Bricks and method of forming bricks with high coal ash content using a press mold machine and variable firing trays
AssigneesThe Belden Brick Company, LLC, Eco-Ash, LLC
InventorsRobert Thomas Belden, Michel Cristallo, George W. Ittmann, Robert W. Ittmann
Life of this patent
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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.
Claims21
A process for the manufacture of bricks or pavers by press molding, the process comprising:
- a) providing a mixture of at least 60% by weight fly ash and up to 40% by weight of clay, shale, or a mixture thereof;
- b) introducing the mixture from (a) to a press mold and molding the mixture into green bricks or pavers;
- c) arranging the press molded bricks or pavers in stacks and drying the green bricks or pavers for about 12 to 18 hours to render dried bricks or pavers;
- d) after the drying step, loading the dried bricks or pavers onto variable firing trays and stacking the variable firing trays on kiln cars;
- e) firing the dried bricks or pavers in a kiln for up to about 55 hours after the loading step;
- and
- f) removing the fired bricks or pavers from the variable firing trays, wherein the process consumes about 560 BTUs per pound of manufactured brick or paver.
A process for the manufacture of bricks by press molding, the process comprising:
- a) providing a mixture of at least 60% by weight fly ash and up to 40% by weight 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;
- f) removing the fired bricks from the variable firing trays, wherein the process consumes about 560 BTUs per pound of manufactured brick;
- and
- g) using ground glass in a total amount of approximately 1-5% by weight of the mixture.
A process for the manufacture of bricks by press molding and subsequently used as a filter material, the process comprising:
- a) providing a mixture of at least 60% by weight fly ash and up to 40% by weight 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, wherein the manufactured brick is ground and used as filter material to remediate solids contaminated with hazardous waste materials.
Dependencies are inferred from the claim text.