The present invention discloses a novel, improved, simple and economic process for manufacturing lightweight ceramic sand. The lightweight ceramic sand is produced from the industrial wastes, wherein the major raw materials are fly ash, bauxite residue and biomass-coal fly ash. The present invention relates to the production of new fine particulates at high throughput and at low manufacturing cost to provide an alternative or substitute to the fast-depleting natural sand including crushed stones and lightweight fine aggregates produced from expanded clay, expanded glass and volcanic activities. Lightweight ceramic sand of the present invention can be used as a building and construction material and foundry sand.

A continuous operation method is employed for the microwave high-temperature pyrolysis of a solid material containing an organic matter. The method includes the steps of mixing a solid material containing an organic matter with a liquid organic medium; transferring the obtained mixture to a microwave field; and in the microwave field, continuously contacting the mixture with a strong wave absorption material in an inert atmosphere or in vacuum. The strong wave absorption material continuously generates a high temperature under a microwave such that the solid material containing an organic matter and the liquid organic medium are continuously pyrolyzed to implement a continuous operation.

A porous composite material capable of generating an arc in a microwave field includes an inorganic porous framework and a carbon material loaded on the inorganic porous framework. The average pore size of the inorganic porous framework is 0.2-1000 μm. The porous composite material has an excellent mechanical performance, can generate an arc in a microwave field to quickly generate a high temperature, and thus can be used in fields such as microwave high-temperature heating, biomass pyrolysis, vegetable oil treatment, waste polymer material pyrolysis, petrochemical pyrolysis, carbon-fiber composite material recovery, waste treatment, VOC waste gas treatment, COD wastewater treatment, high-temperature catalysis, waste circuit board full-component recycling, and hydrogen preparation.

To provide a prestressed concrete which can be used for non-primary structural members such as general building members by using a chemical stress induced by an expansive material and a mechanical stress induced by a rust-resistant wire together and achieving reduction in weight and suppression of cracking. A prestressed concrete for non-primary structural members is characterized in that a mechanical stress induced by a tensional material and a chemical stress induced by an expansive material for a concrete are introduced and that the tensional material is a rust-resistant continuous fiber reinforcing wire.

A method for forming a flow channel in a MIO structure includes positioning a plurality of sacrificial spheres along a base substrate, heating a region of the plurality of sacrificial spheres above a melting point of the plurality of sacrificial spheres, thereby fusing the plurality of sacrificial spheres together and forming a solid channel, electrodepositing material between the plurality of sacrificial spheres and around the solid channel, removing the plurality of sacrificial spheres to form the MIO structure, and removing the solid channel to form the flow channel extending through the MIO structure.

Some variations provide a pre-ceramic matrix composite comprising: a precursor pre-ceramic matrix; reinforcing elements disposed within the precursor pre-ceramic matrix; and a compressible material disposed on the surface of the reinforcing elements and interposed between the reinforcing elements and the precursor pre-ceramic matrix. Other variations provide a ceramic matrix composite comprising: a ceramic matrix; reinforcing elements disposed within the ceramic matrix; and a compressed material disposed on the surface of the reinforcing elements and interposed between the reinforcing elements and the matrix. The coating of compressible material prevents cracking during processing because the coating absorbs stresses associated with volumetric shrinkage of the ceramic matrix during densification, thereby reducing the stresses at the interface between the reinforcing elements and the ceramic matrix. Methods of fabricating ceramic matrix composites using the principles of the invention are disclosed. Methods include pyrolysis of pre-ceramic polymers, sintering of pre-ceramic materials, and sol-gel processing.

A process for manufacturing a porous abradable coating includes: filling a mold with hollow glass or thermosetting polymer beads and a slurry; and sintering heat treatment to obtain a ceramic layer with pores. A maximum sintering temperature of the green body of the ceramic part is either higher than the melting temperature of the hollow glass beads so that at the end of the sintering heat treatment the hollow glass beads are melted, or higher than the decomposition temperature of the hollow thermosetting polymer beads so that at the end of the sintering heat treatment the hollow thermosetting polymer beads are decomposed.

The invention discloses high-strength glass-ceramic-based lightweight aggregates and the preparation method thereof. The mass ratio of raw material components is 50-70 parts of engineering muck, 20-40 parts of glass, 3-7 parts of calcium carbonate, 3-7 parts of magnesium oxide, and 2-10 parts of a nucleating agent; the nucleating agent is at least one of calcium fluoride, titanium dioxide, and chromium oxide. After crushing, mixing, and granulating, spherical particles with a particle size of 10-12 mm are formed; and then the product can be obtained after drying, sintering, and cooling. The obtained lightweight aggregate from the invention has a diopside matrix which provides high strength and a low water absorption rate at low densities. Moreover, waste glass and engineering muck could be utilized with high value.

A method of agglomerating bulk ceramic fibers includes mixing the bulk ceramic fibers with water to form wet fibers; mixing the wet fibers with a binder including an organic binder and/or an inorganic binder to form agglomerates; and drying the agglomerates. The agglomerates may be mixed with additional binders and fillers to form an insulating mix that may be used to insulate a furnace or other heat source. A foaming nozzle may be used for the application of agglomerates. A foaming agent and water are air atomized within the foaming nozzle and the resulting foam is mixed into pneumatically conveyed agglomerates, which result results in a lightweight refractory material layer on a target substrate.

This invention relates to a biodegradable composition comprising a low carbon footprint binder comprising a silicate, and bio-based aggregates. The invention also relates to the binder thereof, products, including insulation material and wall boards/panels, formed from the binder and the composition, a method of preparing the binder and composition and/or the products, and a method of using the binder and composition and/or the products in construction.