Abstract: Solid, leach-resistant bodies are formed from aqueous heavy metal sludge and fly ash formed in the combustion of subbituminous coal from the Power River Basin by slurrying the sludge with an amount of fly ash equivalent to between about 20 wt. % and about 70 wt. % based on the weight of the slurry, wherein the initial liquid content of the slurry is such that the slurry will harden into a body having a 7-day compressive strength of at least about 250 psi, and allowing the slurry to harden.

Abstract: Concretes containing Portland cement, fly ash and aggregate are disclosed which are capable of attaining high compressive strength and which contain relatively low proportions of Portland cement and relatively high proportions of a select fly ash component. The inventive concretes may be formulated as highly dense masses particularly suited for use in the manner of conventional structural concretes in buildings, bridges, dams, etc. Comparatively low density concrete masses may also be produced which are light in weight and have thermal insulation value rendering them particularly suited for use as thermal insulating components of roofs and as protective coatings for a variety of substrates.

Abstract: A fiber-free plaster molding composition which comprises by weight approximately 50-70% gypsum plaster, 5-25% fine expanded perlite, and 5-30% of a non-fibrous filler such as mica, silica, fly ash, pyrophyllite or mixtures thereof. The composition of this invention has good dry blending properties, slurry characteristics, and wet and dry mold features, making it a suitable replacement for fiber-containing molding compositions for low fusion metal casting molds.

Abstract: A new decorative and structural product and method of making the same is provided wherein coal flyash as a major component is mixed with a thermosetting or thermoplastic resin and formed under heat and pressure into a desired shape.

Abstract: A foam glass pellet comprising a core of cellular glass and a coating of fine ash particles substantially enclosing said cellular glass core and bonded thereto is disclosed. The foam glass pellet is derived from a glass having a softening point less than 1250.degree. C. The pellets have a median size of about 0.5 to about 20 millimeters and a bulk density of about 8 lbs/ft..sup.3 to about 50 lbs./ft..sup.3 pounds per cubic feet or higher if desired. The ash coating is substantially a mono particle thick layer of ash bonded to the foam glass core. Fly ash is a particularly effective ash for this purpose. Also disclosed are foam glass pellets wherein the core of cellular glass comprises a glass foam body having ash particles dispersed therein. The foam glass pellets of this invention have superior strength and are particularly useful as a light-weight aggregate in matrices such as concrete, thermosetting and thermoplastic organic polymer bodies, metals and gypsum and plaster materials.

Abstract: Shaped articles are produced from compositions of sulfur and a particulate inorganic material, at least 10% by weight of the particulate inorganic material being fly ash. The initial compositions are uniform dry blends, and the finished products are formed by converting the sulfur of the composition to molten form and then cooling while, as in casting, the molten material is confined in the desired shape. Use of fly ash provides articles having a hardness more than twice that of sulfur alone and a compressive strength approaching three times that of a typical aged poured concrete.

Abstract: A wet process is disclosed for the beneficiation of electrostatic fly ash to provide therefrom a series of products which have higher commercial value than the raw fly ash, including a carbon concentrate, cenospheres, an iron concentrate, an enhanced pozzolan, and an inert mineral filler.

Abstract: A brick or similarly fired construction unit and method of making it comprising mixing at least about 50% inorganic, non-ferrous residue from municipal incinerators, by weight, with coal fly ash and a binder, such as sodium silicate, and firing the mixture at a temperature of about 1700 to about 1900 to 2000.degree. F. for about 1/2 hour. A preferred "optimum" composition for lower firing temperatures and less costly binders comprises about 50 to 60% incinerator residue, 0.5 to 10% of sodium silicate or other binder and the remainder fly ash fired at 1700.degree.-1750.degree. F., which produces compressive strength and water absorption properties superior to fly ash brick and equal to better than conventional clay brick, even though the firing temperature is about 300.degree. less.

Abstract: A light weight aggregate is described which is formed of fly ash and solids derived from the caustic extract filtrate produced in a kraft pulping process. In a method for producing the light weight aggregate caustic extract filtrate produced in a kraft pulping process is concentrated to a desired level. The concentrated filtrate is then mixed with water and fly ash to produce a green agglomerate which is extruded into discrete pellets. The pellets are then burned to produce a light weight high strength aggregate.

Abstract: A process for the manufacture of a blistered silicate material having a high content of wollastonite and a low content of cristobalite and containing up to 30 to 40 percent by volume of fine blisters the size of a majority of which are 0.1 to 1mm with a substantial proportion being below 0.1mm wherein raw materials for the silicate material are introduced partly at the upper end of an inclined rotary kiln and partly at the lower end of the rotary kiln, whereby the materials will be distributed in the burning zone and melt.

Abstract: A process which comprises treating hazardous waste with an aluminium silicate or aluminosilicate and with a Portland cement in the presence of water to form a slurry and allowing the slurry to set into rock and a crystal matrix having encapsulated therein a hazardous waste and having a permeability of less than 1 .times. 10.sup.-4 cm. sec.sup.-1 and a compressive strength 28 days after preparation of 100 to 1000 psi.

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 mortar for interior and exterior plastering having anticondensate, antimoisture diffusive, heat insulating and biocidal properties is disclosed.

Abstract: Shaped articles of hydraulic cement compositions reinforced with fiber glass fabric or with chopped fiber glass, and having a smooth, reflective surface, are produced by the admixture of "super" water reducers to the aqueous cementitious slurries followed by casting or spraying into synthetic polymer molds, or molds coated with such synthetic polymers which are water repellent and non-sticking to hydraulic cements, to yield cured articles of high flexural strength with at least one surface which is an exact reproduction of the surface of the synthetic polymer mold, such as high gloss and patterned design. A great variety of useful articles may be produced, such as building panels, curtain walls, hollow utility poles and pipes, "raised" flooring panels, roofing tiles, protective barriers, and other products requiring thin shell, high flexural strength products for decorative and utilitarian uses.

Abstract: A method for the strengthening of glasses, glazes, cement, gypsum board, wood fiber board, mineral fiber board, lime or gypsum by adding fly or filter dust to the starting material after which the mixture is heated or not heated depending upon the product being manufactured. For glasses, glazes and other vitreous products (besides porous ceramic products) and cement the starting material is heated to above 1000.degree. C. For gas concrete, gypsum board, wood fiber board and mineral fiber board the starting material is heated to from 100.degree.-1000.degree. C. For cement, lime and gypsum it is possible that no heating take place to the starting material.

Abstract: A method of treating subsurface layers of the earth to either control movement of the subsurface water or build strength of the subsurface layers, or both, characterized by injecting at a predetermined depth and at a plurality of predetermined, spaced apart locations a limefly ash slurry consisting essentially of water, particulate hydrated lime, particulate fly ash and a surfactant. Also disclosed are the preferred proportions, or concentrations, of the components of the slurry; and a finished product; such as, a railroad track subgrade and ballast supporting cross-ties and rails, the subgrade having been injected with masses of lime and fly ash slurry to leave residual masses of lime and fly ash disposed in fissures and any ballast pockets along the railroad track, the masses having a proportion of lime to fly ash in the range of one to 1:1 to 1:3.

Abstract: A fibrous talc-free plaster molding composition comprises by weight approximately 50-70% gypsum plaster, 5-20% fibrous wollastonite, 5-25% fine expanded perlite, and 0-40% of a filler selected from the group consisting of sand, fly ash, pyrophyllite and mixtures thereof. The composition of this invention has good dry blending properties, slurry characteristics, and wet and dry mold features, making it a suitable replacement for fibrous talc-containing molding compositions for low fusion metal casting molds.

Abstract: A method for manufacturing porous ceramic products by mixing ceramic material with a fly dust containing silica and metal oxides and having a large specific surface area of at least 20 m.sup.2 /g. The mixture is heated to at least 800.degree. C to convert it into a porous ceramic material. The process is carried out so as to result in either products having mainly closed pores by heating at sintering temperatures or products having mainly open pores by heating at consolidation temperatures. The admixture may be wrapped in a sheet of material which upon heating the admixture to form pores in the material encloses the gases formed at low temperatures but which ruptures at high temperatures to expose the clay to an oxidizing atmosphere.

Abstract: Amber glass is made by melting a soda-lime glass-forming batch in which at least 1 percent of the silica content is provided by lignite fly ash.

Abstract: The invention relates to a controlled density fill material and a method of using such fill material in, for examples, the backfilling of sewers, embankments, structures and utility trenches. The material includes Portland cement, fly ash and aggregates. The material, while having some properties of both, is neither a soil nor a concrete.

Abstract: A construction composition developed to provide a material of construction which can be utilized to build essentially all types of structures, including houses, office buildings, and the like, which composition is capable of being wet mixed and subsequently molded into convenient and useful shapes. The composition has great strength, excellent shrink resistance properties, is highly shock resistant, provides good insulation for structures, and is adapted for use with suitable molds to form the entire wall structure of a house or other building in a single pouring.

Abstract: Densified fly ash pellets are produced by the steps comprising:A. Sizing the fly ash to produce a fraction substantially finer than -200 mesh (U.S. Standard);B. Moistening the sized fraction with sufficient water to form green pellets;C. Sizing the green pellets;D. Tumbling the sized green pellets to effect particle packing until excess water has been squeezed out, said pellets being kept dusted during tumbling with sized fly ash from step (a) to absorb the squeezed out water and thereby prevent agglomeration;E. Drying the packed green pellets to remove the free water therefrom;F. Heating the dried pellets from about 1000.degree. F to within about 70 - 90% of the absolute softening temperature of the ash and;G. Sintering the pellets from (f) at a temperature of 70 to 90% of the absolute softening temperature of the ash.The densified fly ash pellets constitute a low cost particulate heat exchange material for supplying heat to a fluidized bed carbon gasification zone.

Abstract: A mixture consisting essentially of fly ash, lime stack dust and aggregate which through pozzolanic reactions produces a hard, strong, durable mass capable of supporting surfacing.

Abstract: Digested sewage sludge resulting from sewage plant treatment of municipal sewage is disposed of and used in an ecologically acceptable manner by the incorporation of such sludge in hardenable compositions further including, for example, lime, fly ash and, in some cases, alkaline earth metal sulfates and/or soil or other inert or complimentary additives. These hardenable compositions may be emplaced in an area open to the atmosphere and permitted to cure over a period of time to act as land fill or as road base materials.

Abstract: Improved cementitious composition results from a process comprised of mechanical size reduction and activation of a mixture of lime and fly ash and the addition thereto of fly ash and aggregate, as needed, to make a mix of the desired proportions. A quicker and more complete reaction between the lime and fly ash results from deagglomeration of lime particles caused by interaction with the fly ash and/or by the increased availability of reactant materials due to particle size reduction of both the lime and the fly ash. The mechanical size reduction and activation process may be carried out, for example, in a ball mill or centrifugal impact mill.

Abstract: A mixture consisting essentially of fly ash, cement kiln dust and aggregate which through pozzolanic reactions produces a hard, strong, durable mass capable of supporting surfacing.

Abstract: Cenospheres have been formed into a closed-cell ceramic foam by the application of heat. The closed-cell ceramic foam has excellent insulating properties, is readily machinable, and has cohesive structure which makes it useful for high-temperature insulating applications such as heat shields to protect space vehicles when they re-enter the earth's atmosphere.

Abstract: A composition comprising an intimate bonded mixture of (a) 30-90 parts by weight of a particulate reinforcement filler formed of the pyrolysis or incineration residue of industrial or municipal solid waste products, and (b) 10-70 parts by weight of a resinous thermosetting (e.g., polyester or epoxy) or thermoplastic (e.g., nylon) adhesive polymer. The filler comprises a combination of silica and alumina and for pyrolysis residue, carbon. The individual particles are characterized by non-porous structure and irregular rough shapes, having a heterogeneous distribution and a size less than 50 microns.

Abstract: Process for insolubilizing water soluble wastes from alkaline sodium or ammonium type sulfur dioxide control systems used in conjunction with industrial or power plants. The sodium or ammonium sulfite or sulfate wastes are reacted in solution with ferric ions and sulfuric acid to produce an insoluble basic, hydrous or anhydrous, sodium and/or ammonium hydroxy ferric sulfate or sulfite compounds of the generic type M.sub.v (Na, NH.sub.4).sub.w Fe.sub.x (SO.sub.u).sub.y (OH.sub.z)nH.sub.2 O, wherein M is selected from an alkali metal other than sodium, or an authigenic metal or other cation present in industrial or power plant wastes, v is selected from zero to six, w is selected from zero to five, x is selected from zero to six, y is selected from one to five, u is 3 and/or 4, z is selected from zero to 12, and n is selected from zero to 20. Principal end product compounds include Natrojarosite, Ammoniojarosite, Metasideronatrite, Sideronatrite, Depegite, Rosarite, Iriite, and mixtures thereof.

Abstract: A method of forming a peat based product comprises the steps of mixing raw peat with a binder, e.g. Portland Cement, and an amount of internal draining agent for the peat, e.g. hydrated lime, and pressing the resulting mix in a mould to remove at least half the chemically free water content from the mix. The amount of internal draining agent for the peat is preferably not less by weight than about half the amount of binder, and the water content of the raw peat is usually at least 90% by weight and this may be reduced to less than 35% by weight of the mix during pressing. In a variation, a mixture of ground silica sand and hydrated lime initially provides the draining agent, and the pressed article is cured in an autoclave, the silica and hydrated lime combining during autoclaving to provide the binder.

Abstract: Strong aggregates of high density are produced from fine particles by heating said particles, then combining a binder solution comprising a saturated, dendritic crystal-forming aqueous sodium chloride solution heated to a temperature below the temperature of the heated particles, mixing thoroughly said heated particles and said heated binder solution in a ratio of 10 to 20 grams, preferably 14 to 18 grams, of particles per milliliter of binder solution, shaping the resulting mixture under pressure and cooling the shaped mixture to recrystallize said binder solution and provide said agglomerate.Aggregates of high porosity and strength can be prepared from siliceous materials such as fly ash by heating the product agglomerated to a temperature of 1600.degree.F-1825.degree.F.

Abstract: Method for disposal of water soluble sodium sulfur oxide-containing wastes resulting from industrial processes producing fly and/or bottom ash from fossil fuel utilization and waste or excess sodium sulfur oxide compounds, particularly disposal of sodium sulfite and/or sodium sulfate resulting from wet or dry sodium alkali scrubbing of tail or flue gases to reduce SO.sub.x emissions therefrom as from smelters, power plants, paper plants, glass plants and industrial boiler operations. Process involves mixing sodium sulfur oxide wastes with an alumina and silica-containing fly ash and/or bottom ash, forming an agglomerate, such as a pellet or briquette, and sintering in the range of about (1000.degree.-2300.degree.F). The resultant sintered particle shows lower solubility than the current standard of calcium sulfate, being 10.sup..sup.-2 to 10.sup..sup.-4 as soluble as the starting sodium sulfur oxides, has increased density (as high as 2.

Abstract: A process for the production of the aggregates for concrete by utilization of the residues from the combustion of predominantly organic material comprising the steps of burning said material, melting the non-combustible residues of said material, chilling the melting material by means of a cooling medium so that a vitreous granulated material is obtained, collecting said granulated material and crushing said granulated material.

Abstract: Waste sludges containing small amounts of certain types of reactive materials are treated by adding to such sludges materials capable of producing aluminum ions, lime and/or sulfate bearing compounds to produce a composition having a sufficient concentration of sulfate ions, aluminum ions and equivalents thereof, and calcium ions and equivalents thereof. Fly ash is preferred source of aluminum ions for this purpose. Over a period of time such compositions harden by the formation of calcium sulfo-aluminate hydrates. Hardening of the sludge facilitates its disposition and may permit the reclamation of the land now occupied by large settling ponds for such sludge. Still further, the solidification of such settling ponds may provide permanent land fill which permits immediate use of the land without the necessity for removal of the sludge. Aggregate materials may also be incorporated in the solidified waste.