Coal combustion by-products-based lightweight structural materials and processes for making them
First Claim
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1. A mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material.
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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.
170 Citations
81 Claims
- 1. A mortar mix comprising synergistic amounts of Class F fly ash and fluidized bed combustion (FBC) ash, and a cementitious material.
- 7. 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.
- 26. 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:
- 42. 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.
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47. 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.
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48. 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.
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49. 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.
- View Dependent Claims (50, 51)
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52. 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.
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53. 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.
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54. 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.
- View Dependent Claims (55, 56)
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57. 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.
- View Dependent Claims (58, 59)
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60. A method for making a coal combustion by-product-based structural member comprising the steps of:
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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. - View Dependent Claims (61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71)
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72. 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. - View Dependent Claims (73, 74, 75, 76, 77, 78)
- about 1% to about 20% by weight fluidized bed combustion (FBC) ash;
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79. 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.
- about 50% to about 85% by weight fluidized bed combustion (FBC) ash;
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80. 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.
- about 1% to about 20% by weight fluidized bed combustion (FBC) ash;
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81. 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.
- about 50% to about 85% by weight fluidized bed combustion (FBC) ash;
Specification