This investigation seeks to utilize fly ash in fired-clay products such as building and patio bricks, ceramic blocks, field and sewer tile, and flower pots. This goal is accomplished by 1) one or more plant-scale, 5000-brick tests of fly ash mixed with brick clays at the 20% or higher level; 2) a laboratory-scale study to measure the firing reactions of a range of compositions of clay and fly ash mixtures; 3) a preliminary study to evaluate the potential environmental and economic benefits of brick manufacture with fly ash. Bricks and feed materials will be tested for compliance with market specifications and for leachability of pollutants derived from fly ash. The laboratory study will combine ISGS databases, ICCI-supported characterization methods, and published information to improve predictions of the firing characteristics of Illinois fly ash and brick clay mixtures. Because identical methods are used to test clay firing and coal ash fusion, and because melting mechanisms are the same, improved coal ash fusion predictions are an additional expected result of this research. If successful, this project should convert a disposal problem (fly ash) into valuable products-bricks.During this quarter we completed a manufacturing run at Colonial Brick Co. and began laboratory testing of samples from that run: clays, fly ash (from Illinois Power Company's Wood River Plant), and green and fired bricks-with and without fly ash. Bricks with 20% fly ash "scummed" during firing, and the fly ash failed to increase oxidation rate or water absorption, which were both expected. We obtained chemical and mineralogical analyses of the fireclays and shales at Colonial and Marseilles Brick Companies and began a series of selective dissolution analyses to more accurately determine the composition of the principal clay minerals in brick clays and the components in fly ash. We began related work of calculating 'normative' mineralogical analyses for all clays and fly ashes that we sample. Ilham Demir kindly gave us a copy of the chemical database from their ICCI study of commercial coals; this database has been reformulated to estimate the fly ash composition from each of these coals, which should allow us to select three standard fly ashes for next year's optimization studies. We completed a computer database of the locations and geological affinities of all ceramic clays studied by the Clay Minerals Unit since about 1930 (-25,000 entries). Dust from fly ash was an unanticipated problem at the brick plant. We will look for improved methods of handling next year's fly ash deliveries. A summary report on this project was presented to the Coal Advisory Committee of the Survey on May 15, 1995. EXECUTIVE SUMMARYThis project seeks methods for the efficient utilization of coal combustion wastes. This project precisely meets this purpose by examining the use of Illinois fly ash in the manufacture of bricks and similar fired-clay products. The project is composed of three parts: 1) one or more plant-level manufacturing runs, and 2) a ...

The goals of this project are to investigate the behavior of sulfur and chlorine during pyrolysis and combustion of Illinois coals, the chemistry and mineralogy of boiler deposits, the effects of combustion gases on boiler materials, and remedial measures to reduce the sulfur and chlorine compounds in combustion gases.

This investigation seeks to utilize fly ash in fired-clay products such as building and patio bricks, ceramic blocks, field and sewer tile, and flower pots. This goal is accomplished by 1) one or more plant-scale, 5000-brick tests with fly ash mixed with brick clays at the 20% or higher level;2) a laboratory-scale study to measure the firing reactions of a range of compositions of clay and fly ash mixtures; 3) a technical and economic study to evaluate the potential environmental and economic benefits of brick manufacture with fly ash. Bricks and feed materials will be tested for compliance with market specifications and for leachability of pollutants derived from fly ash.The laboratory study will combine ISGS databases, ICCI-supported characterization methods, and published information to improve predictions of the firing characteristics of Illinois fly ash and brick clay mixtures. Because identical methods are\used to test clay firing and coal ash fusion, and because melting mechanisms are the same, improved coal ash fusion predictions are an expected result of this research. If successful, this project should convert an environmental problem (fly ash) into valuable products-bricks.During this quarter we set up the manufacturing run at Colonial Brick Co., provided an expanded NEPA questionnaire for DOE, made preliminary arrangements for. a larger brick manufacturing run at Marseilles Brick Co., revised our laboratory procedures for selective dissolution analysis, and began our characterization of brick clays that could be mixed with fly ash for fired-clay products.U. S. DOE Patent Clearance is NOT required prior to the publication of this document.. EXECUTIVE SUMMARYThe proposed effort seeks methods for the efficient disposal or utilization of coal combustion wastes. This project precisely meets this purpose by examining the use of Illinois tly ash in the manufacture of bricks and similar fired-clay products. The project is composed of three parts: 1) one or more plant-level manufacturing runs, and 2) a set of laboratory-scale experiments designed to predict the firing properties of mixtures of a range of compositions of fly ashes with clays and shales that represent the range of compositions typical of mines in Illinois; 3) a technical and economic investigation of the potential environmental and economic benefits of brick manufacture with fly ash. The completion of these two program elements will provide strategies for maximizing the use of fly ash in bricks and related products.The first task in this project is to obtain approximately 20 tons of fly ash from Illinois Power Co.'s Wood River Plant and ship it to Colonial Brick Company in Cayuga, Indiana, where in-plant tests of mixtures of Colonial's brick clays and 1.P.k fly ash will be made at the 20% or higher level. Colonial Brick will add progressively higher levels of fly ash until the bricks approach established specifications on water absorption. A single plant-scale run will probably be 5,000-10,000 bricks with fly ash, with pre-and post-fly ...

The goals of this project are to investigate the behavior of sulfur , , L L_, Kentucky University COMMENTS The project has proceeded well. The expenditures are consistent with the projected amounts. J

This investigation seeks to utilize fly ash in fired-clay products such as building and patio bricks, ceramic blocks, field and sewer tile, and flower pots. This goal is accomplished by 1) one or more plant-scale, 5000-brick tests with fly ash mixed with brick clays at the 20% or higher level; 2) a laboratory-scale study to measure the firing reactions of a range of compositions of clay and fly ash mixtures; 3) a preliminary study to evaluate the potential environmental and economic benefits of brick manufacture with fly ash. Bricks and feed materials will be tested for compliance with market specifications and for leachability of pollutants derived from fly ash. The laboratory study will combine ISGS databases, ICCI-supported characterization methods, and published information to improve predictions of the firing characteristics of Illinois fly ash and brick clay mixtures. Because identical methods are used to test clay firing and coal ash fusion, and because melting mechanisms are the same, improved coal ash fusion predictions are an additional expected result of this research. If successful, this project should convert a disposal problem (fly ash) into valuable products-bricks.During this quarter we set up the manufacturing run at Colonial Brick Co., finalized arrangements for a larger brick manufacturing run at Marseilles Brick Co. in YR2, revised our laboratory procedures for selective dissolution analysis, obtained information to select three standard fly ashes, and continued our characterization of brick clays that could be mixed with fly ash for fired-clay products. Due to delays in other areas, we began construction of the optimization program for year 2. We discovered recently that fly ash dust will be an unanticipated problem at the brick plant. U. S. DOE Patent Clearance is NOT required prior to the publication of this EXECUTIVE SUMMARYThe proposed effort seeks methods for the efficient disposal or utilization of coal combustion wastes. This project precisely meets this purpose by examining the use of Illinois fly ash in the manufacture of bricks and similar fired-clay products. The project is composed of three parts: 1) one or more plant-level manufacturing runs, and 2) a set of laboratory-scale experiments designed to predict the firing properties of mixtures of a range of compositions of fly ashes with clays and shales that represent the range of compositions typical of mines in Illinois; 3) a preliminary investigation of the potential environmental and economic benefits of brick manufacture with fly ash. The completion of these three program elements will provide strategies for maximizing the use of fly ash in bricks and related products.The first task in this project is to obtain approximately 20 tons of fly ash from Illinois Power Co.'s Wood River Plant and ship it to Colonial Brick Company in Cayuga, Indiana, where in-plant tests of mixtures of Colonial's brick clays and I.P.'s fly ash will be made at the 20% or higher level. Colonial Brick will add progressively higher levels of fly a...