It has been unexpectedly discovered that the addition of a natural or other pozzolan to non-spec fly ash significantly improves the properties of the non-spec fly ash to the extent it can be certified under ASTM C618 and AASHTO 295, as either a Class F or Class C fly 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 fly ash into certifiable Class F fly ash. Additionally, this disclosure provides a method of converting a Class C fly ash to a more valuable Class F fly ash. This discovery will extend diminishing Class F fly ash supplies and turn non-spec fly ash waste streams into valuable, certified fly ash pozzolan which will protect and enhance concrete, mortars and grouts.

An apparatus for recycling fly ash has a quantum energy generator therein. The apparatus recycles fly ash generated as the combustion waste from the burning of coal in thermal power plants, into construction materials such as cement substitutes, environment-friendly cover materials, etc. Unburned pulverized coal is removed while generating carbon monoxide (CO) or carbon dioxide (CO.sub.2) through a combustion reaction, in which the unburned pulverized coal of the fly ash contacts the thermal electrons discharged during a thermal decomposition process at a high temperature, the negative electrodes of the thermal decomposition part, which are heated at a high temperature of 500 C., which is an ignition point of the unburned pulverized coal, or higher, and a high-voltage discharge electrode of an electrochemical reaction part, then heated at 500 C. or higher, and then naturally burned under an oxygen atmosphere (oxygen or ionized oxygen ions in air contained in the fly ash).

An apparatus for recycling fly ash has a quantum energy generator therein. The apparatus recycles fly ash generated as the combustion waste from the burning of coal in thermal power plants, into construction materials such as cement substitutes, environment-friendly cover materials, etc. Unburned pulverized coal is removed while generating carbon monoxide (CO) or carbon dioxide (CO.sub.2) through a combustion reaction, in which the unburned pulverized coal of the fly ash contacts the thermal electrons discharged during a thermal decomposition process at a high temperature, the negative electrodes of the thermal decomposition part, which are heated at a high temperature of 500 C., which is an ignition point of the unburned pulverized coal, or higher, and a high-voltage discharge electrode of an electrochemical reaction part, then heated at 500 C. or higher, and then naturally burned under an oxygen atmosphere (oxygen or ionized oxygen ions in air contained in the fly ash).

It has been unexpectedly discovered that the addition of a natural or other pozzolan to non-spec fly ash significantly improves the properties of the non-spec fly ash to the extent it can be certified under ASTM C618 and AASHTO 295, as either a Class F or Class C fly 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 fly ash into certifiable Class F fly ash. Additionally, this disclosure provides a method of converting a Class C fly ash to a more valuable Class F fly ash. This discovery will extend diminishing Class F fly ash supplies and turn non-spec fly ash waste streams into valuable, certified fly ash pozzolan which will protect and enhance concrete, mortars and grouts.

The invention provides compositions and methods directed to carbonation of a cement mix during mixing. The carbonation may be controlled by one or more feedback mechanisms to adjust carbon dioxide delivery based on one or more characteristics of the mix or other aspects of the mixing operation.

The invention provides compositions and methods directed to carbonation of a cement mix during mixing. The carbonation may be controlled by one or more feedback mechanisms to adjust carbon dioxide delivery based on one or more characteristics of the mix or other aspects of the mixing operation.

A process for producing fly ash in a fluidized bed boiler includes combusting a fuel in a fluidized bed combustor in the presence of limestone particles, recovering fly ash, and recovering bottom ash. The fuel contains hydrocarbons and sulfur. A majority of the sulfur from the fuel is recovered from the bottom ash. The fly ash may contain less than 5% by weight of sulfur oxides. This may be achieved by using limestone particles having certain properties and/or narrowing an inlet from the boiler into a cyclone.

A process for producing fly ash in a fluidized bed boiler includes combusting a fuel in a fluidized bed combustor in the presence of limestone particles, recovering fly ash, and recovering bottom ash. The fuel contains hydrocarbons and sulfur. A majority of the sulfur from the fuel is recovered from the bottom ash. The fly ash may contain less than 5% by weight of sulfur oxides. This may be achieved by using limestone particles having certain properties and/or narrowing an inlet from the boiler into a cyclone.

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 m 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 m 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.