The present invention is directed to a method of making such gypsum panel. For instance, the method comprises: providing a first facing material; providing a gypsum slurry including calcium sulfate hemihydrate, water, and a silicon containing compound onto the first facing material; providing a second facing material onto the gypsum slurry to form a continuous gypsum sheet; allowing the calcium sulfate hemihydrate to hydrate to form calcium sulfate dihydrate; cutting the continuous gypsum sheet to form a gypsum panel; supplying the gypsum panel to a heating or drying device; and providing a gaseous mixture from the heating or drying device to a regenerative thermal oxidizer.

The present invention is directed to a method of making such gypsum panel. For instance, the method comprises: providing a first facing material; providing a gypsum slurry including calcium sulfate hemihydrate, water, and a silicon containing compound onto the first facing material; providing a second facing material onto the gypsum slurry to form a continuous gypsum sheet; allowing the calcium sulfate hemihydrate to hydrate to form calcium sulfate dihydrate; cutting the continuous gypsum sheet to form a gypsum panel; supplying the gypsum panel to a heating or drying device; and providing a gaseous mixture from the heating or drying device to a regenerative thermal oxidizer.

A plurality of granules comprising particulate silicate material bonded together with an inorganic binder, the inorganic binder comprising reaction product of at least alkali silicate and hardener, wherein the hardener is at least one of aluminum phosphate, amorphous aluminosilicate, fluorosilicate, Portland cement, or a calcium silicate, wherein the particulate silicate material is present as at least 50 percent by weight of each granule, based on the total weight of the respective granule, wherein each granule has a total porosity in a range from greater than 0 to 50 percent by volume, based on the total volume of the respective granule, and wherein the granules have Tumble Toughness Value of at least 70 before immersion in water and at least 40 after immersion in water at 20° C.±2° C. for two months. The granules are useful, for example, as roofing granules.

A plurality of granules comprising particulate silicate material bonded together with an inorganic binder, the inorganic binder comprising reaction product of at least alkali silicate and hardener, wherein the hardener is at least one of aluminum phosphate, amorphous aluminosilicate, fluorosilicate, Portland cement, or a calcium silicate, wherein the particulate silicate material is present as at least 50 percent by weight of each granule, based on the total weight of the respective granule, wherein each granule has a total porosity in a range from greater than 0 to 50 percent by volume, based on the total volume of the respective granule, and wherein the granules have Tumble Toughness Value of at least 70 before immersion in water and at least 40 after immersion in water at 20° C.±2° C. for two months. The granules are useful, for example, as roofing granules.

A method for making a carbonated precast concrete product includes: obtaining a mixture including at least one binder material, an aggregate, and water; molding the mixture into a molded intermediate; demolding the molded intermediate to obtain a demolded intermediate, the demolded intermediate having a first water-to-binder ratio; conditioning the demolded intermediate to provide a conditioned article having a second water-to-binder ratio less than the first water-to-binder ratio of the demolded intermediate; moisturizing at least one surface of the conditioned article with an aqueous medium, thereby causing a weight gain of the conditioned article and providing a moisturized product, a first portion of the moisturized product having a third water-to-binder ratio greater than a fourth water-to-binder ratio of a remainder of the moisturized product; and curing the moisturized product with carbon dioxide to obtain the carbonated precast concrete product.

A method for making a carbonated precast concrete product includes: obtaining a mixture including at least one binder material, an aggregate, and water; molding the mixture into a molded intermediate; demolding the molded intermediate to obtain a demolded intermediate, the demolded intermediate having a first water-to-binder ratio; conditioning the demolded intermediate to provide a conditioned article having a second water-to-binder ratio less than the first water-to-binder ratio of the demolded intermediate; moisturizing at least one surface of the conditioned article with an aqueous medium, thereby causing a weight gain of the conditioned article and providing a moisturized product, a first portion of the moisturized product having a third water-to-binder ratio greater than a fourth water-to-binder ratio of a remainder of the moisturized product; and curing the moisturized product with carbon dioxide to obtain the carbonated precast concrete product.

A non-conforming (or barely conforming) fly ash is converted into conforming (or better conforming) fly ash by: (1) obtaining an initial fly ash with at least one non-conforming (or barely conforming) characteristic selected from excess carbon content, low strength activity index, or low SAF as defined by ASTM C-618 and having a D10, D50 and D90; (2) classifying the initial fly ash using one or more air classifiers to produce at least two separate fly ash streams, including fine fly ash and coarse fly ash; (3) collecting the fine fly ash and the coarse fly ash, the fine fly ash having a D90 less than the D90 of the initial fly ash; (4) combining the fine fly ash with an aluminosilicate source to form a modified fly ash having a conforming carbon content, a conforming reactivity index, and a conforming SAF as defined by ASTM C-618.

A non-conforming (or barely conforming) fly ash is converted into conforming (or better conforming) fly ash by: (1) obtaining an initial fly ash with at least one non-conforming (or barely conforming) characteristic selected from excess carbon content, low strength activity index, or low SAF as defined by ASTM C-618 and having a D10, D50 and D90; (2) classifying the initial fly ash using one or more air classifiers to produce at least two separate fly ash streams, including fine fly ash and coarse fly ash; (3) collecting the fine fly ash and the coarse fly ash, the fine fly ash having a D90 less than the D90 of the initial fly ash; (4) combining the fine fly ash with an aluminosilicate source to form a modified fly ash having a conforming carbon content, a conforming reactivity index, and a conforming SAF as defined by ASTM C-618.

A cement composition including a hydraulic cement material, a latent-hydraulic cement material, and a non-hydraulic cement material. Also provided is a method including combining, at a jobsite, the cement composition comprising the hydraulic cement material, the latent-hydraulic cement material, and the non-hydraulic cement material with water to provide a cement slurry, and allowing the cement slurry to harden in the presence of carbon dioxide (CO.sub.2) to provide a hardened cement.

A cement composition including a hydraulic cement material, a latent-hydraulic cement material, and a non-hydraulic cement material. Also provided is a method including combining, at a jobsite, the cement composition comprising the hydraulic cement material, the latent-hydraulic cement material, and the non-hydraulic cement material with water to provide a cement slurry, and allowing the cement slurry to harden in the presence of carbon dioxide (CO.sub.2) to provide a hardened cement.