Title: Demonstration of Technology for the Production of High Value Materials from the Ultra-Fine (PM 2.5) Fraction of Coal Combustion Ash

Abstract

Three types of chemically and functionally different thermoplastic polymers have been chosen for evaluation with the fly ash derived filler: high density polyethylene (HDPE), thermoplastic elastomer (TPE) and polyethylene terephthalate (PET). The selections were based on volumes consumed in commercial and recycled products. The reference filler selected for comparison was 3 {micro}m calcium carbonate, a material which is commonly used with all three types of polymers. A procedure to prepare filled polymers has been developed and the polymer/filler blends have been prepared. Selected samples of filled polymers were subjected to SEM analysis to verify that the fly ash derived filler and the calcium carbonate were well dispersed. Material taken from a utility ash pond was classified using a novel combination of hydraulic and lamellar classifiers to produce an ultra-fine ash product. This product was dried and used in a series of tests to determine its potential as a filler in plastics. The general properties of the ultra-fine ash from several runs are as follows: D{sub 50}: 3-5 {micro}m; Specific gravity: {approx}2.41; Loss on ignition: 2-3%; Carbon content: 1-2%; Color: dark grey on content: 1-2%; and Morphology: spherical. The addition of fillers increased the modulus of the HDPE composite, but decreasedmore » both the offset yield stress and offset yield strain, showing that the fillers essentially made the composite stiffer but the transition to plastic deformation occurred earlier in filled HDPE as stress was applied. Similar results were obtained with TPE, however, the decrease in either stress or strain at offset yield were not as significant. Dynamic mechanical analyses (DMA) were also completed and showed that although there were some alterations in the properties of the HDPE and TPE, with the addition of CaCO{sub 3} and fly ash, the alterations are small, and more importantly, transition temperatures are not altered. A utility patent on the design of the hydraulic classifier, described extensively during our last reporting period, was written and filled with the U. S. Patent and Trademark Office during the period.« less

Authors:

Perrone, R S; Groppo, J G; Robl, T L

Publication Date:

Thu Jul 20 00:00:00 EDT 2006

Research Org.:

University of Kentucky Research Fdn

Sponsoring Org.:

USDOE

OSTI Identifier:

894295

DOE Contract Number:  

FC26-03NT41726

Resource Type:

Technical Report

Country of Publication:

United States

Language:

English

Subject:

01 COAL, LIGNITE, AND PEAT; CALCIUM CARBONATES; CARBON; COAL; COMBUSTION; DEFORMATION; DENSITY; ELASTOMERS; FILLERS; FLY ASH; HYDRAULICS; IGNITION; MORPHOLOGY; PLASTICS; POLYETHYLENES; POLYMERS; PONDS; STRAINS; THERMOPLASTICS; TRANSITION TEMPERATURE