Stock material or miscellaneous articles – Compacted trash or refuse bundle
Reexamination Certificate
1997-03-24
2001-01-30
Vargot, Mathieu D. (Department: 1732)
Stock material or miscellaneous articles
Compacted trash or refuse bundle
C264S109000, C264S122000, C428S423100
Reexamination Certificate
active
06180192
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to solids for use as bricks, building blocks, landscaping blocks, walkway stones, railroad ties, building blocks, steps, retaining wall blocks and other structural components. In particular, this invention provides for the use of a substantial proportion of bottom ash combined with a polymeric binder and optionally other components including fly ash in a feed mixture material to be pressed and dried to form solids, including building blocks, landscaping blocks and the like.
Wood-burning power plants produce large quantities of bottom ash and fly ash. Bottom ash presents disposal and handling difficulties because it is relatively heavy, wet, and is inconsistent in terms of texture and components. The major components of bottom ash include ash, wood, unburned carbons and sand. Heretofore this material has been primarily landfilled, although some attempts have been made to use it.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a process for economically and environmentally recovering bottom ash produced by power plants, and especially wood-burning power plants. It is another object of this invention to produce solids including building blocks, landscaping blocks and the like from bottom ash generated by burning of scrap wooden railroad ties. It is an another object to provide railroad ties which have the strength of concrete ties, the density of wooden ties, and a high bottom ash content.
Briefly, therefore, the invention is directed to a compressed solid produced from a feed mixture comprising bottom ash and a binder, the feed mixture comprising at least about 50% by weight bottom ash.
The invention is also directed to a compressed solid for use as a building block, landscaping block or walkway stone produced by pressing and drying a feed mixture comprising about 80-95% by weight wood burning bottom ash and about 5-20% binder. The block has a compressive strength in the range of about 1000-10,000 psi and a flexural strength of at least about 500 psi. The bottom ash contains about 5-20% water, and the binder is selected from the group consisting of an isocyanatebased binder and an isocyanate-based binder in mixture with a polyol.
The invention is further directed to a compressed solid for use as a building block, landscaping block or walkway stone produced by pressing and drying a feed mixture comprising at least about 50% by weight first filler material consisting of wood burning bottom ash, 5-45% by weight second filler material, and about 5-20% binder. The block has a compressive strength in the range of about 1000-10,000 psi and a flexural strength of at least about 500 psi, the bottom ash contains about 5-20% water, and the binder is selected from the group consisting of an isocyanate-based binder and an isocyanate-based binder in mixture with a polyol.
Still further, the invention is directed to a process for producing a compressed solid from filler material comprising bottom ash., A filler material comprising at least about 50% bottom ash is mixed with a binder to form a feed mixture material of bottom ash and binder in intimate admixture. The feed mixture material is pressed into a solid shape suitable for use as a building block, landscaping block, or walkway stone.
Other objects and features of the invention will be in part apparent and in part pointed out hereinafter.
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Frisch Kurt C.
Klempner Daniel
Sendijarevic Vahid
Smith Greg M.
Senniger Powers Leavitt & Roedel
Vargot Mathieu D.
Wood Waste Energy, Inc.
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