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US 5,935,885 AGranted
Manufacture of ceramic tiles from fly ash
AssigneeVortec Corporation
InventorsJames G. Hnat, Akshay Mathur, James C. Simpson
Life of this patent
Estimating the term…
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.
Claims32
A process of forming glass ceramic tiles comprising:
- providing a spent ash containing organic material, metallic contaminants, and glass forming materials;
- oxidizing the spent ash under conditions effective to oxidize the organic material and to partially oxidize the metallic contaminants and the glass forming materials, wherein said oxidizing is carried out in a suspension preheater in which the ash containing the organic material, metallic contaminants, and glass forming materials is suspended in an oxidizing fluid;
- vitrifying the oxidized glass forming materials to form a glass melt;
- forming the glass melt into glass ceramic tiles containing metallic contaminants.
1 more element
A process of forming glass ceramic tiles comprising:
- providing an ash containing organic material, metallic contaminants, and glass-forming materials;
- oxidizing the ash under conditions effective to oxidize the organic material and to partially oxidize the metallic contaminants and the glass forming materials, wherein said oxidizing is carried out in a suspension preheater in which the ash containing the organic material, the metallic contaminants, and glass-forming materials is entrained in an oxidizing fluid;
- vitrifying the oxidized glass-forming materials to form a glass melt, wherein said vitrifying is carried out in a cyclone melting chamber;
- forming the glass melt into tiles containing the metallic contaminants;
- cooling the tiles to effect nucleation;
- heating the tiles after said cooling to cause crystallization of said tiles, whereby the tiles become a glass ceramic;
- and
- glazing the heat treated tiles.
5 more elements
A process of forming glass ceramic tiles comprising:
- providing a spent ash containing organic material, metallic contaminants, and glass forming materials;
- oxidizing the spent ash under conditions effective to oxidize the organic material and to partially oxidize the metallic contaminants and the glass forming materials;
- vitrifying the oxidized glass forming materials to form a glass melt;
- and
- forming the glass melt into glass ceramic tiles containing metallic contaminants, wherein crystals are not formed in the glass melt until said forming.
2 more elements
A process of forming glass ceramic tiles comprising:
- providing a spent ash containing organic material, metallic contaminants, glass forming materials, and a nucleating agent;
- oxidizing the spent ash under conditions effective to oxidize the organic material and to partially oxidize the metallic contaminants and the glass forming materials;
- vitrifying the oxidized glass forming materials to form a glass melt;
- and
- forming the glass melt into glass ceramic tiles containing metallic contaminants.
2 more elements
A process of forming glass ceramic tiles comprising:
- providing a spent ash containing organic material, metallic contaminants, and glass forming materials;
- oxidizing the spent ash under conditions effective to oxidize the organic material and to partially oxidize the metallic contaminants and the glass forming materials;
- vitrifying the oxidized glass forming materials to form a glass melt;
- forming the glass melt into tiles containing metallic contaminants;
- cooling tiles to effect nucleation;
- heat treating the cooled tiles to cause crystallization, whereby the tiles become a glass ceramic;
- and
- glazing the heat treated tiles at an elevated temperature.
5 more elements
A process of forming glass ceramic tiles comprising:
- providing a spent ash containing organic material, metallic contaminants, and glass forming materials;
- oxidizing the spent ash under conditions effective to oxidize the organic material and to partially oxidize the metallic contaminants and the glass forming materials;
- vitrifying the oxidized glass forming materials to form a glass melt;
- forming the glass melt into tiles containing metallic contaminants;
- cooling the tiles to effect nucleation;
- glazing the cooled tiles;
- and
- heat treating the glazed tiles, whereby the tiles become a glass ceramic.
5 more elements
Dependencies are inferred from the claim text.