A system and method for producing a modified coal ash involves collecting a bulk quantity of such coal ash, generally after it has been produced or landfilled, or is otherwise at temperatures closer to ambient, as opposed to power plant operational temperatures. In one possible implementation, the method herein involves removing carbon from the coal ash, such removal occurring by exposing the carbon to indirect heat, that is, externally-applied heat. For coal ashes with higher ash content. This removal is accomplished by subjecting the coal ash stream to heat, in one implementation, ranging between 850? F. and 1200? F., and such heat exposure occurring from about 10 minutes to about 30 minutes. The range of exposure time for the coal ash is determined so as to reduce the LOI from its initial level to a level acceptable for intended re-use or recycling. In one application, the LOI of carbon in the ash is reduced to 3% or less carbon. Upon completion of the range of the exposure time, the coal ash stream is removed from the sublimation heat, thereby forming a modified coal ash.

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses described, including survival bunkers, composting pits, mine reclamation encapsulation and carbon sequestration facilities, water storage facilities, compressed air storage facilities, carbon sequestration/mineral carbonation facilities and a pumped hydroelectric facility adapted for use with a lock system of a waterway.

Beneficial use structures are disclosed that include coal combustion residuals (CCR) mixed with water and a binder to form a structural material and adapted to be compacted for use in the formation of the beneficial use structure. Various structures having beneficial uses described, including survival bunkers, composting pits, mine reclamation encapsulation and carbon sequestration facilities, water storage facilities, compressed air storage facilities, carbon sequestration/mineral carbonation facilities and a pumped hydroelectric facility adapted for use with a lock system of a waterway.

Sorbent components containing halogen, calcium, alumina, and silica are used in combination during coal combustion to produce environmental benefits. Sorbents such as calcium bromide are added to the coal ahead of combustion and other components are added into the flame or downstream of the flame, preferably at minimum temperatures to assure complete formation of the refractory structures that result in various advantages of the methods. When used together, the components reduce emissions of elemental and oxidized mercury; increase the level of Hg, As, Pb, and/or Cl in the coal ash; decrease the levels of leachable heavy metals (such as Hg) in the ash, preferably to levels below the detectable limits; and make a highly cementitious ash product.

Sorbent components containing halogen, calcium, alumina, and silica are used in combination during coal combustion to produce environmental benefits. Sorbents such as calcium bromide are added to the coal ahead of combustion and other components are added into the flame or downstream of the flame, preferably at minimum temperatures to assure complete formation of the refractory structures that result in various advantages of the methods. When used together, the components reduce emissions of elemental and oxidized mercury; increase the level of Hg, As, Pb, and/or Cl in the coal ash; decrease the levels of leachable heavy metals (such as Hg) in the ash, preferably to levels below the detectable limits; and make a highly cementitious ash product.

A method for treating powdered activated carbon (PAC) and/or coal combustion residues (CCRs) by heating at least one of a spent PAC and/or a CCR to separate at least one heavy metal from the at least one of the spent PAC and/or the CCR to create a clean stream and a heavy metal stream, combining the heavy metal stream with a water soluble alkaline-earth metal sulfide to create a combined stream, and removing at least a portion of the at least one heavy metal from the combined stream. The heating may further include heating the at least one of the spent PAC and/or the CCR in an inert atmosphere. Further, the combining may include combining the heavy metal stream with the water soluble alkaline-earth metal sulfide and a catalyst and/or a surfactant or hyperdispersant.

A method of producing an additively manufactured casting mould for the production of components using the cold casting process or lamination process, comprising the steps of a) determining a three-dimensional structure of the casting mould, b) providing a mixture, the mixture comprising a binding agent and an aggregate, c) providing a printing fluid comprising an aqueous solution of magnesium chloride or magnesium sulfate, d) applying a layer of the mixture to a support, e) applying the printing fluid only to those parts of the mixture which are supposed to constitute a part of the casting mould, f) applying a further layer of the mixture to the previous layer of the mixture, g) applying the printing fluid only to those parts of the mixture which are supposed to constitute a part of the casting mould, h) repeating steps f) and g) until the desired shape of the casting mould is achieved, i) allowing those parts of the mixture to set which have been mixed with the aqueous solution of magnesium chloride or magnesium sulfate, j) removing the mixture which has not been mixed with an aqueous solution, and coating with a formwork skin at least those parts of the casting mould which come into contact with the material of the cold-casting lamination process.

A method of producing an additively manufactured casting mould for the production of components using the cold casting process or lamination process, comprising the steps of a) determining a three-dimensional structure of the casting mould, b) providing a mixture, the mixture comprising a binding agent and an aggregate, c) providing a printing fluid comprising an aqueous solution of magnesium chloride or magnesium sulfate, d) applying a layer of the mixture to a support, e) applying the printing fluid only to those parts of the mixture which are supposed to constitute a part of the casting mould, f) applying a further layer of the mixture to the previous layer of the mixture, g) applying the printing fluid only to those parts of the mixture which are supposed to constitute a part of the casting mould, h) repeating steps f) and g) until the desired shape of the casting mould is achieved, i) allowing those parts of the mixture to set which have been mixed with the aqueous solution of magnesium chloride or magnesium sulfate, j) removing the mixture which has not been mixed with an aqueous solution, and coating with a formwork skin at least those parts of the casting mould which come into contact with the material of the cold-casting lamination process.

Techniques are disclosed for providing a high-strength, water-resistant, fire-proof magnesium oxysulfate (MOS) plate. In accordance with some embodiments, the MOS plate may include one or more fibrous layers disposed within a sizing agent. The sizing agent may include backing materials, intermediate materials, and surface materials components. In some embodiments, the sizing agent may be homogeneous, such that its backing, intermediate, and surface materials components are all of the same material composition. In other embodiments, the sizing agent may be heterogeneous, such that one or more of its backing, intermediate, and surface materials components differ in material composition relative to other component(s). In accordance with some embodiments, a MOS plate provided via the disclosed techniques may be utilized, for example, as a cementitious skin of a structural insulated panel (SIP).

Techniques are disclosed for providing a high-strength, water-resistant, fire-proof magnesium oxysulfate (MOS) plate. In accordance with some embodiments, the MOS plate may include one or more fibrous layers disposed within a sizing agent. The sizing agent may include backing materials, intermediate materials, and surface materials components. In some embodiments, the sizing agent may be homogeneous, such that its backing, intermediate, and surface materials components are all of the same material composition. In other embodiments, the sizing agent may be heterogeneous, such that one or more of its backing, intermediate, and surface materials components differ in material composition relative to other component(s). In accordance with some embodiments, a MOS plate provided via the disclosed techniques may be utilized, for example, as a cementitious skin of a structural insulated panel (SIP).