US 2012/0031306 A1 · BRICKS AND METHOD OF FORMING BRICKS WITH HIGH COAL ASH CONTENT USING A PRESS MOLD MACHINE AND VARIABLE FIRING TRAYS

Abstract

There is provided an apparatus and process for manufacturing a brick or paver with a high content of coal ash (ranging from 60% to 100% coal ash or fly ash) so that a waste product (coal ash, and more particularly Class F coal ash) from a coal-fired power plant is incorporated into a building product (high content fly ash brick or paver). Also provided is a variable firing tray to support the dried, high content coal ash bricks/pavers as the dried products are sent through a tunnel kiln, to improve circulation around the individual bricks/pavers and thereby result in reduced firing time in the kiln.

Claims20

Dependent claims

A process for the manufacture of bricks by press molding, the process comprising:

a) providing a mixture of at least 60% fly ash and up to 40% of clay, shale, or a mixture thereof;
b) introducing the mixture from (a) to a press mold and molding the mixture into green bricks;
c) drying the green bricks for about 12 to 18 hours to render dried bricks;
d) loading the dried bricks onto variable firing trays and stacking the variable firing trays on kiln cars;
e) firing the dried bricks in a kiln for up to about 55 hours;
and
f) removing the fired bricks from the variable firing trays, wherein the process consumes about 560 BTUs per pound of manufactured brick.

4 more elements

Dependencies are inferred from the claim text.

Facts

Application

13/182,112Filed 13 Jul 2011

Priority

13 Jul 2010

Published

9 Feb 2012

Term ends

Not estimatedThe source records don’t support an estimate.

Classification26 codes

C04B 33/1352
Combustion residues, e.g. fly ash, incineration waste: fuel ashes, e.g. fly ash
B28B 5/025
The shaped articles being of definite length: the moulds or the moulding surfaces being divided by separating walls and being continuously fed
B28B 11/248
For curing, setting or hardening: supports for drying
B28B 15/00
General arrangement or layout of plant

Bricks and method of forming bricks with high coal ash content using a press mold machine and variable firing trays

Life of this patent

Bricks and method of forming bricks with high coal ash content using a press mold machine and variable firing trays

Life of this patent

Abstract

Claims20