Coal combustion by-products-based lightweight structural materials and processes for making them
AssigneeBoard of Trustees of Southern Illinois University
InventorYoginder P. Chugh
Life of this patent
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Abstract
Mortar mixes comprising as a major part, Class F fly ash and fluidized bed combustion ash in amounts and proportions sufficient to reduce the negative effects of the presence of unburned carbon in the Class F fly ash and the presence of sulfate in the fluidized bed combustion ash and which mortar mixes also include, as a minor part, a cementitious material. The mortar produced by mixing the mortar mix with water can include a density reduction material and can be formed into support members for use in mines.
Claims81
A mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material.
A mortar comprising about 22 parts to about 35 parts by weight water per 100 parts by weight of a mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material.
A mortar comprising about 22 parts to about 35 parts by weight water per 100 parts by weight of a mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material, wherein the weight ratio of the Class F fly ash to the FBC ash is at most about 1:2.
A structural composition comprising a cured product of a mortar comprising about 22 parts to about 35 parts by weight water per 100 parts by weight of a mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material.
A structural composition comprising a cured product of a mortar comprising about 22 parts to about 35 parts by weight water per 100 parts by weight of a mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material, wherein the weight ratio of the Class F fly ash to the FBC ash is at most about 1:2 and the mortar mix comprises about 10% to about 25% by weight Class F fly ash, about 50% to about 85% by weight FBC ash, about 5% to about 30% by weight cementitious material, about 0.5-1.5% by volume fibers selected from the group consisting of cellulose, wool, cotton, hair, hemp, ramie, metal, carbon, boron, and polymeric fibers, and blends thereof, and a density reducer in an amount sufficient to provide a cured mortar having a density of from about 20 to about 50 pounds per cubic foot, and wherein the Class F fly ash contains calcium oxide in an amount of from about 8% to about 30% by weight.
A structural composition comprising a cured product of a mortar comprising about 22 parts to about 35 parts by weight water per 100 parts by weight of a mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material, wherein the weight ratio of the Class F fly ash to the FBC ash is at most about 1:2.
A structural composition comprising a cured product of a mortar comprising about 22 parts to about 35 parts by weight water per 100 parts by weight of a mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material, wherein the weight ratio of the Class F fly ash to the FBC ash is at most about 1:2 and the mortar mix comprises about 10% to about 25% by weight Class F fly ash, about 50% to about 85% by weight FBC ash, and about 5% to about 30% by weight cementitious material.
A method for preparing a mortar mix comprising mixing together into a mortar mix about 50% to about 85% by weight Class F fly-ash and about 1% to about 20% by weight fluidized bed combustion (FBC) ash;
- and about 5% to about 30% by weight cementitious material.
A method for preparing a mortar mix comprising mixing together into a mortar mix about 10% to about 25% by weight Class F fly-ash and about 50% to about 85% by weight fluidized bed combustion (FBC) ash;
- and about 5% to about 30% by weight cementitious material.
A method for preparing a mortar comprising mixing together about 22 parts to about 35 parts by weight water per 100 parts of a mortar mix that includes about 50% to about 85% by weight Class F fly-ash and about 1% to about 20% by weight fluidized bed combustion (FBC) ash;
- and about 5% to about 30% by weight cementitious material.
A method for preparing a mortar comprising mixing together about 22 parts to about 35 parts by weight water per 100 parts of a mortar mix that includes about 10% to about 25% by weight Class F fly-ash and about 50% to about 85% by weight fluidized bed combustion (FBC) ash;
- and about 5% to about 30% by weight cementitious material.
A method for making a coal combustion by-product-based structural member comprising the steps of:
- a. preparing a mortar by mixing about 22 parts to about 35 parts by weight water with 100 parts by weight of a mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material;
- b. molding the mortar into a shape;
- and
- c. curing the molded mortar into a structural member.
A support member for use in mining comprising a cured product of about 50% to about 85% by weight Class F fly-ash;
- about 1% to about 20% by weight fluidized bed combustion (FBC) ash;
- about 5% to about 30% by weight cementitious material;
- about 0.5-1.5% by volume fibers selected from the group consisting of cellulose, wool, cotton, hair, hemp, ramie, metal, carbon, boron, and polymeric fibers, and blends thereof;
- about 22 parts to about 35 parts by weight water per 100 parts combined weight of the Class F fly-ash, the FBC ash, the cementitious material and the fibers;
- and a density reducer;
- the cured product having a density of from about 50 to about 100 pounds per cubic foot.
A support member for use in mining comprising a cured product of about 10% to about 20% by weight Class F fly-ash;
- about 50% to about 85% by weight fluidized bed combustion (FBC) ash;
- about 5% to about 30% by weight cementitious material;
- about 0.5-1.5% by volume fibers selected from the group consisting of cellulose, wool, cotton, hair, hemp, ramie, metal, carbon, boron, and polymeric fibers, and blends thereof;
- about 30 parts to about 45 parts by weight water per 100 parts combined weight of the Class F fly-ash, the FBC ash, the cementitious material and the fibers;
- and a density reducer;
- the cured product having a density of from about 20 to about 50 pounds per cubic foot.
A method of supporting a mine ceiling, the mine also having a floor, comprising installing between the ceiling and the floor of the mine a support member comprising a cured product of about 50% to about 85% by weight Class F fly-ash;
- about 1% to about 20% by weight fluidized bed combustion (FBC) ash;
- about 5% to about 30% by weight cementitious material;
- about 0.5-1.5% by volume fibers selected from the group consisting of cellulose, wool, cotton, hair, hemp, ramie, metal, carbon, boron, and polymeric fibers, and blends thereof;
- about 22 parts to about 35 parts by weight water per 100 parts combined weight of the Class F fly-ash, the FBC ash, the cementitious material and the fibers;
- and a density reducer;
- the cured product having a density of from about 50 to about 100 pounds per cubic foot.
A method of supporting a mine ceiling, the mine also having a floor, comprising installing between the ceiling and the floor of the mine a support member comprising a cured product of about 10% to about 20% by weight Class F fly-ash;
- about 50% to about 85% by weight fluidized bed combustion (FBC) ash;
- about 5% to about 30% by weight cementitious material;
- about 0.5-1.5% by volume fibers selected from the group consisting of cellulose, wool, cotton, hair, hemp, ramie, metal, carbon, boron, and polymeric fibers, and blends thereof;
- about 30 parts to about 45 parts by weight water per 100 parts combined weight of the Class F fly-ash, the FBC ash, the cementitious material and the fibers;
- and a density reducer;
- the cured product having a density of from about 20 to about 50 pounds per cubic foot.
Dependencies are inferred from the claim text.