Method for the production of granular materials designed to be used as aggregates and fillers in a mix containing a binder for the manufacture of articles in slab or block form. The method comprises a step of melting a mixture of selected minerals having a specific chemical composition, a step of casting the molten material, a step of cooling the cast material until a predetermined temperature is reached and a step of crushing and/or grinding the cooled material to obtain granular materials having a selected particle size and suitable for use as aggregates or fillers in the mix for the manufacture of articles in slab or block form. Moreover, the method comprises, upstream of the melting step, a step for recovery and collection of the manufacturing waste of other previously manufactured articles. The manufacturing waste is designed to compose at least partially the mixture of selected minerals. The invention also relates to a method for manufacturing articles in slab or block form from a mix containing the aggregates and the fillers and a binder.

Method for the production of granular materials designed to be used as aggregates and fillers in a mix containing a binder for the manufacture of articles in slab or block form. The method comprises a step of melting a mixture of selected minerals having a specific chemical composition, a step of casting the molten material, a step of cooling the cast material until a predetermined temperature is reached and a step of crushing and/or grinding the cooled material to obtain granular materials having a selected particle size and suitable for use as aggregates or fillers in the mix for the manufacture of articles in slab or block form. Moreover, the method comprises, upstream of the melting step, a step for recovery and collection of the manufacturing waste of other previously manufactured articles. The manufacturing waste is designed to compose at least partially the mixture of selected minerals. The invention also relates to a method for manufacturing articles in slab or block form from a mix containing the aggregates and the fillers and a binder.

Systems and methods are provided for making aggregate from comingled waste plastics. For example, there is provided a method of making a preconditioned absorptive resin aggregate, the method including: obtaining a supply of granulated mixed plastic waste treated with a preconditioning agent that comprises at least one of calcium oxide and calcium hydroxide; mixing the supply of granulated mixed plastic waste treated with the calcium oxide preconditioning agent with one or more additives to form a plastic waste mixture, the one or more additives comprising pozzolans; hot extruding the plastic waste mixture to form an extruded product comprising waste plastic material; cooling the extruded product; and processing the extruded product to form an aggregate. Products incorporating such aggregates, such as, for example, lightweight construction blocks, are also provided. Also provided are methods of forming a waste plastics feedstock.

Systems and methods are provided for making aggregate from comingled waste plastics. For example, there is provided a method of making a preconditioned absorptive resin aggregate, the method including: obtaining a supply of granulated mixed plastic waste treated with a preconditioning agent that comprises at least one of calcium oxide and calcium hydroxide; mixing the supply of granulated mixed plastic waste treated with the calcium oxide preconditioning agent with one or more additives to form a plastic waste mixture, the one or more additives comprising pozzolans; hot extruding the plastic waste mixture to form an extruded product comprising waste plastic material; cooling the extruded product; and processing the extruded product to form an aggregate. Products incorporating such aggregates, such as, for example, lightweight construction blocks, are also provided. Also provided are methods of forming a waste plastics feedstock.

Method for the production of granulate materials designed to be used for manufacturing articles in slab or block form from a mixture. The method comprises the steps of a) melting a mixture of selected minerals having a specific chemical composition for obtaining a casting of molten material, c) cooling the cast material until a predetermined temperature is reached and d) crushing and/or grinding the material to obtain granules having a selected grain size and suitable for use respectively as aggregates or fillers in the mixture for manufacture of the articles. Moreover, the method comprises, downstream of the melting and casting step a), a step b) of keeping the molten and cooled material at a temperature of between 1030-1170° C. for a predetermined time period of at least 15 minutes. The granulate materials thus obtained have a content of silicon dioxide in crystalline form of less than 1%. The invention also relates to a plant for the production of granulate materials suitable for use as aggregates or fillers for the manufacture of articles in slab or block form.

Method for the production of granulate materials designed to be used for manufacturing articles in slab or block form from a mixture. The method comprises the steps of a) melting a mixture of selected minerals having a specific chemical composition for obtaining a casting of molten material, c) cooling the cast material until a predetermined temperature is reached and d) crushing and/or grinding the material to obtain granules having a selected grain size and suitable for use respectively as aggregates or fillers in the mixture for manufacture of the articles. Moreover, the method comprises, downstream of the melting and casting step a), a step b) of keeping the molten and cooled material at a temperature of between 1030-1170° C. for a predetermined time period of at least 15 minutes. The granulate materials thus obtained have a content of silicon dioxide in crystalline form of less than 1%. The invention also relates to a plant for the production of granulate materials suitable for use as aggregates or fillers for the manufacture of articles in slab or block form.

A lightweight composite having an activated surface contains a lightweight hollow core particle having cement grains which may be adhered to the hollow core or embedded in the surface of the hollow core. The hollow core particle may be prepared from calcium carbonate and a mixture of clay, such as bentonite, and a glassy inorganic material, such as glass spheres, glass beads, glass bubbles, borosilicate glass and fiberglass.

A lightweight composite having an activated surface contains a lightweight hollow core particle having cement grains which may be adhered to the hollow core or embedded in the surface of the hollow core. The hollow core particle may be prepared from calcium carbonate and a mixture of clay, such as bentonite, and a glassy inorganic material, such as glass spheres, glass beads, glass bubbles, borosilicate glass and fiberglass.

Manufacturing lightweight aggregate (LWA) by a sintering technique requires a delicate balance among three conditions: forming sufficient amount of molten liquid phase during sintering; reaching an appropriate viscosity for solid-liquid suspension; and emitting sufficient amount of gas that can be entrapped by the liquid phase to form pores. LWAs were made from low-calcium and high-calcium Waste Coal Combustion Ash (W-CCA) including fly ash and bottom ash. A mass fraction of at least 40% liquid phase for fly ash and 50% for bottom ash is required for a successful entrapment of emitted gaseous phases during sintering. Larger pores were observed in the microstructure of LWA samples made using high-calcium W-CCA in comparison to low-calcium W-CCA. This result was mainly attributed to the high-calcium samples forming liquid phases with lower viscosity values and emitting higher amounts of gaseous phase during sintering than did the low-calcium samples. The gaseous phase was generated by hematite reduction and anhydrite decomposition.

Manufacturing lightweight aggregate (LWA) by a sintering technique requires a delicate balance among three conditions: forming sufficient amount of molten liquid phase during sintering; reaching an appropriate viscosity for solid-liquid suspension; and emitting sufficient amount of gas that can be entrapped by the liquid phase to form pores. LWAs were made from low-calcium and high-calcium Waste Coal Combustion Ash (W-CCA) including fly ash and bottom ash. A mass fraction of at least 40% liquid phase for fly ash and 50% for bottom ash is required for a successful entrapment of emitted gaseous phases during sintering. Larger pores were observed in the microstructure of LWA samples made using high-calcium W-CCA in comparison to low-calcium W-CCA. This result was mainly attributed to the high-calcium samples forming liquid phases with lower viscosity values and emitting higher amounts of gaseous phase during sintering than did the low-calcium samples. The gaseous phase was generated by hematite reduction and anhydrite decomposition.