In an earlier dispatch, now accessible on the West Virginia Coal Association's web site via the link:
Wyoming Converts Coal Ash to Construction Aggregates | Research & Development; concerning: United States Patent 6,334,895 - Producing Manufactured Materials from Coal Combustion Ash; 2002; Inventor: Alan Bland, Wyoming; Assignee: The University of Wyoming Research Corporation; 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";
we documented that the University of Wyoming had developed an economical process for converting some solid Coal Utilization Byproducts into a variety of "aggregates", replacements for crushed stone and other materials, that met the applicable standards for use in road, and other, construction.
Herein, we learn that they continued to refine and improve their technology for the "cold bond processing" of Coal Ash, with the result being the capability to manufacture a greater range of both lightweight and standard construction aggregates from Coal Ash, and, which Coal Ash aggregates exhibit even better physical properties, relative to the established standards for conventional construction aggregates.
The Coal Ash synthetic aggregates are so good, in fact, that they have even been given a name.
Comment follows, and is inserted within, excerpts from the initial link in this dispatch to:
"United States Patent 6,517,631 - Producing a Coal Combustion Ash Composition
Date: February, 2003
Inventor: Alan Bland, Wyoming
(A note about Alan Bland: He is now Vice President of the "Western Research Institute", aka "WRI", which was originally established as a quasi-governmental think tank to help the petroleum industry develop oil and gas extraction technologies. WRI is situated on the campus of the University of Wyoming; and, more can be learned via:
WRI - History; wherein we're told: "Western Research Institute has developed with the West and evolved to meet global needs. WRI, an independent research corporation, was established in 1983 when the U.S. Department of Energy de-federalized the Laramie Energy Technology Center. Our timeline, however, stretches back to 1924, when a petroleum research station was established here by the Bureau of Mines to support development of Wyoming’s petroleum resources. During World War II, research was directed to the sources and characterization of aviation fuels. Asphalt research began in 1964 and to this day, WRI has continued to build on this lead. Shale oil and underground gasification programs were at the fore of research here during the 1970s. The energy program was augmented in the 80s by an analytical laboratory business, which now has been refocused to offer only non-routine, specialized analyses not available elsewhere. Today, Western Research Institute is a leader in materials research and technology development to meet energy, environmental and transportation materials needs."
And, we might as well deliver a punch line here: So successful is Bland's, and the University of Wyoming's, technology for the conversion of Coal Ash into construction aggregates, that WRI and the University of Wyoming have begun to market the products, and the technology.
It is called "Synag"(TM), and, more can be learned via:
WRI - SYNAG™ Synthetic Aggregate Process; wherein we're told: "The market for construction-grade aggregate in the United States offers a significant opportunity for the use of coal ashes. In WRI’s patented SYNAG (TM) process, specialized chemicals are used to cold-bond fly ash to produce a hardened product that can be crushed and sized for construction applications. The product has the properties of construction aggregate as specified by ASTM and AASHTO the American Association of State Highway Transportation Officials). The SYNAG (TM) process is cost-competitive with other processes for producing synthetic aggregate, and the resulting product is competitive with natural materials. Although process economics are determined by ash availability and transportation costs, estimated costs for synthetic aggregate produced using the SYNAG (TM) process are significantly lower than for other synthetic aggregates.")
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: A method of generating a combustion ash composition, comprising the steps of: a. providing an amount of combustion ash; b. providing an amount of water having a weight of about 10% to about 40% relative to the weight of said combustion ash; c. mixing said amount of combustion ash and said amount of water; and d. reducing the average pore volume of the generated combustion ash composition to between about 15% to about 40%.
A method of generating a combustion ash composition ... wherein said combustion ash is selected from the group consisting of fluidized bed combustion ash, pressurized fluidized combustion ash, Class C ash, off specification Class C ash, Class F ash, off specification Class F ash, CFBC ash, spray drier ash, sorbent injection ashes, and incinerator ash.
A method of generating a combustion ash composition ... wherein said combustion ash comprises Class F, and wherein said strength additive is selected from the group consisting of Portland Cement, Class C ash, lime, and self cementing ash.
(If we do, as immediately above, need a little "Portland"-type cement to help "cold bond" the Coal Ash, we remind you, that, as in:
Exxon Converts Coal Conversion Residues to Cement | Research & Development; concerning: "United States Patent 4,260,421 - Cement Production from Coal Conversion Residues; 1981; Exxon Research and Engineering Company; Abstract: Cement is produced by feeding residue solids containing carbonaceous material and ash constituents obtained from converting a carbonaceous feed material into liquids and/or gases into a cement-making zone and burning the carbon in the residue solids to supply at least a portion of the energy required to convert the solids into cement"; and, in:
US Government Coal Ash Cement Stronger than Portland Cement | Research & Development; concerning: "United States Patent 4,256,504 - Fly Ash-based Cement; 1981; The United States of America (as represented by the Secretary of the Interior); Abstract: A cement composition comprising a high calcium-content fly ash and calcium sulfate, and mortar and concrete compositions containing the cement";
we have some intriguing options available to us for consuming additional Coal Utilization Byproducts in the making of a perfectly-acceptable substitute for that Portland Cement.).
A method of generating a combustion ash composition ... which further comprise the steps of: a. generating a cured combustion ash composition; and b. sizing said cured combustion ash composition to meet specifications selected from the group consisting of ASTM specifications and AASHTO specifications.
A method of generating a combustion ash composition ... wherein said step of providing an amount of 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, and incinerator ash.
(One) option involves the direct contacting of a high CO2 -rich gas with the ash. Conceptually, the contacting of the high lime ash with a gaseous CO2 stream such as flue gas or enriched flue gas could be an option for ashes with high free lime contents in that direct gas contacting may be more economical. The contacting mechanism would most likely be integrated with the hydration or pre-conditioning step. The CO2 would react with the CaO or Ca(OH)2 in the ash and form a carbonate as in the case of soluble carbonate addition.
There may be an economical basis for capturing CO2 from the flue gas and producing a CO2 rich gas for carbonation of the ash".
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Now, how about that: Not only can we make perfectly-acceptable, and lower-cost, construction aggregates out of our solid Coal Utilization Byproducts, we can make some of those aggregates in a "more economical" way by effecting one of the needed chemical reactions through the use of "a gaseous CO2 stream such as flue gas".
And, again: "Synag"(TM) is now, apparently, not only a product, but, a commercial and available technology that enables the productive and profitable consumption and use of solid Coal Utilization Byproducts.
We'll have a little more to report on the University of Wyoming's basis for their, and WRI's, Synag(TM)technology in a report or two to follow.
But, herein, again, we have further documentation of the fact that all of our Coal Utilization Byproducts, even, as in our final excerpted statement concerning the use of Carbon Dioxide for the "carbonation of the ash", to make a better Synag(TM) product, the gaseous ones, can find profitable employment in our nation's other economic, and environmental, arenas.
Far past time the US citizens in the very heart of US Coal Country, and their elected representatives, were treated to a little public education on the matter, don't you think?