Processes Of Using Fly Ash Patents (Class 264/DIG49)
  • Patent number: 6126738
    Abstract: A method for making aggregate includes the following steps: (a) preparing a wet mixture by mixing water with a combination of ingredients in a mixer, the combination of ingredients including by weight about, 68% to 95% fly-ash and 2% to 10% lime; (b) dropping the wet mixture into at least one pile on a base surface; (c) allowing the wet mixture in the pile to substantially completely hydrolyze into a hard product; and (d) crushing the product to form the aggregate. Preferably, step (b) further includes forming an arcuate stack having multiple overlapping conical piles of the dropped wet mixture such that the stack extends a circular distance over the surface. The wet mixture may be transported from the mixer to a height above the surface and dropped to the surface by a radial stacker. The combination of ingredients, preferably, further includes by weight 0.5% to 12% alkali hydroxide and, more particularly, sodium hydroxide.
    Type: Grant
    Filed: July 6, 1998
    Date of Patent: October 3, 2000
    Assignee: TransAsh
    Inventors: John W. Gerbus, Daniel P. Ivkovich
  • Patent number: 6054074
    Abstract: This is a method of producing manufactured aggregates from coal combustion by-products having sulfur. Recycle fines containing calcium hydroxide, an aluminum-containing material, and water are mixed together to form a feed mix which is agglomerated into an agglomerated product. The agglomerated product is combined with curing fines which contain calcium oxide which together form a blended mix. The blended mix is cured using the moisture in the blended mix which is used to exothermally hydrate the calcium oxide in the blended mix to form calcium hydroxide and which autogenically provides the required heat for curing and converts the calcium oxide in the blended mix to a dry calcium hydroxide-containing material to form aggregate products and dry fines. The aggregate products are separated from the dry fines, the dry fines are recycled to the mixing step and the aggregates are taken and used as a useful product for other purposes.
    Type: Grant
    Filed: September 14, 1999
    Date of Patent: April 25, 2000
    Assignee: Consol, Inc.
    Inventors: Muh-Cheng M. Wu, George E. Wasson
  • Patent number: 5935885
    Abstract: The present invention relates to a process for forming glass-ceramic tiles. Fly ash containing organic material, metal contaminants, and glass forming materials is oxidized under conditions effective to combust the organic material and partially oxidize the metallic contaminants and the glass forming materials. The oxidized glass forming materials are vitrified to form a glass melt. This glass melt is then formed into tiles containing metallic contaminants.
    Type: Grant
    Filed: October 20, 1997
    Date of Patent: August 10, 1999
    Assignee: Vortec Corporation
    Inventors: James G. Hnat, Akshay Mathur, James C. Simpson
  • Patent number: 5863477
    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.degree. to 165.degree. C. for 7 to 10 hours.
    Type: Grant
    Filed: November 19, 1996
    Date of Patent: January 26, 1999
    Assignee: Nichiha Corporation
    Inventor: Hidenori Kawai
  • Patent number: 5853475
    Abstract: The present invention relates to concrete, mortar and other hardenable mixtures comprising cement and fly ash for use in construction. The invention includes a method for predicting the compressive strength of such a hardenable mixture, which is very important for planning a project. The invention also relates to hardenable mixtures comprising cement and fly ash which can achieve greater compressive strength than hardenable mixtures containing only concrete over the time period relevant for construction. In a specific embodiment, a formula is provided that accurately predicts compressive strength of concrete containing fly ash out to 180 days. In other specific examples, concrete and mortar containing about 15% to 25% fly ash as a replacement for cement, which are capable of meeting design specification required for building and highway construction, are provided. Such materials can thus significantly reduce construction costs.
    Type: Grant
    Filed: November 20, 1996
    Date of Patent: December 29, 1998
    Assignee: New Jersey Institute of Technology
    Inventors: John W. Liskowitz, Methi Wecharatana, Chai Jaturapitakkul, Anthony E. Cerkanowicz, deceased
  • Patent number: 5846313
    Abstract: A method for regulating the quality, such as the combustion loss values, of coal ashes so as to make the same suitable for use in cements is disclosed. The method includes mixing ashes having high combustion loss values with fly ashes having low combustion loss values so that the high combustion loss ashes can be used in cements. The ashes are preferably burned prior to the mixing step in order to reduce residual carbon and oily substances present in the ashes. Bottom ashes collected at the bottom of furnaces are ground and fired to have a combustion loss value and a particle size close to those of fly ashes.
    Type: Grant
    Filed: April 18, 1997
    Date of Patent: December 8, 1998
    Inventor: Yu-Liang Chuang
  • Patent number: 5837052
    Abstract: Contaminated coal ash, for example flyash contaminated with carbon is introduced to hot clinker in a cooler downstream of a cement kiln; the carbon is combusted in the cooler to provide a cement clinker having an effective content of flyash free of carbon; this permits use of flyash contaminated with carbon without the need for separate special steps for carbon removal; volatile contaminants or contaminants having a volatile component, for example adsorbed ammonia are similarly removed in the cooler by volatilization.
    Type: Grant
    Filed: April 10, 1997
    Date of Patent: November 17, 1998
    Assignee: Lafarge Canada Inc.
    Inventors: David Bridson Oates, Horace Hershel Compton, Syed Suhail Akhtar
  • Patent number: 5772752
    Abstract: The present invention relates to concrete, mortar and other hardenable mixtures comprising cement and fly ash for use in construction and other applications, which hardenable mixtures demonstrate significant levels of acid and sulfate resistance while maintaining acceptable compressive strength properties. The acid and sulfate hardenable mixtures of the invention containing fly ash comprise cementitious materials and a fine aggregate. The cementitous materials may comprise fly ash as well as cement. The fine aggregate may comprise fly ash as well as sand. The total amount of fly ash in the hardenable mixture ranges from about 60% to about 120% of the total amount of cement, by weight, whether the fly ash is included as a cementious material, fine aggregate, or an additive, or any combination of the foregoing. In specific examples, mortar containing 50% fly ash and 50% cement in cementitious materials demonstrated superior properties of corrosion resistance.
    Type: Grant
    Filed: November 20, 1996
    Date of Patent: June 30, 1998
    Assignee: New Jersey Institute of Technology
    Inventors: John W. Liskowitz, Methi Wecharatana, Chai Jaturapitakkul, Anthony E. Cerkanowicz, deceased
  • Patent number: 5769936
    Abstract: A method for producing fly ash granules, which comprises mixing 100 parts by weight of fly ash, from 0.001 to 1 part by weight of a water-soluble polymer having from 2 to 80 mol %, based on the total repeating units, of repeating units having carboxyl groups, and from 40 to 100 parts by weight of water, for granulation.
    Type: Grant
    Filed: December 29, 1995
    Date of Patent: June 23, 1998
    Assignee: Mitsubishi Chemical Corporation
    Inventor: Kenji Mori
  • Patent number: 5766338
    Abstract: A way of using fly ash and water to make a road base material is disclosed. Class C fly ash, which sets up very quickly, is mixed with a hydrating liquid and compacted prior to initial set. To facilitate mixing, transportation and placement of the wet mixture, a set sequestering additive may be added to the water before mixing the water and the fly ash. Also disclosed is a mixing device designed to be attached to the underside of a tanker trailer of the type used to transport dry fly ash. The mixer introduces water to the inside and outside areas of a falling tubular stream of fly ash.
    Type: Grant
    Filed: January 26, 1996
    Date of Patent: June 16, 1998
    Assignee: American Fly Ash Company
    Inventor: LaVerne Weber
  • Patent number: 5759260
    Abstract: This invention is directed to a lightweight concrete combination. The combination includes a lightweight concrete product having auxiliary structures, such as at least one fastener, embedded therein. The lightweight concrete product comprises (a) cement and (b) a lightweight additive material. The invention also relates to a method for using the lightweight concrete product, and to a method for producing the lightweight concrete combination.
    Type: Grant
    Filed: January 23, 1996
    Date of Patent: June 2, 1998
    Assignee: Rigro Inc.
    Inventor: Richard E. Groh
  • Patent number: 5725652
    Abstract: An improved lightweight cementitious product made up of an aqueous cementious mixture using cement and expanded shale, clay and slate mix, that can incorporate fly ash, lime, and the weight saving component, which is micronized polystyrene particles having particle sizes in the range of 50 to 2000 microns, and characterized by having water contents in the range of from about 0.5% to 50% v/v. The ultra low water compositions can be extruded and can be molded under high pressure.
    Type: Grant
    Filed: August 21, 1996
    Date of Patent: March 10, 1998
    Inventor: David M. Shulman
  • Patent number: 5714003
    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.
    Type: Grant
    Filed: February 12, 1997
    Date of Patent: February 3, 1998
    Assignee: Mineral Resource Technologies, LLC
    Inventor: Robert William Styron
  • Patent number: 5714002
    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.
    Type: Grant
    Filed: February 12, 1997
    Date of Patent: February 3, 1998
    Assignee: Mineral Resource Technologies, LLC
    Inventor: Robert William Styron
  • Patent number: 5704972
    Abstract: The present invention provides a method and mixture for use in forming strong light-weight aggregate and includes by weight about; 68% to 95% fly-ash, 2% to 10% hydrated lime, and 3% to 12% alkali hydroxide such as Sodium Hydroxide. While many types of fly-ash may be used, Type F or Type C fly-ash are preferred. The admix is mixed with water to form a slurry including water in a range of 10% to 25% by weight of the dry mixture and the slurry is then compacted. The compacted slurry is then cured such as by using a rotary kiln or by in situ open air curing. The cured slurry is then allowed to hydrolyzed to form a hard material which then may be crushed and optionally screened to form an aggregate having a particular size or range of sizes.
    Type: Grant
    Filed: January 23, 1997
    Date of Patent: January 6, 1998
    Assignee: Trans Ash, Inc.
    Inventor: Daniel P. Ivkovich
  • Patent number: 5693137
    Abstract: A cementitious mixture includes hydraulic cement, fly ash, and an effective amount of unfired nature finely divided material, such as a clay, containing at least about 35% alumina, to accelerate the early strength of a mix. A method of accelerating early strength in a cementitious mix comprises the adding of alumina in the form of an unfired raw material, such as clay, in an effective amount in such mix.
    Type: Grant
    Filed: November 29, 1995
    Date of Patent: December 2, 1997
    Assignee: JTM Industries, Inc.
    Inventor: Robert W. Styron
  • Patent number: 5681384
    Abstract: The present invention relates to concrete, mortar and other hardenable mixtures comprising cement and fly ash for use in construction. The invention provides a method for increasing the rate of strength gain of a hardenable mixture containing fly ash by exposing the fly ash to an aqueous slurry of calcium oxide (lime) prior to its incorporation into the hardenable mixture. The invention further relates to such hardenable mixtures, e.g., concrete and mortar, that contain fly ash pre-reacted with calcium oxide. In particular, the fly ash is added to a slurry of calcium oxide in water, prior to incorporating the fly ash in a hardenable mixture. The hardenable mixture may be concrete or mortar. In a specific embodiment, mortar containing fly ash treated by exposure to an aqueous lime slurry are prepared and tested for compressive strength at early time points.
    Type: Grant
    Filed: April 24, 1995
    Date of Patent: October 28, 1997
    Assignee: New Jersey Institute of Technology
    Inventors: John W. Liskowitz, Methi Wecharatana, Chai Jaturapitakkul, Anthony E. Cerkanowicz, deceased
  • Patent number: 5669969
    Abstract: A process for forming an ash aggregate is provided. The process involves mixing a cellulose sludge material with an ash component. The ash component may comprise fly ash or sanitary waste ash in combination with fly ash. The sludge component preferably comprises paper mill sludge or pulp mill sludge. The hard lightweight aggregate may be utilized in a variety of manners, for example, to provide lightweight concrete and lightweight concrete mixes.
    Type: Grant
    Filed: October 30, 1995
    Date of Patent: September 23, 1997
    Assignee: Greengrove Corporation
    Inventors: William Delbert Meade, John William Pearson
  • Patent number: 5624491
    Abstract: The present invention relates to concrete, mortar and other hardenable mixtures comprising cement and fly ash for use in construction. The invention includes a method for predicting the compressive strength of such a hardenable mixture, which is very important for planning a project. The invention also relates to hardenable mixtures comprising cement and fly ash which can achieve greater compressive strength than hardenable mixtures containing only concrete over the time period relevant for construction. In a specific embodiment, a formula is provided that accurately predicts compressive strength of concrete containing fly ash out to 180 days. In other specific examples, concrete and mortar containing about 15% to 25% fly ash as a replacement for cement, which are capable of meeting design specifications required for building and highway construction, are provided. Such materials can thus significantly reduce construction costs.
    Type: Grant
    Filed: May 20, 1994
    Date of Patent: April 29, 1997
    Assignee: New Jersey Institute of Technology
    Inventors: John W. Liskowitz, Methi Wecharatana, Chai Jaturapitakkul, Anthony E. Cerkanowicz, deceased
  • Patent number: 5584895
    Abstract: A process for preparing a solid material containing coal ash includes a first step of mixing coal ash with a calcium compound to obtain a mixture, a second step of molding the mixture to obtain a molded article, and a third step of subjecting the molded article obtained in the second step to a hydrothermal treatment at a temperature of at least 120.degree. C. under high pressure. In the first step, 40 to 95 parts by weight of the coal ash is mixed with 60 to 5 parts by weight of the calcium compound, and the coal ash to be used has a bulk density of at least 0.8 g/cm.sup.3, an average particle diameter of 5 to 40 .mu.m and an aluminum content of 35% by weight or less in terms of Al.sub.2 O.sub.3. By the use of a blowing agent or the like, it is also possible to obtain a porous lightweight solid.
    Type: Grant
    Filed: March 8, 1995
    Date of Patent: December 17, 1996
    Assignee: NGK Insulators, Ltd.
    Inventors: Shoji Seike, Osamu Imai, Junko Yoshizawa
  • Patent number: 5536310
    Abstract: A cementitious composition comprising(A) 10-30 parts cementitious material;(B) 50-80 parts fly ash weight; and(C) 1.5-8 parts hydroxycarboxylic acid and/or salt thereof.
    Type: Grant
    Filed: October 6, 1994
    Date of Patent: July 16, 1996
    Assignee: Sandoz Ltd.
    Inventors: John W. Brook, David F. Factor, Frederick D. Kinney, Celeste L. McCallen, Andrea M. Young
  • Patent number: 5521132
    Abstract: A ceramic material made from raw coal fly ash or raw municipal solid waste fly ash and (1) sodium tetraborate or (2) a mixture of sodium tetraborate and a calcium containing material that is triple superphosphate, lime, dolomitic lime, or mixtures thereof.
    Type: Grant
    Filed: September 1, 1994
    Date of Patent: May 28, 1996
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Inna G. Talmy, Deborah A. Haught, Curtis A. Martin
  • Patent number: 5520730
    Abstract: From about 25% to about 50% but not more than about 200 lbs of the Portland cement of a general purpose concrete mix which contains for each cubic yard of the concrete to be produced in generally homogeneous admixture about 400-750 lbs. portland cement, about 1600-2000 lbs. coarse aggregate of a size of at least about 3/8 inch, and sufficient fine aggregate of a size less than 3/8 inch and up to minor amounts of conventional additives to yield one cubic yard when the admixture is combined with water in an amount equal to about 40-70% by weight of said portland cement, is replaced with a) Class F fly ash having a calcium oxide content up to about 6% and b) cement kiln dust (CKD) in a weight ratio of fly ash to CKD of about 2:3-3:2. Preferably, 30% or more of the Portland cement is replaced.
    Type: Grant
    Filed: October 27, 1993
    Date of Patent: May 28, 1996
    Inventor: Ronald L. Barbour
  • Patent number: 5500044
    Abstract: A process for forming an ash aggregate is provided. The process involves mixing a cellulose sludge material with an ash component. The ash component may comprise fly ash or sanitary waste ash in combination with fly ash. The sludge component preferably comprises paper mill sludge or pulp mill sludge. The hard lightweight aggregate may be utilized in a variety of manners, for example, to provide lightweight concrete and lightweight concrete mixes.
    Type: Grant
    Filed: October 15, 1993
    Date of Patent: March 19, 1996
    Assignee: Greengrove Corporation
    Inventors: William D. Meade, John W. Pearson
  • Patent number: 5490889
    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.
    Type: Grant
    Filed: January 20, 1995
    Date of Patent: February 13, 1996
    Inventors: William D. Kirkpatrick, Carole W. Kirkpatrick
  • Patent number: 5489334
    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.
    Type: Grant
    Filed: January 20, 1995
    Date of Patent: February 6, 1996
    Inventors: William D. Kirkpatrick, Carole W. Kirkpatrick
  • Patent number: 5484479
    Abstract: A method for making synthetic aggregate. Fly ash is combined with water to form a soil-like mixture. The mixture is then compacted into slabs and allowed to set. After setting, the material is crushed to appropriate size. Since fly ash and water mixtures set quickly, and since compaction should take place prior to setting of the mixture, a set sequestering admixture may be used to facilitate the process.
    Type: Grant
    Filed: December 21, 1993
    Date of Patent: January 16, 1996
    Assignee: American Fly Ash Company
    Inventor: LaVerne Weber
  • Patent number: 5484480
    Abstract: A cementitious mixture includes hydraulic cement, fly ash, and an effective amount of unfired nature finely divided material, such as a clay, containing at least about 35% alumina, to accelerate the early strength of a mix. A method of accelerating early strength in a cementitious mix comprises the adding of alumina in the form of an unfired raw material, such as clay, in an effective amount in such mix.
    Type: Grant
    Filed: October 19, 1993
    Date of Patent: January 16, 1996
    Assignee: JTM Industries, Inc.
    Inventor: Robert W. Styron
  • Patent number: 5435843
    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.
    Type: Grant
    Filed: September 10, 1993
    Date of Patent: July 25, 1995
    Assignee: Board of Supervisors of Louisiana State University and Agricultural and Mechanical College
    Inventors: Amitava Roy, Paul J. Schilling, Harvill C. Eaton
  • Patent number: 5425807
    Abstract: The present invention relates to a novel composition which is useful for forming construction blocks and encapsulating hazardous materials, a process for producing blocks and encapsulating the material, and blocks made of the material. This composition is a mixture of klin dust or volcanic fly ash and aggregate. The process comprises the steps of (a) blending a dry mixture comprising the kiln dust or volcanic fly ash mixture with water; (b) transferring the blended mixture into a compression zone and (c) compressing the blended mixture in the compression zone to form a brick of the desired size.
    Type: Grant
    Filed: July 14, 1994
    Date of Patent: June 20, 1995
    Assignee: TIDE Company
    Inventor: Mitchell S. Riddle
  • Patent number: 5405441
    Abstract: The present invention relates to a novel composition which is useful for forming construction blocks and encapsulating hazardous materials, a process for producing blocks and encapsulating the material, and blocks made of the material. This composition is a mixture of pozzoulanic fly ash and bottom ash. The weight ratio of fly ash:bottom ash is preferably in the range 80:20% by weight to 20:80% by weight. The process comprises the steps of (a) blending a dry mixture comprising the ash mixture with water; (b) transferring the blended mixture into a compression zone and (c) compressing the blended mixture in the compression zone to form a brick of the desired size.
    Type: Grant
    Filed: July 11, 1994
    Date of Patent: April 11, 1995
    Assignee: Tide Company
    Inventor: Mitchell S. Riddle
  • Patent number: 5387283
    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.
    Type: Grant
    Filed: June 29, 1994
    Date of Patent: February 7, 1995
    Inventors: William D. Kirkpatrick, Carole W. Kirkpatrick
  • Patent number: 5374307
    Abstract: The present invention relates to a novel composition which is useful for forming construction blocks and encapsulating hazardous materials, a process for producing blocks and encapsulating the material, and blocks made of the material. This composition is a mixture of pozzoulanic fly ash and bottom ash. The weight ratio of fly ash:bottom ash is preferably in the range 80:20% by weight to 20:80% by weight. The process comprises the steps of (a) blending a dry mixture comprising the ash mixture with water; (b) transferring the blended mixture into a compression zone and (c) compressing the blended mixture in the compression zone to form a brick of the desired size.
    Type: Grant
    Filed: June 18, 1993
    Date of Patent: December 20, 1994
    Inventor: Mitchell S. Riddle
  • Patent number: 5374308
    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.
    Type: Grant
    Filed: May 27, 1993
    Date of Patent: December 20, 1994
    Inventors: William D. Kirkpatrick, Carole W. Kirkpatrick
  • Patent number: 5366548
    Abstract: The present invention relates to a novel composition which is useful for forming construction blocks and encapsulating hazardous materials, a process for producing blocks and encapsulating the material, and blocks made of the material. This composition is a mixture of kiln dust or volcanic fly ash and aggregate. The process comprises the steps of (a) blending a dry mixture comprising the kiln dust or volcanic fly ash mixture with water; (b) transferring the blended mixture into a compression zone and (c) compressing the blended mixture in the compression zone to form a brick of the desired size.
    Type: Grant
    Filed: April 17, 1992
    Date of Patent: November 22, 1994
    Inventor: Mitchell S. Riddle
  • Patent number: 5362320
    Abstract: A polymer modified cement, low shrinkage mortar patching and/or coating compound that can be sanded after drying and has the consistency of drywall compound for coating, patching or taping drywall, plaster, stucco, concrete or wood surfaces.
    Type: Grant
    Filed: September 13, 1993
    Date of Patent: November 8, 1994
    Inventor: Burton K. Whatcott
  • Patent number: 5351630
    Abstract: A hydrated granular fly ash composition is disclosed. The granular fly ash may be transported with minimal dust problems while maintaining its capacity to act as a solidifying agent at a remote destination. The process for producing the fly ash involves evenly dispersing a pre-determined amount of water into the fly ash so that it is transformed into a granular form substantially eliminating dust production. An apparatus for processing the fly ash includes a hopper for receiving the fly ash, a conveyor and a modified conditioner in which the fly ash is hydrated.
    Type: Grant
    Filed: July 3, 1991
    Date of Patent: October 4, 1994
    Assignee: Monex Resources, Inc.
    Inventors: Robert A. Lister, William H. Barrow, James B. Merkel, Gary W. Beckcom, I Samuel Young
  • Patent number: 5350549
    Abstract: Cementitious compositions useful as lightweight aggregates are formed from a blend of spent bed material from fluidized bed combustion and fly ash. The proportions of the blend are chosen so that ensuing reactions eliminate undesirable constituents. The blend is then mixed with water and formed into a shaped article. The shaped article is preferably either a pellet or a "brick" shape that is later crushed. The shaped articles are cured at ambient temperature while saturated with water. It has been found that if used sufficiently, the resulting aggregate will exhibit minimal dimensional change over time. The aggregate can be certified by also forming standardized test shapes, e.g., cylinders while forming the shaped articles and measuring the properties of the test shapes using standardized techniques including X-ray diffraction.
    Type: Grant
    Filed: April 15, 1993
    Date of Patent: September 27, 1994
    Assignee: Valley Forge Laboratories, Inc.
    Inventor: Michael J. Boyle
  • Patent number: 5302200
    Abstract: An admixture for a dense and durable concrete mix consisting essentially of diatomaceous earth and silica fume in the ratio of from 1 to 1 up to 1 to 8. Optionally, fly ash and lignosulfonate dispersant may be added to the admixture.
    Type: Grant
    Filed: November 27, 1991
    Date of Patent: April 12, 1994
    Assignee: Specrete - IP Incorporated
    Inventors: David A. Smetana, Alfonzo L. Wilson, Richard J. Lenczewski
  • Patent number: 5286292
    Abstract: Commercially available fly ash is prepared and charged in a vessel. A halogen gas is supplied to the vessel and is brought into contact with the fly ash in the vessel.
    Type: Grant
    Filed: June 26, 1992
    Date of Patent: February 15, 1994
    Assignee: Onoda Cement Co., Ltd.
    Inventors: Kazuhisa Tsukada, Takeshi Kuroda, Takane Mukaino, Yukinori Saiki
  • Patent number: 5266111
    Abstract: In general purpose concrete compositions, from about 10% but less than about 25% by wt of the usual amount of portland cement for such compositions is replaced with Class F fly ash and cement kiln dust, both abundant and inexpensive waste products, in the weight ratio of such fly ash to cement kiln dust of about 3:1-1:1 with a minimum of about 5% of the replaced portland cement being cement kiln dust. General purpose concrete prepared from these mix compositions exhibit early strength characteristics, especially from day 1 to day 3, generally equal to or better than those exhibited by comparable all portland cement mix compositions.
    Type: Grant
    Filed: October 13, 1992
    Date of Patent: November 30, 1993
    Inventor: Ronald L. Barbour
  • Patent number: 5256198
    Abstract: A method for increasing the porosity of fly ash comprising adding an effective amount of a polymer/nitrate composition to fly ash produced from the combustion of fuels such as coal.
    Type: Grant
    Filed: October 13, 1992
    Date of Patent: October 26, 1993
    Assignee: Calgon Corporation
    Inventor: Rabindra K. Sinha
  • Patent number: 5256197
    Abstract: A process for the production of a water-insoluble, abrasion-resistant, synthetic solid article or aggregate, as well as the products produced thereby. Fly ash, lime, water and FGD sludge are mixed intimately and formed at pressures exceeding 1,000 psi, preferably 4000-8000 psi. The product is cured for at least the equivalent of 28 days at 73.degree. F., and crushed and sized to produce a commercial aggregate, for example, for concrete, asphalt, concrete masonry units, etc.
    Type: Grant
    Filed: June 19, 1991
    Date of Patent: October 26, 1993
    Assignee: Conversion Systems, Inc.
    Inventor: Charles L. Smith
  • Patent number: 5244608
    Abstract: A moulding process and system for producing small wooden objects such as, for example, pipe heads or furniture handles from a moulding material formed of an aqueous suspension of wood dust. The moulding material is injection moulded into injection mould parts in which electrodes are placed for subjecting moulding cavities to a HF-heating field such that both a rapid curing of a heat setting glue agent in the aqueous wood dust mass and a rapid driving out of a major part of the water is realized. The moulding cavities include exhaust or release channels for steam resulting from the evaporation of the water of the moulding material and an arrangement is provided for maintaining the mould parts together in spite of the high steam pressure developed in the mould cavities.
    Type: Grant
    Filed: December 16, 1991
    Date of Patent: September 14, 1993
    Assignee: Mix-Wood ApS
    Inventor: Ulrik F. Andersen
  • Patent number: 5173232
    Abstract: A process for producing spherical pellets from stack gas desulfurization residue filter cake. The process includes mixing dry fly ash with a filter cake in a mixer and discharging the blend onto a shallow pan disc pelletizer where pellets are produced. Additional fly ash produces pellets in a reroll ring. Instead of fly ash, cement kiln dust, portland cement, lime kiln dust or lime is utilized.
    Type: Grant
    Filed: April 25, 1991
    Date of Patent: December 22, 1992
    Inventor: Carl A. Holley
  • Patent number: 5137753
    Abstract: Ash from a fluidized bed combustor in which limestone particles are suspended in the presence of carbonaceous fuel being burned is pelletized. Lime-containing bed ash ("FBCR") is produced in the combustor, and fly ash ("FBC fly ash") is generated as a by-product of the combustion process. FBCR and FBC fly ash generated during the combustion process are obtained. Water is added to the FBCR so as to convert a substantial portion of the lime to hydrated lime. Water is added to the FBC fly ash and pellets are formed from the FBC fly ash. The FBC fly ash pellets are coated with the hydrated FBCR. The coated FBC fly ash pellets are cured in a curing silo for a minimum of 6-10 hours, preferably by nesting them in a bed of hydrated FBCR. The cured pellets then are separated from the bed of hydrated FBCR. New pellets are formed by mixing the separated, hydrated FBCR with FBC fly ash and water.
    Type: Grant
    Filed: October 25, 1990
    Date of Patent: August 11, 1992
    Inventors: Alan E. Bland, Richard K. Cox, E. Ray Lichty, Allen R. Rowen, Richard A. Schumann
  • Patent number: 5108679
    Abstract: A process for the production of concrete roofing products of reduced weight loading having a thickness in section of not greater than 15 mm. The process involves forming an asbestos-free cementitious composition comprising (i) lightweight aggregate, (ii) hydraulic cement, (iii) water and (iv) reinforcing fibers in an amount of not more than 4% by weight of the total weight of the composition but the fibers being present in an amount sufficient to provide a reinforcing effect and impact strength in the roofing product, the cementitious composition being capable of being shaped by a roller and slipper method, and thereafter shaping the cementitious composition by the method to provide a shaped extrudate, dividing the extrudate to form sections and curing the sections to provide roofing products, wherein the reinforcing fibers have lengths of 0.5 mm to 20 mm. The impact resistant roofing products are useful as roofing tiles, or a replacement for shingles, shakes and slates.
    Type: Grant
    Filed: November 2, 1990
    Date of Patent: April 28, 1992
    Assignee: Redland Roof Tile Limited
    Inventors: Eric Rirsch, Jeremy Wingfield
  • Patent number: 5106557
    Abstract: The production of concrete building products having thickness in section of not greater than 15 mm includes forming a cementitious composition containing aggregate, hydraulic cement and water. The composition is shaped by a roller and slipper method to produce a shaped extrudate which is then divided into form sections. The sections are then cured to provide the aesthetically pleasing product. The cementitious composition also contains reinforcing fibres. The building products are used for roofing tiles or replacement of shingles, shakes and slates.
    Type: Grant
    Filed: June 7, 1989
    Date of Patent: April 21, 1992
    Assignee: Redland Roof Tiles Limited
    Inventors: Eric Rirsch, Jeremy Wingfield
  • Patent number: 4880582
    Abstract: A process for manufacturing hardened granules produced by mixing at least fly ash obtained from combustion of a material selected from a coal product and lignite, a binder and water, forming granules of said mixture, hardening said granules in an embedding material at a temperature between 85.degree. and 212.degree. F. by applying heat and separating the hardened granules from the embedding material, said embedding material being used for forming new granules, including the step of embedding the non hardened granules after granulation in a hardening reactor in a fine grained material with a water absorption capacity of at least 8% and being free from a compound generating heat by contacting water, and supplying heat to the mixture of granules and embedding material in said hardening reactor by introducing steam into the mixture of granules and embedding material as present in the hardening reactor to raise and maintain the temperature at a value comprised between 85.degree. F. and 212.degree. F.
    Type: Grant
    Filed: July 22, 1987
    Date of Patent: November 14, 1989
    Assignee: Aardelite Holding B. V.
    Inventors: Jacobs J. Spanjer, Pieter D. Rademaker
  • Patent number: 4869846
    Abstract: A carboxylic acid which has a pK.sub.a within the range of 2 to 7 and the ability to increase the effective alkalinity of fly ash for flue gas desulfurization. Carboxylic acid may be combined with adjuvants. Generally carboxylic acids with dispersant properties are preferred. Adjuvants which enhance the dispersant qualities of carboxylic acid are desirable.
    Type: Grant
    Filed: March 28, 1988
    Date of Patent: September 26, 1989
    Assignee: Nalco Chemical Company
    Inventors: Richard J. Mouche, Mei-Jan L. Lin