Abstract: A high density carbon material produced from coal is described. The carbon material may have a density ranging from about 1.0 g/cc to about 1.6 g/cc and may have a crush strength of up to about 20,000 psi. The high density carbon material is produced by slowly heating comminuted swelling bituminous coal particles under pressures of 400 psi to about 500 psi to a first temperature at about the initial plastic temperature of the coal. The material is held at this temperature for a period of time sufficient to provide for a uniform temperature throughout the coal. The material is then heated to a second temperature for a period of time sufficient to provide for the coal achieving an essentially uniform temperature. The resulting product is a three-dimensional, self-supporting carbon that has a substantially continuous carbon matrix defining grain boundaries within the carbon matrix.

Abstract: Methods for the production of carbon foam from swelling coals that do not require the use of high process pressures, oxidized coal, devolatized coal, or high-strength, foam expansion confining molds are described. In some embodiments, a comminuted swelling bituminous coal is heated to a first elevated temperature sufficient to result in the coal particles softening and melting together to form a substantially homogeneous open cell plastic carbon material. The substantially homogeneous open cell plastic carbon material may then be heated to a second elevated temperature at a slow rate to form carbon foam. In some embodiments, the resulting carbon foam may be heated to a higher third elevated temperature. The resulting carbon foam may be subsequently heated to elevated temperatures as great as 3200° C. or more.

Abstract: A method for increasing the yield of carbon foam is described. The method includes placing a foaming sheet over the top surface of the material to be foamed. In certain embodiments, the foaming sheet is placed over the top surface of particulate coal prior to and during the foaming process. In some embodiments the foaming sheet is a smooth, continuous sheet, such as aluminum foil or the like. The resulting carbon product includes an increased amount of usable carbon foam.

Abstract: In drying coal to be used as fuel for a coal-fired boiler, the coal is dried at a temperature of 80 to 150° C. by using combustion exhaust gas having passed through an air heater for the coal-fired boiler. Moreover, after medium-quality or low-quality coal is heated to a temperature of 300 to 500° C. at a heating rate of not less than 100° C. per minute and then cooled to a temperature of 250° C. or below at a cooling rate of not less than 50° C. per minute, the resulting reformed coal is cooled to a temperature of 70° C. or below and stored for 1 month or more in a state of isolation from the atmosphere. In producing the aforesaid reformed coal, the medium-quality or low-quality coal is heated by using combustion exhaust gas obtained at the outlet of an economizer included in the coal-fired boiler equipment or at the outlet of a denitrator included therein.

Abstract: Thus, a novel process for producing a passivated coal material has been disclosed, comprising the steps of (a) drying a coal material by heating said coal material in the presence of a first gas comprised of less than about five volume percent of oxygen until said coal material has a moisture content of from above about 1 to about 20 weight percent, thereby producing a partially dried coal material, wherein said coal material is selected from the group consisting of lignitic coal, sub-bituminous coal, bituminous coal, coal char, and mixtures thereof; (b) heating said partially dried coal material to a temperature of from about 100 to about 600 degrees Fahrenheit, thereby producing a heated partially dried coal material; (c) charging said heated partially dried coal material to a fluidized bed reactor; (d) feeding a second gas with an oxygen content of from about 6 to about 15 volume percent into said fluidized bed reactor; (e) contacting said heated partially dried coal material with said second gas while mai

Abstract: The feeding of coal slurries into a gasifier for the production of synthesis gas is improved by modifying the rheological properties of the coal particles so that conventional liquid transfer equipment can be used in the feed transfer process to the gasifier. The coal particle surface modification is accomplished by adsorbing asphaltenes derived from petroleum onto the surfaces of coal particles prior to and/or during contact with the slurry liquid. The coal particles with their surfaces thus modified exhibit lower particle-particle interaction in the liquid slurries to form a shear independent Newtonian fluid or a weakly shear thickening pseudoplastic fluid. The rheological properties of the slurries permit them to be transported reliably into a pressurized, entrained feed gasifier vessel using convention slurry pumps with a low potential expenditure of energy.

Abstract: A method for drying coal using microwave energy to achieve a controlled aggregate moisture content target range without starting combustion or degrading the coking qualities of the coal. Coal feed stock is first separated into fine grade coal and one or more larger grades. The fine grade coal is loaded onto a conveyor as a bed of fixed depth. The fine grade coal is conveyed continuously through a microwave-energized heating chamber for drying. The fine grade coal is dried sufficiently so that when it is combined with the larger grade coals, the moisture content of the aggregate is within a target moisture content range. By volumetrically and uniformly heating the coal, the microwave heating chamber boils away the water without heating the coal itself above about 90° C. In this way, the coal does not combust or oxidize, and its coking qualities are retained.

Abstract: The present invention relates to a fuel system and to a process for the production of such a fuel system. The fuel system according to the present invention shows a content of fossil carbon which is clearly reduced compared to that of fossil fuels while the fuel-technological properties are the same. Thus the emission of the carbon dioxide based on fossil carbon is notably reduced during the use of the fuel system according to the invention. In one embodiment of the process according to the invention, the fuel system according to the invention is provided consisting of at least two different fossil regular fuels and at least one biogenic carbon donor, with biomasses serving as a biogenic carbon donor.

Abstract: A method of reducing mercury emissions using a combustion device including at least a combustion zone. The method includes receiving a flow of fuel including mercury at the combustion device assembly; injecting a first mercury oxidizer flow including MgCl2 on the fuel upstream of the combustion device assembly; and oxidizing the mercury using a mercury oxidizer flows and the combustion device assembly.

Abstract: The present invention relates to a chemical change reagent which is used as an additive to coal to enhance the complete combustion of the coal after turning it into a synthetic fuel. The composition is a chemical change agent in that it converts the coal/composition mix into a different material which, when burned, results in lower NOx emissions. The composition includes a wax, a base for ph adjustment and water and is mixed with the coal prior to combustion.

Abstract: The present invention includes methods for simultaneously producing, within a single container, two or more sections of high density carbon foam materials of defined shape. A method used to prepare high density carbon foam sections may involve heating a comminuted agglomerating bituminous coal bed, that is at least partially divided into two or more sections by the use of partitions within the coal bed, to an elevated temperature sufficient to result in the coal particles softening and melting together to form sections of a generally homogeneous, continuous, open cell carbon material. The sections of homogeneous open cell carbon material are then maintained at an elevated temperature for a period of time sufficient to substantially reduce or essentially eliminate the plastic properties of the bituminous coal. As desired, the resultant high density carbon foam sections may be cooled to essentially ambient temperatures or immediately or subsequently heated to elevated temperatures as great as about 3200° C.

Abstract: A method for improving the combustion properties of a coalcomprises treating said coal with a metal porphyrin. The invention also provides a coal having a metal porphyrin deposited thereon, and a method of producing heat, comprising combusting the coal.

Abstract: Chemical looping combustion of coal utilizing a rotating regenerative assembly to expose coal particles to alternating conditions of oxidation and regeneration.

Abstract: According to the present invention there is provided a porous coal-based material having a density of between about 0.1 g/cm3 and about 0.6 g/cm3 that is produced by the controlled heating of small coal particulate in a “mold” and under a non-oxidizing atmosphere. The coal starting material preferably exhibits a free swell index of between about 3.5 and about 5.0 and most preferably between about 4.0 and about 4.5. The porous product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, heat or electrical insulator etc. Such porous products, without further treatment exhibit compressive strengths of up to about 6000 psi. Further treatment by carbonization or graphitization yields products that can be used as electrical or heat conductors. Methods for the production of these coal-based cellular products are also described.

Abstract: According to the present invention there is provided a coal-based carbon foam having a density of between about 0.1 g/cm3 and about 0.8 g/cm3, preferably between about 0.2 g/cm3 and about 0.6 g/cm3 and most preferably between about 0.3 g/cm3 and about 0.4 g/cm3 that is produced by the controlled heating of high volatile bituminous coal particulate in a “mold” and under a non-oxidizing atmosphere. The high volatile bituminous coal starting material preferably exhibits a free swell Index of between about 3.5 and about 5.0 and most preferably between about 3.75 and about 4.5. A number of additional highly desirable characteristics of the high volatile bituminous coal starting material are also described. The carbon foam product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, beat or electrical insulator etc.

Abstract: The invention provides compositions of matter comprising coal body surfaces having improved characteristics for hydration and preservation of pristine surfaces, and which are compatible with both hydrophilic and hydrophobic liquid media. The coal body surfaces of the invention facilitate burning at low temperatures, avoiding emissions of nitrogen oxides, and also have improved properties for surfactant-free suspension in either water or oil media, as well as for liquefaction and gasification.

Abstract: The present invention is directed toward a method of solubilizing coal. The method includes providing coal and providing an oxoacid ester of phosphorus or a mixture of an oxoacid of phosphorus and an alcohol. A blend of the coal, the oxoacid ester of phosphorus or the mixture of the oxoacid of phosphorus and alcohol is formed. The blend is then treated under conditions effective to solubilize the coal.

Abstract: An ablation resistant, monolithic, activated, carbon foam produced by the activation of a coal-based carbon foam through the action of carbon dioxide, ozone or some similar oxidative agent that pits and/or partially oxidizes the carbon foam skeleton, thereby significantly increasing its overall surface area and concurrently increasing its filtering ability. Such activated carbon foams are suitable for application in virtually all areas where particulate or gel form activated carbon materials have been used. Such an activated carbon foam can be fabricated, i.e. sawed, machined and otherwise shaped to fit virtually any required filtering location by simple insertion and without the need for handling the “dirty” and friable particulate activated carbon foam materials of the prior art.

Abstract: A multistage process for drying coal in which coal is passed into a first fluidized bed reactor at a temperature of 300 to 550 degrees Fahrenheit, air is fed into the first reactor in order to maintain the density of the fluidized bed at from 20 to 50 pounds per cubic foot, and from about 40 to about 60 percent of the water from the coal is removed from the coal and the first reactor. The partially dried coal is then fed to a second fluidized bed reactor which is maintained at a temperature at least 50 degrees Fahrenheit higher than that present in the first reactor, and substantially all of the water remaining in the coal is removed from the coal.

Abstract: In drying coal to be used as fuel for a coal-fired boiler, the coal is dried at a temperature of 80 to 150° C. by using combustion exhaust gas having passed through an air heater for the coal-fired boiler. Moreover, after medium-quality or low-quality coal is heated to a temperature of 300 to 500° C. at a heating rate of not less than 100° C. per minute and then cooled to a temperature of 250° C. or below at a cooling rate of not less than 50° C. per minute, the resulting reformed coal is cooled to a temperature of 70° C. or below and stored for 1 month or more in a state of isolation from the atmosphere. In producing the aforesaid reformed coal, the medium-quality or low-quality coal is heated by using combustion exhaust gas obtained at the outlet of an economizer included in the coal-fired boiler equipment or at the outlet of a denitrator included therein.

Abstract: Processes and compositions are provided for decreasing emissions of mercury upon combustion of fuels such as coal. Various sorbent compositions are provided that contain components that reduce the level of mercury and/or sulfur emitted into the atmosphere upon burning of coal. In various embodiments, the sorbent compositions are added directly to the fuel before combustion; are added partially to the fuel before combustion and partially into the flue gas post combustion zone; or are added completely into the flue gas post combustion zone. In preferred embodiments, the sorbent compositions comprise a source of halogen and preferably a source of calcium. Among the halogens, iodine and bromine are preferred. In various embodiments, inorganic bromides make up a part of the sorbent compositions.

Abstract: Measurements are taken of moisture, BTU/lb (British Thermal Units per pound), ash, forms of sulfur, volatile material, grindability, and absorption properties of any of a wide variety of mine-run solid fuels. Using that information, a dry electromagnetic process technology has been developed that can be controlled and monitored to selectively alter and enhance metallurgical solid fuel properties. Specific changes include altering the mechanical structure and chemical composition of solid fuels such as coal, coal coke or petroleum coke, increasing the BTU/lb to optimum levels, decreasing all forms of sulfur, and decreasing ash, while maintaining the BTU/lb of the fuels. A new family of solid fuel designer coals not found in nature can be produced via these methods and apparatus.

Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.

Abstract: An amount of photosynthetic biomass such as wood is converted into coal such as charcoal and a substantial amount thereof is permanently stored until the atmospheric CO2 level is reduced to an extent which is unable to cause a greenhouse effect. While a main portion of the charcoal remains in permanent storage, a fraction thereof may be retained prior to or retrieved during or after achievement of the reduction in the atmospheric CO2 level. Such fraction is converted into energy or an energy source, for example hydrogen, in a manner such that thereby the atmospheric CO2 is maintained at a level which does not cause an undesired greenhouse effect.

Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.

Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of: starting materials, thermal treatment conditions and/or mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold and/or the use of fibrous carbonaceous layers to obtain selected reinforcement to enhance bending and/or impact resistance. Carbon foams of a homogeneous composition comprising at least fibrous carbonaceous mat as a reinforcing element are also described.

Abstract: Coal-based jet fuel, diesel fuel and/or distillate fuels are produced by selectively introducing a coal-based product directly into the petroleum refinery process flow to thereby create an integrated refinery process for producing the distillate fuels.

Abstract: A process of treating high sulfur coal to reduce sulfur dioxide emission when the high sulfur coal is burned comprising placing coal in pressure tank (16) of reduced pressure sufficient to fracture a portion of the coal by withdrawing ambient fluids trapped within the coal. The fractured coal is contacted with an aqueous silica colloid composition supersaturated with calcium carbonate via conduit (21), and the majority of the aqueous composition is then removed from contact with the coal. The aqueous composition-treated coal is pressurized in pressure tank (16) under a carbon dioxide atmosphere for a period of time sufficient for the calcium carbonate to enter fractures in the coal produced in the first step.

Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of starting materials, thermal treatment conditions and mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold.

Abstract: The present invention is directed to additives for coal-fired furnaces, particularly furnaces using a layer of slag to capture coal particles for combustion. The additive(s) include iron, mineralizer(s), handling aid(s), flow aid(s), and/or abrasive material(s). The iron and mineralizers can lower the melting temperature of ash in low-iron, high alkali coals, leading to improved furnace performance.

Abstract: Carbon foams exhibiting a dielectric constant of from about 2 to about 6 and simultaneously an electrical resistivity in the range of between about 1.E+00 ohm-cm and about 1.E+06 ohm-cm, demonstrate excellent radar emission absorptivity in the megahertz and gigahertz ranges.

Abstract: The present invention discloses methods to reduce dusting in bulk materials, such as coal. The method includes mixing with the bulk material either a fraction of the bulk material having an electrostatic charge opposite that of the remainder of the bulk material or a heterologous charge control agent having an electrostatic charge opposite that of the bulk material. The attractive forces between the opposite electrostatic charges agglomerate dust particles to larger particles that quickly settle to control dusting. Also disclosed are materials produced by the methods described above.

Abstract: A method of producing a synthetic fuel by treating fines of bituminous coal with an emulsion of a tall-oil mix, which may include enhancers that either increase the chemical change in the coal or reduce the cost of the synthetic fuel. Enhancers include poly vinyl acetate (PVA) and/or ethyl vinyl acetate (EVA), glycol, lignosulfonate, beet sugar bottoms, corn bottoms, brewery bottoms, vegetable tall oil, vegetable oil, and/or spent frying oil. The emulsion is sprayed into, and reacted with, the coal fines, resulting in a cost effective and industry-usable source of synthetic fuel.

Abstract: The ash content of raw coals, lignite, and other carbonaceous materials is reduced by leaching the high-ash material with an aqueous acidic waste product produced by a Fischer-Tropsch reaction. The acidic aqueous waste is mixed with coal and process conditions are described. The claim takes advantage of using otherwise uneconomic coal, lignite or other carbonaceous material by upgrading the material to a suitable feedstock for combustion in a power plant or gasifier.

Abstract: A self-contained, floating, waterway supplied and moveable synthetic fuel plant includes apparatus for receiving components of and for making synthetic fuel of coal and binder for energy consumers. Processes are disclosed.

Abstract: A method of preventing the generation of dust or agglomeration of particulate material comprising coal by applying to the particulate material a mixture of from about 45 to about 90 weight percent of glycerin, from about 5 to about 50 weight percent of water, about 0.5 to about 3 weight percent of fatty acids and esters thereof and from 2 to about 15 weight percent of water soluble salts, which has been diluted with about 10–400 weight percent of water. The diluted compositIon is applied in an affective amount to suppress agglomeration of particulate material and its adhesion to surfaces and to substantially prevent the generation of dust. The concentrated composition has a freezing point of at least ?35° C.

Abstract: A method of preparing a synthetic fuel from coal comprising applying to the coal an aqueous emulsion of one or more reactive polymers and thoroughly mixing the coal to yield a complete reaction of the coal with the reactive polymers, wherein the reactive polymers are selected from the group consisting of ethylene/vinyl acetate copolymers, ethylene/vinyl alcohol copolymers, poly(acrylic acid), poly(vinyl alcohol), vinyl alcohol/vinyl acetate copolymers, poly(vinyl acetate), vinyl acetate/acrylic acid copolymers, poly(vinyl acetate/acrylic acid/ethylene), acrylic acid/acrylamide copolymers and poly(acrylamide).

Abstract: A coal transformation system comprises an ecological coal production unit for transforming raw coal into ecological coal. The production unit has an exhaust for carrying in a storage unit combustible, gaseous, waste by-products generated during the transformation of raw coal. A control system is provided for allowing the combustible, gaseous, waste by-products to be withdrawn and subsequently used as an additional source of energy when the system energy demand reaches a predetermined value, thereby contributing to reduce the energy costs during peak power needs.

Abstract: A method of stabilizing a thermally beneficiated carbonaceous material is disclosed. The method includes the steps of supplying a charge of the carbonaceous material at an elevated temperature to a process vessel to form a packed bed and cooling the carbonaceous material to a target temperature by indirect heat exchange. The method is characterised by supplying an oxygen-containing gas to the packed bed to partially oxidise the carbonaceous material to a required degree to stabilize the carbonaceous material prior to the carbonaceous material reaching the target temperature. The method is also characterised by removing heat from the packed bed that is produced by oxidation of carbonaceous material to control the temperature of the carbonaceous material during oxidation to avoid thermal runaway.

Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.

Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.

Abstract: The present invention re lates to a liquid synfuel additive composition which is used as an additive to coal fines to enhance the complete combustion of the coal after turning it into a synthetic fuel. The composition is a chemical change agent in that it converts the coal/composition mix into a different material which, when burned, results in lower noxious emissions. The composition includes a wax, a base for ph adjustment and water.

Abstract: Coal-based cellular products that can be custom designed to have integral stiffeners or load paths, directed heat transfer paths, and/or directed mass transfer paths and methods for their production are described. Such design and production is made possible by the appropriate selection of: starting materials, thermal treatment conditions and/or mold materials combined in at least some instances with segregation of different starting materials in different regions of a forming mold and/or the use of fibrous carbonaceous layers to obtain selected reinforcement to enhance bending and/or impact resistance. Carbon foams of a homogeneous composition comprising at least fibrous carbonaceous mat as a reinforcing element are also described.

Abstract: Carbonaceous, composite tooling fabricated from pitch-based or coal-based cellular or porous products, “carbonaceous foams” having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 that are produced by: 1) conventional pitch foaming processes or; 2) the controlled beating of coal particulate preferably up to ¼ inch in diameter in a “mold” and under a non-oxidizing atmosphere. According to a specifically preferred embodiment, the starting material coal has a free swell index as determined by ASTM test D720 of between about 3.5 and about 5.0.

Abstract: A process for upgrading brown coal is disclosed, including providing at least two converging surfaces defining a nip, wherein at least one of the surfaces is rollable in a direction toward the nip; feeding the brown coal to the nip where, by the rolling action of the rollable surface, the brown coal is subjected to shearing stresses, causing attritioning of the microporous structure of the brown coal and the release of water contained in the micropores; and continuing the shearing attritioning until the brown coal forms into a plastic mass. Processes for the production of char are also disclosed utilizing as feed material pellets formed from the upgraded brown coal produced by the above process, as well as a process for recovering metal from a metal containing material.

Abstract: An apparatus and process for producing charcoal in a kiln from hardwood. The kiln is constructed over an array of hardwood logs supported on a suitable platform. Fill material is used to form a surrounding jacket surrounding the hardwood, a sawdust layer is applied over the surrounding jacket, and an airtight layer of clay earth and sand is applied over the sawdust layer. An ignition access port is provided through the several layers to allow ignition and combustion of the hardwood, after which the access port is closed to prevent air from entering the interior of the kiln during burning of the hardwood. After a predetermined burning time, the kiln and its contents are allowed to cool, and the filler, clay earth, sand and any remaining debris are removed from the hardwood. The hardwood is then cooled a second time, and then cooled a third time by stifling the hardwood, such as in a cooling box capped with earth.

Abstract: According to the present invention there is provided a coal-based carbon foam having a density of between about 0.1 g/cm3 and about 0.8 g/cm3, preferably between about 0.2 g/cm3 and about 0.6 g/cm3 and most preferably between about 0.3 g/cm3 and about 0.4 g/cm3 that is produced by the controlled heating of high volatile bituminous coal particulate in a “mold” and under a non-oxidizing atmosphere. The high volatile bituminous coal starting material preferably exhibits a free swell index of between about 3.5 and about 5.0 and most preferably between about 3.75 and about 4.5. A number of additional highly desirable characteristics of the high volatile bituminous coal starting material are also described. The carbon foam product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, heat or electrical insulator etc.

Abstract: The incorporation or blending of from about 1 to about 10% by volume of a “carbide precursor” powder, preferably on the order of <100 microns in size, with a coal particulate starting material and the subsequent production of carbon foam in accordance with the method described herein, results in a carbon foam that exhibits significantly enhanced abrasive characteristics typical of those required in the polishing of, for example glass, in the manufacture of cathode ray tubes.

Abstract: According to the present invention there is provided a porous coal-based material having a density of between about 0.1 g/cm3 and about 0.6 g/cm3 that is produced by the controlled heating of small coal particulate in a “mold” and under a non-oxidizing atmosphere. The coal starting material preferably exhibits a free swell index of between about 3.5 and about 5.0 and most preferably between about 4.0 and about 4.5. The porous product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, heat or electrical insulator etc. Such porous products, without further treatment exhibit compressive strengths of up to about 6000 psi. Further treatment by carbonization or graphitization yields products that can be used as electrical or heat conductors. Methods for the production of these coal-based cellular products are also described.

Abstract: Methods of controlling the bulk density, permeability, moisture retention and thermal properties of bulk materials are provided by selectively sizing the bulk material. Preferably, the bulk material is sized into successively smaller particle size fractions, with the largest fraction placed into a confined area. The next smaller size fraction is then added until the largest sized fraction begins to dilate. The next successive smaller size fraction is added until the mixture beams to dilate, with the process being continued until the smallest size fraction is used. Methods of decreasing the density of bulk materials are also provided.