It has been unexpectedly discovered that the addition of a natural or other pozzolan to non-spec coal ash significantly improves the properties of the non-spec coal ash to the extent it can be certified under ASTM C618 and AASHTO 295, as either a Class F or Class C coal ash. The natural pozzolan may be a volcanic ejecta, such as pumice or perlite. Other pozzolans may also be used for this beneficiation process. Many pozzolans are experimentally tested and may be used to beneficiate non-spec coal ash into certifiable Class F coal ash. Additionally, this disclosure provides a method of converting a Class C coal ash to a more valuable Class F coal ash. This discovery will extend diminishing Class F coal ash supplies and turn non-spec coal ash waste streams into valuable, certified coal ash pozzolan which will protect and enhance concrete, mortars and grouts.

Disclosed is a liquid regulator for ultra-dispersed, high-mud-resistance, high-foam-stability, low-shrinkage and enhanced autoclaved aerated concrete, which comprises the following ingredients in parts by weight: 75 parts to 85 parts of hyperdispersant; 5 parts to 10 parts of anti-mud agent; 1 part to 3 parts of shrinkage reducing ingredient; 10 parts to 20 parts of reinforcing ingredient; and 0.05 part to 0.1 part of foam stabilizing ingredient; and the invention further discloses a preparation and application thereof. By adding the liquid regulator into the autoclaved aerated concrete, the effects of ultra-dispersion, high mud resistance, high foam stability, low shrinkage and performance enhancement can be achieved.

Disclosed is a liquid regulator for ultra-dispersed, high-mud-resistance, high-foam-stability, low-shrinkage and enhanced autoclaved aerated concrete, which comprises the following ingredients in parts by weight: 75 parts to 85 parts of hyperdispersant; 5 parts to 10 parts of anti-mud agent; 1 part to 3 parts of shrinkage reducing ingredient; 10 parts to 20 parts of reinforcing ingredient; and 0.05 part to 0.1 part of foam stabilizing ingredient; and the invention further discloses a preparation and application thereof. By adding the liquid regulator into the autoclaved aerated concrete, the effects of ultra-dispersion, high mud resistance, high foam stability, low shrinkage and performance enhancement can be achieved.

Method of efficiently manufacturing cement-SCM compositions having improved strength compared to cement-SCM compositions made using conventional methods. The cement-SCM compositions may contain: (A) a fine interground particulate component with (1) a hydraulic cement fraction and (2) a supplementary cementitious material (SCM) fraction; (B) a coarse particulate component comprised of coarse SCM particles not interground with the fine interground particulate component; and optionally (C) an auxiliary particulate component not interground with the fine interground particulate component or the coarse particulate component. A method of manufacturing a cement-SCM composition may be performed by: (A) intergrinding hydraulic cement (e.g., cement clinker) with one or more SCMs to form a fine interground particulate component; (B) blending, without intergrinding, the fine interground particulate component with a coarse particulate component comprised of coarse SCM particles; and optionally (C) further combining, without intergrinding, an auxiliary particulate component with the fine interground particulate component and the coarse particulate component.

Method of efficiently manufacturing cement-SCM compositions having improved strength compared to cement-SCM compositions made using conventional methods. The cement-SCM compositions may contain: (A) a fine interground particulate component with (1) a hydraulic cement fraction and (2) a supplementary cementitious material (SCM) fraction; (B) a coarse particulate component comprised of coarse SCM particles not interground with the fine interground particulate component; and optionally (C) an auxiliary particulate component not interground with the fine interground particulate component or the coarse particulate component. A method of manufacturing a cement-SCM composition may be performed by: (A) intergrinding hydraulic cement (e.g., cement clinker) with one or more SCMs to form a fine interground particulate component; (B) blending, without intergrinding, the fine interground particulate component with a coarse particulate component comprised of coarse SCM particles; and optionally (C) further combining, without intergrinding, an auxiliary particulate component with the fine interground particulate component and the coarse particulate component.

An activated pozzolan composition includes a fine interground particulate blend of an initially unactivated natural pozzolan and a supplementary cementitious material (SCM) different than the initially unactivated natural pozzolan. The initially unactivated natural pozzolan may include volcanic ash or other natural pozzolanic deposit having a moisture content of at least 3%, and the activated pozzolan composition can have a moisture content less than 0.5% The initially unactivated natural pozzolan may have a particle size less than 1 mm before intergrinding with the SCM. The SCM used to activate the initially unactivated natural pozzolan can be initially coarse or granular with a size greater than 1-3 μm and may include granulated blast furnace slag, steel slag, other metallurgical slag, pumice, limestone, fine aggregate, shale, tuff, trass, geologic material, waste glass, glass shards, basalt, sinters, ceramics, recycled bricks, recycled concrete, refractory materials, other waste industrial products, sand, or natural mineral.

An activated pozzolan composition includes a fine interground particulate blend of an initially unactivated natural pozzolan and a supplementary cementitious material (SCM) different than the initially unactivated natural pozzolan. The initially unactivated natural pozzolan may include volcanic ash or other natural pozzolanic deposit having a moisture content of at least 3%, and the activated pozzolan composition can have a moisture content less than 0.5% The initially unactivated natural pozzolan may have a particle size less than 1 mm before intergrinding with the SCM. The SCM used to activate the initially unactivated natural pozzolan can be initially coarse or granular with a size greater than 1-3 μm and may include granulated blast furnace slag, steel slag, other metallurgical slag, pumice, limestone, fine aggregate, shale, tuff, trass, geologic material, waste glass, glass shards, basalt, sinters, ceramics, recycled bricks, recycled concrete, refractory materials, other waste industrial products, sand, or natural mineral.

A process for reforming the fly ash, including the heating step that heats a raw fly ash powder containing the unburned carbon at a temperature of 780 to 1000° C. to decrease the amount of the unburned carbon contained in the raw fly ash powder; the classifying step that introduces the heat-treated fly ash containing the unburned carbon in decreased amounts obtained through the heating step into a classifying apparatus in the state of being heated at a high temperature so as to separate the fly ash into a coarse powder and a fine powder; the fine powder recovering step that recovers the fine powder of the heat-treated fly ash obtained through the classifying step by using a dust-collecting apparatus; and the milling step that mills the coarse powder of the heat-treated fly ash obtained through the classifying step until a 45 μm sieve residue becomes not more than 34% by mass, and then recovers the milled powder.

A process for reforming the fly ash, including the heating step that heats a raw fly ash powder containing the unburned carbon at a temperature of 780 to 1000° C. to decrease the amount of the unburned carbon contained in the raw fly ash powder; the classifying step that introduces the heat-treated fly ash containing the unburned carbon in decreased amounts obtained through the heating step into a classifying apparatus in the state of being heated at a high temperature so as to separate the fly ash into a coarse powder and a fine powder; the fine powder recovering step that recovers the fine powder of the heat-treated fly ash obtained through the classifying step by using a dust-collecting apparatus; and the milling step that mills the coarse powder of the heat-treated fly ash obtained through the classifying step until a 45 μm sieve residue becomes not more than 34% by mass, and then recovers the milled powder.

A method of designing a cement slurry comprising: (a) selecting at least a cement and concentration thereof, a water and concentration thereof, and one or more chemical additives concentration thereof such that a cement slurry formed from the cement, one or more chemical additives, and the water meet a density requirement; (b) calculating a thickening time of the cement slurry at the wellbore temperature using a thickening time model; (c) comparing the thickening time of the cement slurry to a thickening time requirement and performing steps (a)-(c) if the thickening time of the cement slurry does not meet or exceed the thickening time requirement, wherein the step of selecting comprises selecting different concentrations and/or different chemical identities for the cement and/or one or the more chemical additives than previously selected, or performing step (d) if the thickening time of the cement slurry meets or exceeds the thickening time requirement; and (d) preparing the cement slurry.