A method of preparing a concrete composition for downhole injection includes utilizing a controller to control a process including circulating process water in a process water supply loop for a predetermined period while monitoring and controlling the temperature and flow rate of the process water, circulating aqueous-based air entrainment solution in an aqueous-based air entrainment solution supply loop for the predetermined period and controlling the flow rate of the aqueous-based air entrainment solution and after the predetermined period of time in which the flow of process water and aqueous-based air entrainment solution have stabilized, simultaneously actuating valves to divert and mix the process water, the aqueous-based air entrainment solution and compressed air to produce an air-entrained foam and mixing the foam with a concrete composition to be deployed downhole.

A system and method for introducing a slurry mixture for making gypsum board is disclosed. The system includes a mixer for mixing slurry and directing it to an exit gate, a foam injector for injecting foam into the slurry, and a canister connected to the mixer for inducing swirl to the slurry. The system also includes an elongated hose and an optional adapter for depositing the slurry onto paper to form the board. Ends of the elongated hose are coupled to the canister and to the inlet of the adapter. Slurry is directed from the canister, through the hose, and into the adapter for exiting its outlet. Optionally, a mixing boot and/or elbow joints may be included. Use of the hose and adapter enhances the flexibility of the system, including moving the mixer offline or adjacent to the paper or belt, and improves foam blending in the slurry mixture.

A system and method for introducing a slurry mixture for making gypsum board is disclosed. The system includes, for example, a mixer, a foam injector, and a canister for mixing and moving a slurry mixture of foam and gypsum slurry. Also included in the system is an apparatus having a funnel body constructed and arranged to further mix the slurry mixture. The funnel body includes a number of baffles projecting from its inner wall towards a center and that are spaced around the inner wall. The baffles induce turbulence into the slurry mixture as the slurry mixture moves towards its outlet, thus further mixing the mixture and reducing the flow rate of the slurry mixture before its exits from the outlet for depositing onto paper to form the gypsum board.

A method of preparing a concrete composition for downhole injection includes utilizing a controller to control a process including circulating process water in a process water supply loop for a predetermined period while monitoring and controlling the temperature and flow rate of the process water, circulating aqueous-based air entrainment solution in an aqueous-based air entrainment solution supply loop for the predetermined period and controlling the flow rate of the aqueous-based air entrainment solution and after the predetermined period of time in which the flow of process water and aqueous-based air entrainment solution have stabilized, simultaneously actuating valves to divert and mix the process water, the aqueous-based air entrainment solution and compressed air to produce an air-entrained foam and mixing the foam with a concrete composition to be deployed downhole.

This disclosure describes volumetric mobile powder mixer (VMPM) systems and methods for VMPM operation and use. The VMPM is providing with a number of storage compartments (or bins) for liquid or solid ingredients including at least one powder storage bin, a powder transport system, a dust handling system, a solid/liquid mixing system, a cellular foam generator, a product delivery system, and a controller capable of monitoring the delivery and mixing of each of the ingredients, as well as the discharge of the final product. The controller determines if the proper mixture is being discharged by the VMPM and, if not, alerts the VMPM operator. In an automated embodiment, the VMPM controller is also configured to independently control the delivery and mixing of each of the ingredients, as well as the delivery of the final product.

Provided is a gypsum-based board producing apparatus including: a mixer configured to prepare a gypsum slurry; a foaming apparatus; and a pump configured to convey foam generated by the foaming apparatus to the mixer, wherein the pump is a positive displacement pump.

This disclosure describes volumetric mobile powder mixer (VMPM) systems and methods for VMPM operation and use. The VMPM is providing with a number of storage compartments (or bins) for liquid or solid ingredients including at least one powder storage bin, a powder transport system, a dust handling system, a solid/liquid mixing system, a cellular foam generator, a product delivery system, and a controller capable of monitoring the delivery and mixing of each of the ingredients, as well as the discharge of the final product. The controller determines if the proper mixture is being discharged by the VMPM and, if not, alerts the VMPM operator. In an automated embodiment, the VMPM controller is also configured to independently control the delivery and mixing of each of the ingredients, as well as the delivery of the final product.

A system and method for introducing a slurry mixture for making gypsum board is disclosed. The system includes, for example, a mixer, a foam injector, and a canister for mixing and moving a slurry mixture of foam and gypsum slurry. Also included in the system is an apparatus having a funnel body constructed and arranged to further mix the slurry mixture. The funnel body includes a number of baffles projecting from its inner wall towards a center and that are spaced around the inner wall. The baffles induce turbulence into the slurry mixture as the slurry mixture moves towards its outlet, thus further mixing the mixture and reducing the flow rate of the slurry mixture before its exits from the outlet for depositing onto paper to form the gypsum board.

Manufactures, methods and apparatus are provided through which in some implementations a structural cellular lightweight concrete comprises a concrete mixture that is no more than 65% by volume of the manufacture of structural cellular lightweight concrete, the concrete mixture including concrete conforming to the requirements of ASTM C33; foam that has a density of at least 5 lbs/ft.sup.3, having high stability characteristics, and having a closed cell bubble structure; mix water being potable and free of contamination or deleterious materials; and Portland cement conforming to ASTM C150, the Portland cement being Type I, Type III or White Portland cement, and at least 35% air by volume of the manufacture of structural cellular lightweight concrete.

A method of preparing a concrete composition for downhole injection includes utilizing a controller to control a process including circulating process water in a process water supply loop for a predetermined period while monitoring and controlling the temperature and flow rate of the process water, circulating aqueous-based air entrainment solution in an aqueous-based air entrainment solution supply loop for the predetermined period and controlling the flow rate of the aqueous-based air entrainment solution and after the predetermined period of time in which the flow of process water and aqueous-based air entrainment solution have stabilized, simultaneously actuating valves to divert and mix the process water, the aqueous-based air entrainment solution and compressed air to produce an air-entrained foam and mixing the foam with a concrete composition to be deployed downhole.