Abstract: An ultra light weight insulating building block is manufactured from an aggregated particulate formed by mixing expanded perlite together with cement in the proportions of approximately 24 parts of perlite for each part of cement by volume and thereafter adding a minimum amount of potable water to agglomerate the contents until the mixture is tacky. The mixture is thereafter cured in air to form the agglomerated particulate which may thereafter be used together with cementious material to manufacture the building blocks. The cementious material may be cement or a mixture of cement, fly ash and an air entrainer.

Abstract: Method for disposing of (or converting to a construction material) physically unstable wastes comprised of non-biologic, organic, water insoluble compounds, usually dispersed in water, by incorporation thereof in a lime-fly ash water mixture which hardens under atmospheric conditions to form an environmentally acceptable, impermeable, load-bearing material.

Abstract: A composition obtained by mixing fly ash, calciumsulphate hemihydrate and oxisludge, a product caught from gases emanating from converters during steel production.Oxisludge containing substantial amounts of iron is used in an amount comprised between 0,2 and 10%, preferably 1 to 5%.The composition is a loose mass or consists of granular products.

Abstract: Mineral wool produced from fly ash wherein at least 70% to 80% by weight of the mineral wool consists of fibrous strands having a diameter greater than 3 to 5 microns and less than about 7 to 15 microns.

Abstract: A glass-fiber reinforced light-weight cementitious product having a density of less than 85 pounds per cubic foot, a high tensile strength and a high compressive strength, when cured, and hence, suitable for structural articles in which such properties are required. The product is formulated from a mixture in which the aggregate comprises substantially equal parts by weight of fly ash cenospheres and silica fume.

Abstract: A building material consists essentially of an aqueous slurry of a dry residue obtained by treating a flue gas containing fly ash from a fossil fuel combustion chamber with a finely divided absorbent consisting at least primarily of calcium oxide, calcium hydroxide and calcium carbonate to permit reaction between the absorbent and sulfur dioxide in the flue gas, and dry separation of the reacted absorbent from the residual flue gas.

Abstract: A qualification method which enables a fast, exact and numerical determination of puzzoulana-properties of solid materials and thus a short evaluation of said solid materials from the point of view of industrial usability.According to this method the puzzoulana-properties and activity of solid materials can be defined by a single figure as a result of their chemical and physical properties. The material to be analyzed is brought together with fluoride ions in an acidic medium in a system having constant heat capacity and the change of the heat quantity is measured and evaluated in the initial, suitable linear, phase of the resulting reaction. The time function of the change of the heat quantity of the system is converted into a change of voltage and the rise of this curve is determined advantageously in the linear section. Advantageously the change of the heat quantity of the system is measured within less than 30 seconds, favorably at about the 20th second.

Abstract: Granulated material, at least comprising a filler, being bound by an inorganic binder, which filler consists at least partially of a substance possessing latent hydraulic properties, in the form of a substance possessing pozzolanic properties, preferably fly ash, and process for obtaining said material by starting from a calcium oxide product, silica granulate and water in which a portion of the heat development is absorbed by said granulate and is recuperated.

Abstract: A method and system for disposing of fly ash together with water or liquid industrial waste, and the product produced thereby, in an environmentally acceptable manner which includes combining dry fly ash with a liquid additive in an amount of about 5%-25% of weight of liquid additive to weight of fly ash in a mixing operation which closely controls the liquid additive to yield a uniformly conditioned product which can be subjected to earth handling equipment pressures immediately and which eliminates cell preparation and greatly reduces leaching at the disposal site.

Abstract: A byproduct recovered in a dry flue gas desulfurization method for the production of fly ash cement. The flue gas, which results from the combustion of fossil fuel and which also carries along all or a part of the fly ash which results during the combustion, is treated in an absorber with a calcium-containing suspension (absorbing substance) in such a way that the solid materials leave the absorber as dry end product and are added entirely or partially to one or more dust removing apparatuses and are filtered off. The byproduct has a composition of 1 to 99% by weight, preferably 20 to 95% by weight, of fly ash, and 1 to 99% by weight, preferably 5 to 80% by weight, of the sum of the desulfurization products, preferably comprising calcium sulfate dihydrate and/or calcium sulfate hemihydrate and/or calcium sulfate and/or calcium sulfite hemihydrate.

Abstract: A composition and method of its use for stabilizing plastic soils which composition comprises from about 25 to about 85 weight percent portland cement, from about 0 to about 75 weight percent of a filter and from about 0.1 to about 5 weight percent of a retarding agent.

Abstract: A lightweight building material comprises expanded perlite as an additive and a bonding agent structure consisting of an alkalisilicate and containing pores formed by foaming and/or expansion. The pore content which results from the pore structure of the bonding agent amounts to 85 to 99% by volume, with bulk densities of 40 to 200 kg/m.sup.3, and strengths of 0.01 to 0.5 N/mm.sup.2. In a method for producing a lightweight building material mortar mixes of the following composition are used:70 to 85% by volume of perlite (bulk density from 20 to 150 g/l. grain-size from 0 to 6 mm)23.0 to 2.5% by volume of water-glass (38 degrees Be)25.0 to 5.0% by volume of water1.0 to 0.10% by volume of hardener2.0 to 0.05% by volume of air-entrainer.

Abstract: This invention relates to a process for producing a concrete mixture containing an AE fly ash cement having substantially no fluctuation of entrained air contained therein regardless of the amount of unburnt carbon in the fly ash which comprises mixing an aggregate, water, and an AE fly concrete composition characterized in that polyoxyethylenesorbitan oleate having 16 to 41 molar ethylene oxide group for mole of said polyoxyethylenesorbitan oleate is used as said AE agent.

Abstract: This invention relates to a composition, and a method for its production, of a water resistant and heat insulating silicate material in the form of blocks and articles. Such water resistant and heat insulating material possesses a low bulk mass (of from 100 to 300 kg/m.sup.3) and improved heat insulating capacity (=0.04-0.1 W/m.deg.) with a compressive strength of from 0.3 to 1 MPa. The starting chemical composition for the production of the heat insulating material is comprehended within the following limits: SiO.sub.2 of from 62 to 68%; Al.sub.2 O.sub.3 of from 1.5 to 5%; B.sub.2 O.sub.3 of from 5 to 10%; CaO+MgO of from 0.1 to 0.5% and Na.sub.2 O of from 21 to 26%, all percentages being by weight. The light porous silicate articles so produced include the following components (in weight percent): liquid sodium silicate having a modulus of from 2.5 to 3.5--from 55 to 65%; ground solid sodium silicate--from 11 up to 22%; borax--of from 7.4 up to 14%; and perlite--from 6 up to 17%.

Abstract: An improved method for pneumatic stowing of calcium alpha-sulphate hemihydrate, calcium beta-sulphate hemihydrate or mixtures thereof using natural anhydrite, limestone or mixtures thereof is disclosed. In addition, construction reinforcement compositions comprising said hemihydrates and natural anhydrite, limestone or mixtures thereof are taught.

Abstract: A method for preparing an element-rich composition for use as supplement in biological or physiological systems, comprising subjecting fly ash to the influence of reactants capable of dissolving a plurality of the components of the fly ash into a biologically assimilable form selected from chelates, complexes and lactic acid salts and obtaining the biologically assimilable form of the fly ash, and an element-rich composition prepared according to this method, the use of said element-rich composition as source of elements for animal and human consumption and in processes in which one or more elements, including trace elements, are essential.

Abstract: There is described a process for the consolidation of soil in which the moisture containing soil to be consolidated, rubbish or a soil/rubbish mixture is mixed with cement and then compacted. A fluidizing agent is added to the composition to be consolidated.

Abstract: The method of beneficiating kiln dusts which has insufficient reactive properties to produce desired pozzolanic reactions which method comprises adding small amounts of a material selected from the group consisting of CaO, calcium hydroxide and sodium hydroxide. The beneficiated dusts can be utilized with fly ash or fly ash and a filler to produce pozzolanic reactions and provide a durable mass.

Abstract: A unique, high-grade magnetite obtained from fly ash, the use thereof in the cleaning of coal, and low iron content fly ash.

Abstract: Cementitious compositions exhibiting accelerated hardening including improved strength development are formed by the addition of from about 0.5% to about 10% formic acid based on the weight of the cement. Compositions exhibiting accelerated setting as well as accelerated hardening may also be formed. The resulting strengths are superior to those exhibited by compositions using formate salts.

Abstract: A moist sludge as obtained from gases evolved during steel preparation in converters by blowing oxygen through said liquid steel is treated with 30% flue dust. Preferably the mixing is effected in two steps, in the first step 60% of the flue dust is added and the particles as obtained are mixed with the remaining flue dust in a second step without crushing the particles of the first step, particularly by using a whirling process.

Abstract: A method of treating scrubber sludge removed from a gas scrubbing apparatus of the type adapted to reduce SO.sub.x content in the treated gas, is provided. The method comprises collecting the spent residue from a fluidized combustion bed of the type wherein lime or calcium carbonate particles are suspended in a fluidized medium and wherein a carbonaceous fuel is ignited proximate said fluidized medium to absorb therein substantial amounts of SO.sub.x which is generated upon ignition of said carbonaceous fuel. The fluidized bed combustion residue is then subjected to a separating treatment wherein a slurry of residue is mechanically agitated. The supernatant liquor from the slurry is separated therefrom, leaving a precipitate material which latter material is mixed with sludge. The novel composition comprises a combination of scrubber sludge and fluidized bed combustion residue precipitate, as above mentioned.

Abstract: Waste material having a pH not exceeding 2, and which have previously caused a serious disposal problem, are converted into stable, solid, useful, non-polluting products by first mixing the waste material with fly ash using about 30 to 260 parts of weight of ash for 100 parts of waste material, then neutralizing the resultant mixture using lime or calcium carbonate containing materials, next adding a calcium containing binder such as lime or Portland cement, and then solidifying the resultant mixture.

Abstract: A stabilized fill material and method of producing the stabilized fill material comprising approximately 45-80% fly ash, 1-6% cement, and 20-50% water by weight, and mixing the material and depositing it directly in water by equipment supported on previously deposited fill material to form a causeway or the like. The fill material may include up to 2% lime by weight.

Abstract: A method of preparing a snow and ice control composition to improve traction on ice and snow covered surfaces. The composition comprises coal ash, binder, a melting depressant and enough water to form a dough-like mixture with said mixture pelletized by extrusion through a die and cured to form particles ranging in size from 1/16 th to 11/2 inches. The resulting said pellets have excellent strength and can be formulated to be environmentally acceptable.

Abstract: A method of removing a part of a stratum of fly ash comprising particles of relatively fine mean dimensions from the surface of a pond comprising submerging the leading edge of a scoop having a grid structure below the layer of fly ash, driving the scoop forwardly so that ash enters the scoop, lifting the scoop above the pond so that it drains of liquid and then tipping the drained ash from the scoop to a suitable location.

Abstract: Acid industrial waste containing calcium sulfate is reacted and neutralized with another alkaline industrial waste preferably containing iron oxide and aluminum oxide, mixed with water and stabilized with either Portland cement of fly ash to produce a chemically neutral and useful product in the form of soil cement.

Abstract: A method of manufacturing shaped rigid articles comprises preparing a mixture of thermally stable particulate material and a liquid resin having a viscosity of less than about 10 Stokes to form a thin coating of resin on the particles, at least a major portion of the particulate material comprising fly ash spheres, and forming the resulting mixture into a preselected shape with the resin bonding the particles together to form a rigid article having the preselected shape and containing less about 15% by weight resin. A rigid article also preferably has a cold tensile strength of at least about 125 psi.

Abstract: Cementitious compositions and aggregate derivatives of said compositions wherein fluidized bed combustion residue and pozzolanic material, such as pulverized coal combustion system fly ash, are incorporated in a cementitious mix. The mix is cast into desired shape and cured. If desired, the shape may then be crushed so as to result in a fluidized bed combustion residue-fly ash aggregate material or the shape may be used by itself.

Abstract: The physical and chemical fixation and stabilization of waste products from a sulfur-fuel burning unit through controlled crystallization of dissolved calcium sulfite. A low pH calcium sulfite solution is added to the waste containing aqueous sludge produced by a gas desulfurization unit thereby raising the pH of the calcium sulfite to crystalize the calcium sulfite and bind and encapsulate the waste products into a solid mass.

Abstract: A lightweight aggregate of low energy requirements for use in making lightweight concrete comprising cement kiln dust pellets or cement kiln dust and fly ash pellets which have been cured at low temperature and high humidity.

Abstract: A hazardous ammonium jarosite based sludge is solidified by the addition of cement and fly ash under mildly basic conditions, pH 10.+-.1.5. The ammonia does not have to be driven off prior to solidification.

Abstract: Concretes containing a hydratable cementitious binder such as Portland cement and a high strength aggregate material are described. The high strength aggregate material is produced from hydrated cementitious compositions which contain relatively low proportions of Portland cement and relatively high proportions of a select fly ash component. The high strength aggregate material is produced by mixing the aforementioned Portland cement and fly ash components with water and allowing such to hydrate. The hydrated aggregate product may then be reduced in size (e.g. by crushing) and screened prior to combination with the cementitious binder to produce concrete compositions. Concretes can be prepared with such aggregate which have at least comparable compressive strengths to concrete prepared using conventional crushed stone aggregate.

Abstract: A hydraulic cement is prepared by reacting coal fly ash with concentrated phosphoric acid, and crushing or grinding the resulting mixture to granules or a fine powder. The reacted fly ash may be heated to reduce the water of hydration before final crushing or grinding. The resulting hydraulic cement may be mixed with sand and/or gravel aggregate to prepare mortar or concrete mixes for applications similar to Portland cement, or the fly ash cement may be mixed with soils to stabilize them.

Abstract: A unique, high-grade magnetite obtained from fly ash, the use thereof in the cleaning of coal, and low iron content fly ash.

Abstract: A cement composition comprising cement, a self-setting pozzolan material, fine aggregate, air, water, at least one alkali metal constituent selected from the group consisting of sodium, potassium, and lithium ions, and at least one anionic constituent which is soluble in water and forms a calcium salt which is also water soluble, and a water soluble oxide of boron compound wherein the alkali metal constituent is present in an amount up to approximately 4.0 percent by weight, in terms of the equivalent weight of sodium ions, of the pozzolan material, the anionic constituent is present in an amount up to approximately 6.0 percent by weight, in terms of the equivalent weight of chloride ions, of the pozzolan material; the water soluble oxide of boron compound is present in the range of about 0.01 to 2.0 percent, in terms of the equivalent weight of borate ions (BO.sub.3.sup..ident.

Abstract: This invention relates generally to a process and system for wasting fly ash, and is specifically directed to a fly ash wasting system which provides an economical and environmentally acceptable mode of wasting fly ash which has been generated in large quantities per unit of time, as in the case of coal-burning power generating stations.

Abstract: A process for producing a citric acid soluble potassium silicate fertilizer comprises a step for kneading a mixture consisting essentially of potassium carbonate, fly ash, pulverized coal, other necessary starting materials and a caustic potash solution as a binder and then granulating the kneaded mixture, a step for drying the granulated product to a nearly absolutely dry state, and a step for calcining the dried granular product, whereby a chemical reaction takes place between the potassium and the silicon present in fly ash to convert them into a citric acid soluble potassium silicate.

Abstract: A flowable concrete mixture which possesses high strength and which provides facile placement of the mixture in structural forms composed of cement glue and aggregates, the viscosity of the cement glue and volume weight of the aggregates being adjusted so that the aggregates are suspended in the cement glue and remain suspended until the cement glue hardens.

Abstract: Oily wastes which are immiscible with water are treated by mixing them with powdered chalk or other absorbent substance and a liquid hazardous waste. The mixture thus obtained then has added to it cement and fly ash thereby producing a slurry which sets into a detoxified rock.

Abstract: A masonry cement is prepared by blending portland cement, kiln dust, and fly ash. The cement of this invention exhibits no efflorescence, good board life, workability, and acceptable color for use with such construction materials as brick, cinder block, and concrete block.

Abstract: Particulate material, composites containing said material, and a method of making said particulate material. The material is composed of at least about 85% (number basis) of regular, well defined ellipsoidal particles and has a particle size less than about 25 microns, about 90% and 50% by weight of the particles being less than about 15 and about 10 microns respectively in size and has a specific surface in the range of about 0.75 to about 2.5 m.sup.2 /gram as well as a specific gravity of about 2 to about 3. The composites contain said particulate material and up to about 99% of one or more polymeric media. The particulate material may be prepared by subjecting a diverse mixture of flyash particles to dry air classification in an air classifier controlled to recover particulate solids as described above.

Abstract: A process and composition of matter for the treatment of mortar or concrete which includes fly ash containing carbon, for the purpose of increasing air entrainment. A small quantity of a soluble alkaline earth oxide is added to the mortar or concrete at the time of mixing. The material is added in form which is immediately available to inhibit the air-adsorptive properties of the carbon in the fly ash.

Abstract: A cement composition comprising a high calcium-content fly ash and calcium sulfate, and mortar and concrete compositions containing the cement.

Abstract: A cement composition comprising cement, a pozzolan material, fine aggregate, air, water, at least one alkali metal constituent selected from the group consisting of sodium, potassium, and lithium ions, and at least one anionic constituent which is capable of forming complexes with ferric ions, is soluble in water, and forms a calcium salt which is also water soluble, wherein the alkali metal constituent is present in an amount up to approximately 4.0 percent by weight, in terms of the equivalent weight of sodium ions, of the pozzolan material; the anionic constituent is present in an amount up to approximately 6.0 percent by weight, in terms of the equivalent weight of chloride ions, of the pozzolan material; and the cement composition is further characterized by: (a) having a solid volume ratio of cement to the pozzolan material within the range of approximately 0.05 to 2.

Abstract: In a method of making concrete of the Portland Cement type wherein a quantity of cementitious material, such as Portland Cement, is mixed with a quantity of aggregate, generally sand and rock in varying proportions and water; and, wherein, the resulting mixture is stirred or mixed for an appropriate length of time consistent with acceptable practices in the concrete industry after which the mix is poured and allowed to set, the improvement which is characterized by the employment of fly ash as the major ingredient in the cementitious material. The improvement also includes the adding of gypsum to the initial mix in an amount equal to about 2% by weight of the fly ash and, thereafter, adding in and mixing a quantity of calcium chloride equal to about 3% by weight of the fly ash.

Abstract: Disclosed is a method of making lightweight gypsum products wherein expanded substantially monocellular volcanic ash having a loose bulk density of about 0.05 to about 15 pounds per cubic foot is added to calcined gypsum and water to form a slurry. The hydrated gypsum product formed has a bulk density of about 24 to about 45 pounds per cubic foot.

Abstract: A fire retardant coating composition useful as a paint or as a mastic is composed of ultrafine pulverized fly ash, a low viscosity vinyl acrylic type emulsion polymer as a binder and water. The composition also preferably contains one or more of a dispersant, a defoamer, a plasticizer, a thickener, a drying agent, preservative, a fungicide and an ingredient to control the pH of the composition and thereby inhibit corrosion of any metal surface to which the composition is applied.

Abstract: A mixture consisting essentially of fly ash and cement kiln dust which reacts at ambient temperature with water to produce a durable mass.

Abstract: A unique, high-grade magnetite obtained from fly ash, the use thereof in the cleaning of coal, and low iron content fly ash.