Stable consolidated combustion ash material

• US 20030188668A1
• Filed: 12/19/2002
• Published: 10/09/2003
• Est. Priority Date: 07/20/1998
• Status: Active Grant

• Current Assignee: Alan Bland
• Original Assignee: The University of Wyoming Research Corporation
• Inventors: Bland, Alan E.
• Granted Patent: US 6,808,562 B2
• Time in Patent Office: Days
• US Class Current: 106/705
• CPC Class Codes: C04B 18/021 agglomerated by a mineral binder, e.g. cement
• CPC Class Codes: C04B 18/06 Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
• CPC Class Codes: C04B 18/061 Ashes from fluidised bed furnaces
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/106 Fly ash from waste incinerators
• CPC Class Codes: C04B 20/023 Chemical treatment
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 106/01 Fly ash
• CPC Class Codes: Y10S 264/49 Processes of using fly ash

Abstract

This invention discloses a system for cold bond processing of combustion ash which enhances various characteristics of the resulting cured consolidated combustion ash materials. Specifically, the invention relates to processing techniques which enhances both density and strength of the of the consolidated combustion ash materials. The invention also relates to processing techniques which control various chemical reactions which assure that certain types of minerals are formed in the proper amounts which results in a cured consolidated combustion ash material which has greater dimensional stability and enhanced resistance to degradation. Embodiments for both normal weight and light weight combustion ash aggregates are disclosed which meet various ASTM and AASHTO specifications.

Claims

1. A composition made from combustion ash, comprising:

a. an amount of combustion ash;

b. a high energy pore volume having an average pore volume equivalent to a pore volume achieved by combining approximately 2000 grams of combustion ash and between approximately 200 grams to approximately 800 grams of water using a N-50 Hobart mixer utilizing a level one speed for about one minute and a level two speed for at least two minutes; and

c. an amount of water combined with said amount of combustion ash.

2. A composition made from combustion ash as described in claim 1, wherein said amount of combustion ash and said amount of water have an initial water-combustion ash solids ratio between about 0.1 and about 0.4.

3. A composition made from combustion ash as described in claim 1, which further comprises a strength additive determined to achieve a selected strength of a cured consolidated material.

4. A composition made from combustion ash as described in claim 1, wherein said combustion ash is selected from the group consisting of fluidized bed combustion ash, pressurized fluidized bed combustion ash, Class C ash, off specification Class C ash, Class F, off specification Class F ash, Spray drier ash, sorbent injection ashes, or incinerator ash.

5. A composition made from combustion ash as described in claim 1, further comprising an amount of pore filling compound, wherein said amount of combustion ash and said amount of water have reacted to form a pore filling compound and a non-pore filling compound and wherein said non-pore filling compound is stoichiometric relative to said pore filling controlling compound.

6. A composition made from combustion ash as described in claim 5, wherein said combustion ash and said water combine to create a combination material and wherein said combination material has a pH greater than about 10.

7. A composition made from combustion ash as described in claim 6, wherein said combustion ash comprises at least two different types of combustion ash.

8. A composition made from combustion ash as described in claim 1, wherein said amount of water comprises a waste water selected from a group consisting of coal pile runoff, cooling tower blow down, paper mill effluent, industrial waste waters or seawater.

9. A composition made from combustion ash as described in claim 6, wherein said combustion ash and said amount of water are selected in amounts so as to establish a linear expansion selected from the group consisting of:

less than about 0.100 percent in a saturated bath, less than about 0.050 percent in a saturated bath, or less than about 0.010 percent in a saturated bath.

10. A composition made from combustion ash as described in claim 5, wherein said combustion ash and said water create a resultant cured consolidated combination material, and wherein said resultant cured consolidated combination material is meets specifications selected from the group consisting of:

ASTM specifications or AASHTO specifications.

11. A product made from a composition as described in claim 1, 3, 4, 5, 6, 7, 8, 9, or 10.

12. A product made from a composition as described in claim 11, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound have amounts and types which result in a product which meets specifications selected from the group consisting of:

ASTM specifications or AASHTO specifications.

13. A method of making a material from combustion ash, comprising the steps of:

a. selecting a combustion ash;

c. determining an amount of water;

d. using a high amount of energy to produce a combination material from said combustion ash and said amount of water; and

f. curing a consolidated combination material.

14. A method of making a material from combustion ash as described in claim 13, wherein said step of using a high amount of energy to produce a combination material from said combustion ash and said amount of water comprises the step of establishing a high energy pore volume having an average pore volume equivalent to a pore volume achieved by combining approximately 2000 grams of combustion ash and between approximately 200 grams to approximately 800 grams of water using a Hobart mixer utilizing a level one speed for about one minute and a level two speed for at least two minutes.

15. A method of making a material from combustion ash as described in claim 13, which further comprises the step of consolidating said combination material.

16. A method of making a material from combustion ash as described in claim 13, which further comprises the step of selecting a water-combustion ash solids ratio between about 0.1 and about 0.4.

17. A method of making a material from combustion ash as described in claim 14, which further comprises the steps of:

a. selecting an amount of strength of a cured consolidated material;

b. determining an amount of a strength additive to add to said approximate amount of said combustion ash; and

c. adding said approximate amount of strength additive to said combustion ash.

18. A method of making a material from combustion ash as described in claim 14, wherein said step of selecting a combustion ash comprises the step of selecting a combustion ash from a group consisting of fluidized bed combustion ash, pressurized fluidized bed combustion ash, Class C ash, off specification Class C ash, Class F ash, off specification Class F ash, Spray drier ash, sorbent injection ashes, incinerator ash, or flue gas desulferization ash.

19. A method of making a material from combustion ash as described in claim 14, which further comprises the step of combining said water, said combustion ash, and said precursor pore filling compound to form a pore filling compound and a non-pore filling compound and wherein said non-pore filling compound has an amount stoichiometric to said pore filling controlling compound.

20. A method of making a material from combustion ash as described in claim 19, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound are combined to create a combination material and which further comprises the step of establishing the pH of said said combination material at greater than about 10.

21. A method of making a material from combustion ash as described in claim 19, wherein said step of selecting combustion ash comprises the step of combining at least two different types of combustion ash.

22. A method of making a material from combustion ash as described in claim 14, wherein said step of determining an amount of water comprises the step of selecting waste water from a group consisting of coal pile runoff, cooling tower blow down, paper mill effluent, industrial waste waters or seawater.

23. A method of making a material from combustion ash as described in claim 14, which further comprises the step of establishing a linear expansion selected from a group consisting of:

less than about 0.100 percent in a saturated bath, less than about 0.050 percent in a saturated bath, and less than about 0.010 percent in a saturated bath.

24. A method of making a material from combustion ash as described in claim 19, which further comprise the steps of:

a. creating a resultant cured consolidated combination material; and

b. sizing said resultant cured consolidated combination material for standarrds which meets specifications selected from the group consisting of;

ASTM specifications or AASHTO.

25. A product made through use of the methods described in any one of claims 14, 17, 18, 19,20,21,22,23, or 24.

26. A product made through use of the methods described in claim 25, and further comprising the step of selecting the amount and type of said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound to result in a product which meets specifications selected from the group consisting of:

ASTM specifications or AASHTO.

27. A composition made from combustion ash, comprising:

a. an amount of combustion ash;

b. an amount of water combined with said amount of combustion ash;

c. a high energy pore volume having an average pore volume equivalent to a pore volume achieved by combining approximately 2000 grams of combustion ash and between approximately 200 grams to approximately 800 grams of water using a N-50 Hobart mixer utilizing a level one speed for about one minute and a level two speed for at least two minutes;

d. an amount of non-pore filling compounds stoichiometric to an amount of pore filling controlling compound and a remaining portion of a convertible precursor pore filling compound;

e. an amount of pore filling compound stoichiometric to said remaining portion of said convertible precursor pore filling compound; and

f. a portion of said average pore volume filled with said amount of pore filling compound.

28. A composition made from combustion ash as described in claim 27, further comprising a cured consolidation material from the product of step f.

29. A composition made from combustion ash as described in claim 27, wherein said amount of water and said amount of combustion ash have water-combustion ash solids ratio between about 0.1 and about 0.4.

30. A composition made from combustion ash as described in claim 27, further comprising an amount of strength additive determined to achieve a selected strength of cured consolidated mateial.

31. A composition made from combustion ash as described in claim 30, wherein said strength additive is selected from the group of compounds consisting of calcium oxide, soluble sulfates, soluble alumina, soluble silicates, calcium silicate, calcium aluminate, or calcium sulfo-aluminate.

32. A composition made from combustion ash as described in claim 28, wherein said cured consolidation material has a strength greater than about 1000 pounds per square inch.

33. A composition made from combustion ash as described in claim 32, wherein said amount of combustion ash is selected from a group consisting of fluidized bed combustion ash, pressurized fluidized bed combustion ash, Class C ash, off specification Class C ash, Class F ash, off specification Class Fash, Spray drier ash, sorbent injection ashes, or incinerator ash.

34. A composition made from combustion ash as described in claim 30, wherein said amount of water combined with said amount of combustion ash comprises:

a. a first portion of water sufficient to convert an amount of hydratable oxide to hydroxide leaving less than about five weight percent hydratable oxide relative to an amount of hydrated combustion ash; and

b. a second portion of water at least sufficient to covert said less than about five weight percent to hydrated combustion ash as hydratable oxide to hydroxide;

35. A composition made from combustion ash as described in claim 34, further comprising an amount of set retardant determined to allow processing of said amount of combustion ash and said amount of water.

36. A composition made from combustion ash as described in claim 35, wherein said amount of retardant equals an amount of sodium borate between about one weight percent and about two weight percent to said amount of combustion ash.

37. A composition made from combustion ash as described in claim 36, further comprising a light weight filler material added to said combination material.

38. A composition made from combustion ash as described in claim 27, wherein said amount of water is selected from the group of waste waters consisting of cooling tower blow down, coal pile runoff, cooling tower blow down, paper mill effluent, industrial waste waters or seawater.

39. A composition made from combustion ash as described in claim 28, wherein said amount of said portion of said average pore volume filled with said stoichiometric amount of pore filling compound comprises an amount of said pore filling compound insufficient to crack a cured consolidation material adjacent to said pore.

40. A composition made from combustion ash as described in claim 28, wherein said cured consolidated volume has a percent linear expansion of a surface dimension between of less than about 0.100 percent in a saturated bath.

41. A composition made from combustion ash as described in claim 28, wherein said cured consolidation volume has a density greater than 90 pounds per cubic foot.

42. A composition made from combustion ash as described in claim 28, wherein said cured consolidation volume has a density between about 60 pounds per cubic foot and 90 pounds per cubic foot.

43. A composition made from combustion ash as described in claim 28, wherein said consolidation material has a density of greater than 90 pounds per cubic foot having been compacted an amount equal to ASTM 698.

44. A composition made from combustion ash as described in claims 27, 30, 34, 39, or 41 wherein said cured consolidated volume meets ASTM specifications for normal weight aggregate for road base.

45. A composition made from combustion ash as described in claims 27, 30, 34, 39, 37 or 41, wherein said cured consolidated volume meets ASTM specifications for light weight aggregate for concrete.

46. A product manufactured from a composition from combustion ash as described in any one of claims 27, 30, 34, 35, 39, 41, or 43.

47. A method of making a material from combustion ash, comprising the steps of:

a. selecting a combustion ash;

b. determining an amount of combustion ash;

c. determining an amount of water;

d. determining an amount of pore filling controlling compound;

e. combining said water, said combustion ash, and said precursor pore filling controlling compound to form a pore filling compound and a non-pore filling compound and wherein said non-pore filling compound has an amount stoichiometric to said pore filling controlling compound;

f. establishing a high energy pore volume having an average pore volume to a pore volume achieved by combining approximately 2000 grams of combustion ash and between approximately 200 grams to approximately 800 grams of water using a N-50 Hobart mixer utilizing a level one speed for about one minute and a level two speed for between about ten and about twelve minutes;

g. consolidating a combination material; and

h. curing said consolidated combination material.

48. A method of making a material from combustion ash as described in claim 47, wherein said step of selecting said combustion ash comprises selecting said combustion ash from the group consisting of fluidized bed combustion ash, pressurized fluidized bed combustion ash, Class C ash, off specification Class C ash, off specification Class Fash, Spray drier ash, sorbent injection ashes, or incinerator ash.

49. A method of making a material from combustion ash as described in claim 47, which further comprises the steps of:

a. determining an amount of said strength additive; and

b. adding said approximate amount of strength additive to said combustion ash.

50. A method of making a material from combustion ash as described in claim 47, which further comprises the step of achieving a cured consolidated combination material having unconfined compressive strength of at least 1000 pounds per square inch.

51. A method of making a material from combustion ash as described in claim 49, wherein said step of selecting said combustion ash comprises selecting said combustion ash from the group consisting of:

PFBC ash, Class F ash, off specification Class F ash, off specification Class C ash, or incinerator ash.

52. A method of making a material from combustion ash as described in claim 47, which further comprises the step of adjusting the water-combustion ash solids ratio between about 0.1 to about 0.4.

53. A method of making a material from combustion ash as described in claim 52, wherein said step of adjusting the water-combustion ash solids ratio comprises adjusting the water-combustion ash solids ratio to achieve a density of said cured consolidated combination material of greater than 90 pounds per cubic foot.

54. A method of making a material from combustion ash as described in claim 52, wherein said step of adjusting the water-combustion ash solids ratio comprises adjusting the water-combustion ash solids ratio to achieve a density of said cured consolidated combination material of between about 60 to about 90 pounds per cubic foot.

55. A method of making a material from combustion ash as described in claim 47, which further comprises the steps of:

a. converting an amount of hydratable oxide to hydroxide leaving less than about five weight percent hydratable oxide to an amount of hydrated combustion ash;

b. expanding said combination material a first molar volume;

c. allowing said combination material to heat;

d. permitting a portion of said water to be driven from said combination material;

e. allowing said heat to dissipate from said combination material;

f. determining an amount of remaining oxide in said combination material;

g. adding a second amount of water to said combination material sufficient to convert said remaining hydratable oxide to hydrate; and

h. converting said amount of remaining hydratable oxide in said combination material to hydroxide.

56. A method of making a material from combustion ash as described in claim 55, wherein said step of selecting said combustion ash comprises selecting said combustion ash from a group consisting of fludized bed combustion ash, pressurized fluidized bed combustion ash, Class F ash, off specification Class F ash, spray drier ash, sorbent injection ashes, incinerator ash.

57. A method of making a material from combustion ash as described in claim 55, which further comprises the steps of:

a. selecting a set retardant;

b. determining an amount of set retardant; and

c. adding said amount of set retardant to said amount of combustion ash.

58. A method of making a material from combustion ash as described in claim 47, wherein said step of selecting a retardant comprises selecting sodium borate in an amount between about one to two percent.

59. A method of making a material from combustion ash as described in claim 57, which further comprises the steps of:

a. determining an amount of a light weight filler material; and

b. adding said light weight filler.

60. A method of making a material from combustion ash as described in claim 59, wherein said step of selecting said combustion ash comprises selecting said combustion ash from the group consisting of:

fluidized bed combustion ash, pressurized fluidized bed combustion ash, Class C ash, off specification Class C ash, off specification Class Fash, Spray drier ash, sorbent injection ashes, or incinerator ash.

61. A method of making a material from combustion ash as described in claim 47, wherein said step of determining an amount of water to add to said approximate amount of combustion ash comprises determining an approximate amount of waste water selected from the group consisting of cooling tower blow down,coal pile runoff, cooling tower blow down, paper mill effluent, industrial waste waters or seawater.

62. A method of making a material from combustion ash as described in claim 47, wherein said step of determining an amount of a pore filling controlling compound comprises varying the amount of pore filling controlling compound to select an amount of pore volume filled to less than one hundred percent.

63. A method of making a material from combustion ash as described in claim 47, wherein said step of determining an amount of a pore filling controlling compound comprises providing an amount of pore filling controlling compound to select an amount of pore volume filled greater than one hundred percent.

64. A method of making a material from combustion ash as described in claim 47, wherein said step of consolidating said combination material comprises using a ASTM 698 compactive effort to achieve a consolidated combination material density of a ASTM 1557 compactive effort.

65. A method of making a material from combustion ash as described in claim 47, which further comprises the step of mixing at least two types of combustion ash.

66. A method of making a material from combustion ash as described in any one of claims 47, 49, 55, 57, or 59 wherein said step of sizing said cured consolidate combination material comprises meeting ASTM standards for normal weight aggregate.

67. A method of making a material from combustion ash as described in any one of claims 47, 49, 55, 57, or 59, wherein said step of sizing said cured consolidate combination material comprises meeting specifications selected from the group consisting of:

ASTM specifications or AASHTO specifications for normal weight aggregate.

68. A material produced in accordance with the process of any one of claims 47, 49, 55, 57, or 59.

69. A manufactured material produced from a cured consolidated combination material made in accordance with the process of any one of claims 47, 49, 55, 57, or 59.

70. A composition made from combustion ash, comprising:

a. an amount of combustion ash;

b. an amount of hydratable oxide being a component of said combustion ash;

c. a first portion of water sufficient to convert an amount of hydratable oxide to an stoichiometric amount of hydroxide leaving less than about five weight percent to hydrated combustion ash as hydratable oxide; and

d. a second portion of water at least sufficient to covert said hydratable oxide less than about five weight percent to hydrated combustion ash to hydroxide.

71. A composition made from combustion ash as described in claim 70, which further comprises a high energy pore volume having an average pore volume equivalent to a pore volume achieved with a level one speed for about one minute and a level two speed for between about ten and about twelve minutes on a Hobart mixer.

72. A composition made from combustion ash as described in claim 71, which further comprises a strength additive determined to achieve a selected strength of a cured consolidated material.

73. A composition made from combustion ash as described in claim 71, wherein said combustion ash is selected from the group consisting of Class C ash, off specification Class C ash, off specification Class F ash, Spray drier ash, sorbent injection ashes, incinerator ash, or flu gas desulferization ash.

74. A composition made from combustion ash as described in claim 73, wherein said precursor pore filling compound is selected from the group consisting of calcium oxide, magnesium oxide, soluble sulfates, soluble alumina, soluble silicates, calcium silicate, calcium aluminate, or calcium sulfo-aluminate.

75. A composition made from combustion ash as described in claim 74, wherein said pore filling controlling compound is selected from the group consisting of carbon dioxide gases, soluble carbonates, carbonic acid or Mg(OH)₂.

76. A composition made from combustion ash as described in claim 70, wherein said pore filling controlling compound and said precursor pore filling compound have reacted to form a pore filling compound and a non-pore filling compound and wherein said pore filling controlling compound and said precursor pore filling compound are provided in amounts such that they result in a stoichiometric amount of non-pore filling compound relative to said pore filling compound.

77. A composition made from combustion ash as described in claim 76, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and wherein said combination material has a pH greater than about 10.

78. A composition made from combustion ash as described in claim 76, wherein said combustion ash comprises at least two different types of combustion ash.

79. A composition made from combustion ash as described in claim 76, wherein said water comprises a waste water selected from a group consisting of coal pile runoff, cooling tower blow down, paper mill effluent, industrial waste waters or seawater.

80. A product made from a composition as described in claim 70, 71, 73, 74, 75, or 76.

81. A product made from a composition as described in claim 80, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound have amounts and types which result in a product which meets specifications for normal weight aggregate for road base, meets specifications for concrete aggregate, meets ASTM 698 specifications, meets ASTM 1557 specifications, meets ASTM C-88 soundness index, or meets ASTM LA abrasion standards.

82. A method of making a material from combustion ash, comprising the steps of:

a. selecting combustion ash;

b. assessing an amount of hydratable oxide in said combustion ash;

c. determining a first portion of water sufficient to convert said amount of hydratable oxide to less than about five weight percent hydratable oxide of an amount of hydrated combustion ash;

d. combining said amount of water with said combustion ash;

e. converting said amount of hydratable oxide to less than about five weight percent hydratable oxide of an amount of hydrated combustion ash;

f. expanding a combination material to a first molar expansion volume;

g. allowing said combination material to heat;

h. permitting a portion of said water to be driven from said combination material;

i. adding said second amount of water to said combination material;

j. curing said consolidated combination material.

83. A method of making a material from combustion ash as described in claim 82, which further comprises the step of consolidating said combination material.

84. A method of making a material from combustion ash as described in claim 82, which further comprises the steps of:

a. determining an amount of remaining hydratable oxide in said combination material;

b. determining a second amount of water sufficient to convert said substantially all of the remaining hydratable oxide to hydrate; and

c. converting substantially all of said remaining hydratable oxide to hydroxide.

85. A method of making a material from combustion ash as described in claim 84, wherein said step of combining said amount of water with said combustion ash comprises the step of establishing a high energy pore volume having an average pore volume equivalent to a pore volume achieved with a level one speed for about one minute and a level two speed for between about ten and about twelve minutes on a Hobart mixer.

86. A method of making a material from combustion ash as described in claim 84, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and which further comprises the step of allowing said heat to dissipate from said combination material.

87. A method of making a material from combustion ash as described in claim 86, which further comprises the step of determining an amount of said combustion ash.

88. A method of making a material from combustion ash as described in claim 87, which further comprises the steps of:

a. selecting an amount of strength of a cured consolidated material;

b. determining an amount of a strength additive to add to said approximate amount of said combustion ash; and

c. adding said approximate amount of strength additive to said combustion ash.

89. A method of making a material from combustion ash as described in claim 87, which further comprises the steps of:

a. selecting a pore filling controlling compound;

b. determining an amount of pore filling controlling compound; and

c. adding said amount of pore filling controlling compound to said combustion ash.

90. A method of making a material from combustion ash as described in claim 87, wherein said step of selecting a combustion ash comprises the step of selecting a combustion ash from a group consisting of Class C ash, off specification Class C ash, off specification Class F ash, Spray drier ash, sorbent injection ashes, incinerator ash, or flu gas desulferization ash.

91. A method of making a material from combustion ash as described in claim 89, wherein said step of assuring the existence of a pore filling controlling compound comprises the step of selecting a pore filling controlling compound from a group consisting of calcium oxide, soluble sulfates, soluble alumina, soluble silicates, calcium silicate, calcium aluminate, or calcium sulfo-aluminate.

92. A method of making a material from combustion ash as described in claim 89, wherein said step of assuring the existence of a precursor pore filling compound comprises the step of selecting a precursor pore filling compound from a group consisting of carbon dioxide gases, soluble carbonates, carbonic acid or Mg(OH)₂.

93. A method of making a material from combustion ash as described in claim 82, which further comprises the step of reacting said pore filling controlling compound and said precursor pore filling compound to form a pore filling compound and a non-pore filling compound and wherein said steps of assuring the existence of a pore filling controlling compound and assuring the existence of a precursor pore filling compound comprise the steps of providing said pore filling controlling compound and said precursor pore filling compound in amounts such that they result in a stoichiometric amount of non-pore filling compound relative to said pore filling compound.

94. A method of making a material from combustion ash as described in claim 93, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound are combined to create a combination material and which further comprises the step of establishing the pH of said said combination material at greater than about 10.

95. A method of making a material from combustion ash as described in claim 94, wherein said step of selecting combustion ash comprises the step of combining at least two different types of combustion ash.

96. A method of making a material from combustion ash as described in claim 82, wherein said step of determining a first portion of water sufficient to convert said amount of hydratable oxide to less than about five weight percent hydratable oxide of an amount of hydrated combustion ash comprises the step of selecting waste water from a group consisting of coal pile runoff, cooling tower blow down, paper mill effluent, industrial waste waters or seawater.

97. A method of making a material from combustion ash as described in claim 82, wherein said step of combining said amount of water with said combustion ash comprises the step of establishing a high energy mix.

98. A method of making a material from combustion ash as described in claim 97, wherein said step of establishing a high energy mix comprises the step of establishing a high energy pore volume having an average pore volume equivalent to a pore volume achieved with a level one speed for about one minute and a level two speed for between about ten and about twelve minutes on a Hobart mixer.

99. A method of making a material from combustion ash as described in claim 98, which further comprises the step of establishing a linear expansion selected from a group consisting of:

less than about 0.100 percent in a saturated bath, less than about 0.050 percent in a saturated bath, and less than about 0.010 percent in a saturated bath.

100. A method of making a material from combustion ash as described in claim 93, further comprising the steps of:

a. creating a resultant cured consolidated combination material; and

b. sizing said resultant cured consolidated combination material for standarrds which meets specifications for normal weight aggregate for road base, meets specifications for concrete aggregate, meets ASTM 698 specifications, meets ASTM 1557 specifications, meets ASTM C-88 soundness index, or meets ASTM LA abrasion standards.

101. A product made through use of the methods described in any one of claims 82, 84, 85,90,91,92,93,94,96.

102. A product made through use of the methods described in claim 101, and further comprising the step of selecting the amount and type of said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound to result in a product which meets specifications for normal weight aggregate for road base, meets specifications for concrete aggregate, meets ASTM 698 specifications, meets ASTM 1557 specifications, meets ASTM C-88 soundness index, or meets ASTM LA abrasion standards.

103. A method of making a material from combustion ash, comprising the steps of:

a. selecting a combustion ash;

b. assuring the existence of a pore filling controlling compound;

c. assuring the existence of a precursor pore filling compound;

d. determining an amount of water to be added to said combustion ash, said pore filling controlling compound, and said precursor pore filling compound;

e. combining said water with said combustion ash, said pore filling controlling compound, and said precursor pore filling compound; and

f. establishing a high energy pore volume having an average pore volume equivalent to a pore volume achieved with a level one speed for about one minute and a level two speed for between about ten and about twelve minutes on a Hobart mixer.

104. A method of making a material from combustion ash as described in claim 103, wherein said combustion ash has an amount of hydratable oxide, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and which further comprises the steps of:

a. converting said amount of hydratable oxide to less than about five weight percent hydratable oxide;

b. expanding said combination material to a first molar expansion volume;

c. allowing said combination material to heat;

d. permitting a portion of said water to be driven from said combination material;

e. adding said second amount of water to said combination material;

f. curing said combination material.

105. A method of making a material from combustion ash as described in claim 103, wherein said step of selecting a combustion ash comprises the step of avoiding a fluidized bed combustion ash.

106. A method of making a material from combustion ash as described in claim 103, wherein said step of assuring the existence of a pore filling controlling compound comprises the step of avoiding a soluable silicate.

107. A method of making a material from combustion ash as described in claim 105, wherein said step of selecting a combustion ash comprises the step of selecting a combustion ash from a group consisting of FBC, PFBC, Class C ash, off specification Class C ash, off specification Class F ash, Spray drier ash, sorbent injection ashes, incinerator ash, or flu gas desulferization ash.

108. A method of making a material from combustion ash as described in claim 106, wherein said step of assuring the existence of a pore filling controlling compound comprises the step of selecting a pore filling controlling compound from a group consisting of, magnesium oxide, soluble sulfates, soluble alumina, or soluble silicates.

109. A method of making a material from combustion ash as described in claim 103, wherein said step of assuring the existence of a precursor pore filling compound comprises the step of selecting a precursor pore filling compound from a group consisting of carbon dioxide gases, soluble carbonates, carbonic acid or Mg(OH)₂.

110. A method of making a material from combustion ash as described in claim 105, which further comprises the step of reacting said pore filling controlling compound and said precursor pore filling compound to form a pore filling compound and a non-pore filling compound and wherein said steps of assuring the existence of a pore filling controlling compound and assuring the existence of a precursor pore filling compound comprise the steps of providing said pore filling controlling compound and said precursor pore filling compound in amounts such that they result in a stoichiometric amount of non-pore filling compound relative to said pore filling compound.

111. A method of making a material from combustion ash as described in claim 106, which further comprises the step of reacting said pore filling controlling compound and said precursor pore filling compound to form a pore filling compound and a non-pore filling compound and wherein said steps of assuring the existence of a pore filling controlling compound and assuring the existence of a precursor pore filling compound comprise the steps of providing said pore filling controlling compound and said precursor pore filling compound in amounts such that they result in a stoichiometric amount of non-pore filling compound relative to said pore filling compound.

112. A method of making a material from combustion ash as described in claim 109, which further comprises the step of reacting said pore filling controlling compound and said precursor pore filling compound to form a pore filling compound and a non-pore filling compound and wherein said steps of assuring the existence of a pore filling controlling compound and assuring the existence of a precursor pore filling compound comprise the steps of providing said pore filling controlling compound and said precursor pore filling compound in amounts such that they result in a stoichiometric amount of non-pore filling compound relative to said pore filling compound.

113. A method of making a material from combustion ash as described in claim 110, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound are combined to create a combination material and which further comprises the step of establishing the pH of said said combination material at greater than about 10.

114. A method of making a material from combustion ash as described in claim 111, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound are combined to create a combination material and which further comprises the step of establishing the pH of said said combination material at greater than about 10.

115. A method of making a material from combustion ash as described in claim 112, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound are combined to create a combination material and which further comprises the step of establishing the pH of said said combination material at greater than about 10.

116. A method of making a material from combustion ash as described in claim 113, wherein said steps of assuring the existence of a pore filling controlling compound and assuring the existence of a precursor pore filling compound comprise the steps of providing said pore filling controlling compound and said precursor pore filling compound in amounts such that they fill less than one hundred percent of said high energy pore volume.

117. A method of making a material from combustion ash as described in claim 114, wherein said steps of assuring the existence of a pore filling controlling compound and assuring the existence of a precursor pore filling compound comprise the steps of providing said pore filling controlling compound and said precursor pore filling compound in amounts such that they fill less than one hundred percent of said high energy pore volume.

118. A method of making a material from combustion ash as described in claim 115, wherein said steps of assuring the existence of a pore filling controlling compound and assuring the existence of a precursor pore filling compound comprise the steps of providing said pore filling controlling compound and said precursor pore filling compound in amounts such that they fill less than one hundred percent of said high energy pore volume.

119. A method of making a material from combustion ash as described in claim 116, wherein said combustion ash has an amount of hydratable oxide, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and which further comprises the steps of:

a. converting said amount of hydratable oxide to less than about five weight percent hydratable oxide;

b. expanding said combination material to a first molar expansion volume;

c. allowing said combination material to heat;

d. permitting a portion of said water to be driven from said combination material;

e. adding said second amount of water to said combination material;

f. curing said combination material.

120. A method of making a material from combustion ash as described in claim 117, wherein said combustion ash has an amount of hydratable oxide, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and which further comprises the steps of:

a. converting said amount of hydratable oxide to less than about five weight percent hydratable oxide;

b. expanding said combination material to a first molar expansion volume;

c. allowing said combination material to heat;

d. permitting a portion of said water to be driven from said combination material;

e. adding said second amount of water to said combination material;

f. curing said combination material.

121. A method of making a material from combustion ash as described in claim 118, wherein said combustion ash has an amount of hydratable oxide, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and which further comprises the steps of:

a. converting said amount of hydratable oxide to less than about five weight percent hydratable oxide;

b. expanding said combination material to a first molar expansion volume;

c. allowing said combination material to heat;

d. permitting a portion of said water to be driven from said combination material;

e. adding said second amount of water to said combination material;

f. curing said combination material.

122. A product made through use of the methods described in any one of claims 116, 117, or 118.

123. A product made through use of the methods described in any one of claims 103, 105, 106, 107, 108, 109, 110, 111, or 112.

124. A product made through use of the methods described in claim 122, and further comprising the step of selecting the amount and type of said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound to result in a product which meets specifications for normal weight aggregate for road base, meets specifications for concrete aggregate, meets ASTM 698 specifications, meets ASTM 1557 specifications, meets ASTM C-88 soundness index, or meets ASTM LA abrasion standards.

125. A product made through use of the methods described in claim 123, and further comprising the step of selecting the amount and type of said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound to result in a product which meets specifications for normal weight aggregate for road base, meets specifications for concrete aggregate, meets ASTM 698 specifications, meets ASTM 1557 specifications, meets ASTM C-88 soundness index, or meets ASTM LA abrasion standards.

126. A composition made from combustion ash, comprising:

a. an amount of combustion ash;

b. a high energy pore volume having an average pore volume equivalent to a pore volume achieved with a level one speed for about one minute and a level two speed for between about ten and about twelve minutes on a Hobart mixer;

c. an amount of water combined with said amount of combustion ash;

d. a pore filling controlling compound; and

e. a precursor pore filling compound.

127. A composition made from combustion ash as described in claim 126, wherein said combustion ash comprises a combustion ash which avoids fluidized bed combustion ash.

128. A composition made from combustion ash as described in claim 126, wherein said precursor pore filling compound comprises a precursor pore filling compound which avoidssoluable silicate.

129. A composition made from combustion ash as described in claim 127, wherein said combustion ash is selected from the group consisting of Class C ash, off specification Class C ash, off specification Class F ash, Spray drier ash, sorbent injection ashes, incinerator ash, or flu gas desulferization ash.

130. A composition made from combustion ash as described in claim 128, wherein said precursor pore filling compound is selected from the group consisting of calcium oxide, magnesium oxide, soluble sulfates, soluble alumina, soluble silicates, calcium silicate, calcium aluminate, or calcium sulfo-aluminate.

131. A composition made from combustion ash as described in claim 126, wherein said pore filling controlling compound is selected from the group consisting of carbon dioxide gases, soluble carbonates, carbonic acid or Mg(OH)₂.

132. A composition made from combustion ash as described in claim 127, wherein said pore filling controlling compound and said precursor pore filling compound have reacted to form a pore filling compound and a non-pore filling compound and wherein said pore filling controlling compound and said precursor pore filling compound are provided in amounts such that they result in a stoichiometric amount of non-pore filling compound relative to said pore filling compound.

133. A composition made from combustion ash as described in claim 128, wherein said pore filling controlling compound and said precursor pore filling compound have reacted to form a pore filling compound and a non-pore filling compound and wherein said pore filling controlling compound and said precursor pore filling compound are provided in amounts such that they result in a stoichiometric amount of non-pore filling compound relative to said pore filling compound.

134. A composition made from combustion ash as described in claim 131, wherein said pore filling controlling compound and said precursor pore filling compound have reacted to form a pore filling compound and a non-pore filling compound and wherein said pore filling controlling compound and said precursor pore filling compound are provided in amounts such that they result in a stoichiometric amount of non-pore filling compound relative to said pore filling compound.

135. A composition made from combustion ash as described in claim 132, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and wherein said combination material has a pH greater than about 10.

136. A composition made from combustion ash as described in claim 133, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and wherein said combination material has a pH greater than about 10.

137. A composition made from combustion ash as described in claim 134, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound combine to create a combination material and wherein said combination material has a pH greater than about 10.

138. A composition made from combustion ash as described in claim 135, wherein said pore filling controlling compound and said precursor pore filling compound have amounts which fill less than one hundred percent of said high energy pore volume.

139. A composition made from combustion ash as described in claim 136, wherein said pore filling controlling compound and said precursor pore filling compound have amounts which fill less than one hundred percent of said high energy pore volume.

140. A composition made from combustion ash as described in claim 137, wherein said pore filling controlling compound and said precursor pore filling compound have amounts which fill less than one hundred percent of said high energy pore volume.

141. A product made from a composition as described in claim 138, 139, or 140.

142. A product made from a composition as described in claim 126, 127, 128, 129, 130, 131, 132, 133, or 134.

143. A product made from a composition as described in claim 141, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound have amounts and types which result in a product which meets specifications for normal weight aggregate for road base, meets specifications for concrete aggregate, meets ASTM 698 specifications, meets ASTM 1557 specifications, meets ASTM C-88 soundness index, or meets ASTM LA abrasion standards.

144. A product made from a composition as described in claim 142, wherein said combustion ash, said water, said pore filling controlling compound, and said precursor pore filling compound have amounts and types which result in a product which meets specifications for normal weight aggregate for road base, meets specifications for concrete aggregate, meets ASTM 698 specifications, meets ASTM 1557 specifications, meets ASTM C-88 soundness index, or meets ASTM LA abrasion standards.