnace slag. In a preferred embodiment lime is also incorporated into said drilling fluid and/or said drilling fluid is a lime drilling fluid. Thus, there is provided a cementitious composition comprising drilling fluid, low grade blast furnace slag and, generally, lime. Also provided is a drilling and cementing process wherein a cementitious slurry comprising low grade blast furnace slag is introduced into a wellbore to cement a casing or liner.

Abstract: Processes and systems for producing cementitious materials from ferrous blast furnace slags. Processes comprise mixing of a source of CaO with molten slag flowing from at least one slag tap hole of a blast furnace. Sufficient CaO is mixed with the molten slag to raise the ratio of CaO to SiO.sub.2, the C/S Ratio, of the slag to between about 64 1.06 and 1.25, while maintaining the Base Number of the molten slag less than about 1.55. The slag is then water granulated and ground to a predetermined degree of fineness. An activator then is added to the ground granulated slag. The C/S Ratio of the granulated slag determines the degree of fineness to which the granulated slag must be ground to achieve a desired hydration rate in the resultant cementitious material. Cementitious materials with C/S Ratios in this range may be ground less finely, yet possess the same hydration rates, as other more finely ground cementitious materials.

Abstract: An alkali-activated silicate based cement or binder has a cure characteric which is modified by a phosphate additive which retards the set time of the cement or binder. The phosphate allows a longer set time than conventional alkali-activated silicate glass cements.

Abstract: A method is provided for making a fiber-reinforced slag gypsum cement lightweight hardened product. The method consists essentially of mixing (1) from 5 to 140 parts by weight of aggregates having a maximum size of not larger than 2000 .mu.m to (2) 100 parts by weight of a mixture which comprises 100 parts by weight of Portland cement, (3) from 20 to 350 parts by weight of slag fine powder which has a fineness ranging from 6,000 to 12,000 cm.sup.2 /g as Blaine's specific surface area, (4) from 0 to 20 parts by weight of lime, (5) from 20 to 100 parts by weight of calcium aluminate and gypsum fine powder, (6) 0.01 to 1.5 parts of a setting retardant; mixing water, prefoamed foams and reinforcing fibers with the mixture to obtain a slurry; subjecting the slurry to molding to obtain a molded product; removing the molded product to obtain a hardened product; and curing the hardened product with steam.

Abstract: A hydraulic composition comprising blast furnace slag powder, a water-soluble polymer and an alkaline substance, and a high-strength composite material produced by kneading and molding a composition which comprises blast furnace slag powder, a water-soluble polymer, an alkaline substrate and water, and wet curing the molded composition. The high-strength composite material has high bending strength and excellent water resistance by using uncostly blast furnace slag powder.

Abstract: Set-activated cementitious compositions and methods of using such compositions in cementing subterranean zones penetrated by well bores are provided. The compositions are basically comprised of water, particulate condensed silica fume suspended in the water; a dispersing agent for facilitating the dispersal of the silica fume particles in the water and maintaining the particles in suspension therein, a set-activator and a set delaying additive for increasing the time in which the composition sets after the set-activator is combined therewith.

Abstract: A cementitious slurry comprising microfine ground blast furnace slag and normally ground blast furnace slag. A microfine ground blast furnace slag is made of composition having a blaine specific surface area between 8,000 and 20,000 cm.sup.2 /g. By normally ground is meant slag compositions having a surface area of less than 8,000 cm.sup.2 /g. Such cementitious compositions have utility in construction, road building, and cementing wellbores.

Abstract: A light weight formed body used for building materials, heat-insulating materials, furnitures, backing materials and the like, and a method for producing the same. In the light weight formed body and in the manufacturing method thereof, the principal material is a surface-reformed slag of which the reforming involves reforming through the dissolution reaction and the hydration reaction of glass and the reforming through dehydration of the surface-reformed slag above mentioned under heating, and one or more of a polymer dispersion, a reinforcing fiber, a coagulant, a light weight aggregate, a thickener, a dispersing agent, a pigment, a synthetic pulp, a needle- to fiber-shaped calcium silicate hydrate and a hydraulic gypsum are further used together with the above principal material.

Abstract: A low density aggregate product and method for making the same utilizing coal ash slag resulting from a typical coal gasification system wherein the resulting aggregate product has a lower density than the initial coal ash slag. The coal ash slag is combined with a small amount of a binder and then fired for a predetermined time and temperature to produce the aggregate. Also, by heating the coal ash slag and binder, a gaseous efflux is emitted to form interlaced channels throughout the aggregate which have a characteristic length and diameter.

Abstract: There is disclosed a softy mud solidifying agent which comprises cement, and at least two members selected from the group consisting of pozzolanic substances, inorganic compounds and organic compounds. The solidifying agent is capable of solidifying dredged earth, sand, softy mud, etc. in such a manner that their mixture can be re-cast into water to form submerged banks, artificial fish-gathering places, etc., without causing water pollution.

Abstract: Chromite by-products having a composition which includes FeCr.sub.2 O.sub.4 as well as iron, aluminum, magnesium, sodium, calcium and silicon oxides are directly mixed with cement mortar and with the aggregates on use, or added to the water, producing the effect of corrosion inhibition of the steel reinforcements.

Abstract: A method of grouting porous gas--and petroleum--bearing formations with a cementitious material comprising ultrafine ground slag is useful for primary and remedial cementing of a wellbore. A composition is provided which comprises water, a dispersant, slag and an accelerator to activate the slag.

Abstract: Initial granulated blast furnace or phosphatic slag is subjected to heat treatment at a temperature of 1000.degree.-1200.degree. C. in oxidizing gas atmosphere to produce an active mineral additive for binding materials.

Abstract: A low density aggregate product and method for making the same utilizing coal ash slag resulting from a typical coal gasification system wherein the resulting aggregate product has a lower density than the initial coal ash slag. The coal ash slag is combined with a small amount of a binder and then fired for a predetermined time and temperature to produce the aggregate. Also, by heating the coal ash slag and binder, a gaseous efflux is emitted to form interlaced channels throughout the aggregate which have a characteristic length and diameter.

Abstract: A method of making a building material by activation of latently hydraulic finely ground granulated basic blast-furnace slag to form a direct acting hydraulic binder. The slag is mixed with water, sand and ballast material as well as with a combination of acidic and basic components. The acidic components consist of phosphates, optionally in combination with strongly acting sulfates, and the basic components consist of oxides or other compounds of earth metals, optionally in combination with zinc. Thereby, a concrete having great mechanical strength and high chemical resistance is obtained.

Abstract: The advantages of high alumina cement (early strength, resistance to sulphate attack) are preserved and its disadvantage (weakens with age) is solved by mixing it 50:50 with silica fume, gasifier slag, fly ash or other pozzolanic or latently hydraulic material. This encourages formation of gehlenite octahydrate in preference to the harmful `conversion` (weakening) reaction.

Abstract: An improved method of making a building material comprising activating slag with an activator of Portland cement, an acidic component and a basic component. The acidic component is a phosphate or a mixture of phosphates in an amount of 2 to 40% by weight based on the amount of the slag and activator, which serve as binding agents. The phosphate or mixture of phosphates have surface tension reducing action or a detergent or mixture of detergents is added to the binding agents in an amount of 0.1 to 2% by weight of the binding agents. The basic component is present in an amount of 2 to 20% by weight based on the amount of the binding agents. The basic component is magnesium oxide, or magnesium oxide in combination with earth metal oxides selected from the group consisting of calcium oxide, aluminum oxide, titanium oxide, zirconium oxide, and zinc oxide, with the amount of calcium oxide not exceeding 3% by weight based on the slag.

Abstract: Active mineral additive to binding materials, consisting of granulated phosphatic slag 94-98% by mass and sulphate containing component 2-6% by mass, which is a mixture of sodium sulphate 47.2-57.6% by mass, magnesium sulphate 40.5-51.1% by mass and sodium rhodonite 1.7-1.9% by mass.

Abstract: A carbon fiber-reinforced cementitious composite having high strength, which comprises continuous carbon fibers and a cured cement composition, comprising cement particles having an average particle size up to about the average diameter of the carbon fibers, the cured cement composition being substantially interposed between the individual carbon fibers; and a method for producing it.

Abstract: A method of grouting formations with a cementitious material comprising microfine ground slag is useful for stabilizing and strenghtening soil and rock formations as well as underground structures associated with buildings, tunnels and dams. A composition is provided which comprises water, a dispersant, slag and an accelerator to activate the slag. The method and composition are particularly useful for preventing permeation of water such as for grouting dam curtains and containing and stabilizing hazardous wastes including nuclear waste material.

Abstract: A process for treating spent potlining from the electrolytic smelting of aluminum in cryolite includes incinerating the potlining to combust carbonaceous material to form an ash at a temperature low enough to maintain low fluorine vapor pressures, admixing siliceous material with the potlining either before of after the ash-forming stage, and heating the ash and siliceous material to form a glassy residue.The residue formed by the process of the present invention produces a spent potlining suitable for landfill characterized by a low leachability of fluorine in water.

Abstract: The invention provides a method of manufacturing a hydraulic hardening material having the steps of milling vitreous blast furnace slag and classifying the milled slag to provide slag powder having a blaine specific surface area of 6,000 to 12,000 cm.sup.2 /g. The hydraulic hardening material manufactured by the method is used as a Portland blast furance cement raw material.

Abstract: A heat-curing cement composition comprising 60 to 75% by weight of 3CaO.SiO.sub.2, in which the total content of 3CaO.Al.sub.2 O.sub.3 and 4CaO.Al.sub.2 O.sub.3.Fe.sub.2 O.sub.3 is lower than 10% by weight, the alkali content is lower than 0.2% by weight as the Na.sub.2 O equivalent, the balance is composed mainly of 2CaO.SiO.sub.2 and gypsum, and the Blain specific surface area is 3500 to 5500 cm.sup.2 /g. This cement composition provides a hardened body when heat-cured under a high temperature of 35.degree. to 85.degree. C.

Abstract: The present invention provides a process for treating spent potlining from the electrolytic smelting of aluminum in cryolite including burning the spent potlining to form an ash, mixing with a siliceous material either before or after the ash-forming step, and heating to form a residue suitable for landfill. The ash and siliceous material are mixed in a specified mole ratio of at least about 1.4 silicon to sodium. The process further includes cooling the residue rapidly.The residue formed by the process of the present invention produces a spent potlining suitable for landfill characterized by a low leachability of fluorine in water.

Abstract: The present invention relates to a method for preparing iron silicate slags, by means of mixing with ferroalloy slag, to a molten slag which can be defibrated into fire-resistant and chemically resistant fibers. The advantageous composition for the molten slag is 15-25% Fe, 45-69%, SiO.sub.2 0-5% CaO, 4-10% MgO, 5-15% Al.sub.2 O.sub.3 and 0.5-3% Cr (percentages by weight).