Process using fly ash to create chunks of raw material for iron or steel mill activities.

Abstract

A process of preparing for reuse small particles of one or more waste products produced from iron or steel mill activities, comprising the steps of creating a blend of one or more waste products with a blending system, the blend including a predetermined proportion of each of the one or more waste products, combining fly ash and the blend with a liquid in a mixing container to create a mixture, adding a predetermined amount of moisture reduction additive to the mixture, adjusting the amount of the liquid in the mixture to achieve a predetermined moisture and time before set up occurs, mixing the mixture continuously until set up occurs and an agglomeration forms, casting the agglomeration onto a surface, dividing the agglomeration into predetermined size chunks, removing particles of less than the predetermined size from the agglomeration. The chunks produced according to this process.

1 . A process for converting small particles of one or more reusable waste products into an agglomeration, the one or more reusable waste products being produced from iron or steel mill activities, the process comprising:
 (a) creating a blend of one or more waste products with a blending system, the blend including a predetermined proportion of each of the one or more waste products;   (b) combining fly ash and the blend with a liquid in a mixing container to create a mixture;   (c) adding a predetermined amount of moisture reduction additive to the mixture;   (d) adjusting an amount of the liquid in the mixture to achieve a predetermined moisture and time before set up occurs;   (e) mixing the mixture continuously until set up occurs and an agglomeration forms;   (f) casting the agglomeration onto a surface;   (g) dividing the agglomeration into predetermined size chunks;   (h) removing particles of less than the predetermined size from the agglomeration.   
     
     
         2 . The process according to  claim 1  further comprising:
 (a) adding a curing accelerator to the mixture prior to forming the agglomeration, the curing accelerator being selected from the group consisting of sodium carbonate, sodium silicate, calcium chloride, potassium silicate and aluminum silicate. 
 
     
     
         3 . The chunks produced according to the process of  claim 1 . 
     
     
         4 . A process for converting small particles of one or more reusable waste products into an agglomeration, the one or more reusable waste products being produced from iron or steel mill activities, the process comprising:
 (b) creating a blend of one or more waste products with a blending system, the blend including a predetermined proportion of each of the one or more waste products;   (c) combining fly ash and the blend with a liquid in a mixing container to create a mixture;   (d) adding a predetermined amount of moisture reduction additive to the mixture;   (e) adjusting an amount of the liquid in the mixture to achieve a predetermined moisture and time before set up occurs;   (f) adding a curing accelerator to the mixture prior to forming the agglomeration, the curing accelerator being selected from the group consisting of sodium carbonate, sodium silicate, calcium chloride, potassium silicate and aluminum silicate.   (g) mixing the mixture continuously until set up occurs and an agglomeration forms;   (h) casting the agglomeration onto a surface;   (i) dividing the agglomeration into predetermined size chunks;   (j) removing particles of less than the predetermined size from the agglomeration.   
     
     
         5 . The chunks produced according to the process of  claim 4 . 
     
     
         6 . A process for converting small particles of one or more reusable waste products into an agglomeration, the one or more reusable waste products being produced by a metal-processing activity, the process comprising:
 (a) measuring a first amount and a second amount of a first and second reusable waste product, respectively;   (b) blending the first amount and the second amount together to produce a uniform mixture;   (c) adding fly ash and liquid to the mixture;   (d) mixing the mixture continuously until the mixture starts to set-up;   (e) casting the mixture onto a surface to form an agglomeration; and   (f) after the agglomeration sets-up, divide the agglomeration into pieces sized for reintroduction into the metal-making activity.   
     
     
         7 . The pieces produced according to the process of  claim 6 .