Design and fabrication of advanced materials from Illinois coal wastes. Quarterly report, 1 March 1995--31 May 1995

Technical Report · Sun Dec 31 00:00:00 EST 1995

DOI:https://doi.org/10.2172/208374· OSTI ID:208374

Malhotra, V M; Wright, M A

The main goal of this project is to develop a bench-scale procedure to design and fabricate advanced brake and structural composite materials from Illinois coal combustion residues. Scanning electron microscopy (SEM), differential scanning calorimetry (DSC), differential thermal analysis (DTA), and transmission-Fourier transform infrared (FTIR) were conducted on PCC fly ash (Baldwin), FBC fly ash (ADM unit1-6), FBC fly ash (S.I. coal), FBC spent bed ash (ADM unit1-6), bottom ash, and scrubber sludge (CWLP) residues to characterize their geometrical shapes, mineral phases, and thermal stability. Our spectroscopic results indicate that the scrubber sludge is mainly composed of a gypsum-like phase whose lattice structure is different from the lattice structure of conventional gypsum, and sludge does not contain hannebachite (CaSO{sub 3}0.5H{sub 2}O) phase. In the second and third quarters the focus of research has been on developing protocols for the formation of advanced brake composites and structural composites. Our attempts to fabricate brake frictional shoes, in the form of 1.25 inch disks, from PCC fly ash, FBC spent bed ash, scrubber sludge, coal char, iron particles, and coal tar were successful. Based on the experience gained and microscopic analyses, we have now upscaled our procedures to fabricate 2.5 inch diameter disks from coal combustion residues. The SEM and Young`s modulus analyses of brake composites fabricated at 400 psi < Pressure < 2200 psi suggest pressure has a strong influence on the particle packing and the filling of interstices in our composites.

• Research Organization: Southern Illinois Univ., Carbondale, IL (United States)
• Sponsoring Organization: USDOE, Washington, DC (United States); Illinois Dept. of Energy and Natural Resources, Springfield, IL (United States)
• DOE Contract Number: FC22-92PC92521
• OSTI ID: 208374
• Report Number(s): DOE/PC/92521-T237; ON: DE96007009
• Resource Relation: Other Information: PBD: [1995]
• Country of Publication: United States
• Language: English

Related Subjects

01 COAL, LIGNITE, AND PEAT
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
COAL
COMBUSTION PRODUCTS
WASTE PRODUCT UTILIZATION
FLY ASH
STRUCTURAL CHEMICAL ANALYSIS
ASHES
SLUDGES
BRAKES
COMPOSITE MATERIALS
MECHANICAL PROPERTIES
SCRUBBERS
PROGRESS REPORT
EXPERIMENTAL DATA
SCANNING ELECTRON MICROSCOPY
CALORIMETRY
DIFFERENTIAL THERMAL ANALYSIS
INFRARED SPECTRA
FOURIER TRANSFORMATION