Section 15.    MISCELLANEOUS
DEVELOPMENT OF COMMERCIAL PRODUCTS
FROM INDUSTRIAL WASTES
Mir Akbar Ali, President
Glass 8c Ceramics International, Inc.
Lomita, California 90717
INTRODUCTION
The recycling of industrial wastes into the economy epitomizes a constructive use of our abundant
waste material. In fact, this could be the basis for converting the waste into a valued industrial product. In this context, the utilization of fly ash (generated by coal-burning power plants) and cement kiln
dust (generated by cement plants) are a viable commercial opportunity. Each year, the coal-burning
power plants and the cement plants are faced with increasing stringent regulations which prohibit the
dumping of fly ash and cement kiln dust (CKD) and similar industrial waste materials [1,2]. Currently, the coal-burning utilities generate over 40 million tons/year of fly ash and similar quantities of
CKD are collected by the cement plants. This paper describes a synergistic approach wherein both fly
ash and CKD are effectively utilized in the development of a commercial product such as mineral
wool.
Most industrial research efforts result in the development or indicate the potentials for commercial
exploitation. However, a judicious selection has to be made which would establish such exploitation
as economically viable projects. The development of mineral wool and similar products from fly ash
and CKD has the potential for commercial exploitation due to their abundance, negative cost (disposal cost) and close proximity to industrial cities where both the raw materials (industrial wastes) and
the potential product (mineral wool) can be utilized.
IDENTIFICATION AND SELECTION OF WASTES
Coal ash from Southern California Edison's Mojave Generating Plant along with CKD from California Portland Cement Company's Colton Plant was utilized. These two plants are not only close to
each other, but are also close to Los Angeles.
"As Received" fly ash and CKD were chemically analyzed. Table I presents the wet chemical analysis of these two materials.
It should be emphasized that in most of the waste utilization (resource recycling) efforts, the economics dictate that the waste be utilized, as much as possible, in the "as in" condition. The utilization of "as-received" fly ash and CKD was based on this rationale.
TECHNICAL APPROACH
The technical approach for the research was based on a theoretical concept which has been
described in detail in the published articles [3,4]. The salient features of the concept are:
1. Development of mineral wool forming compositions based on fly ash, CKD and a fluxing agent.
2. Establishment of their alkalinity ratio (acid to base ratios for fly ash and CKD).
3. Design and formulation of compositions such that the alkalinity ratio is in the range of 0.8-1.20.
Based on these concepts, over a dozen experimental compositions were successfully designed and
formulated. The batches were melted in 1, 2, and 5 lb. crucibles. The molten batch was poured over a
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