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

During this reporting period, efforts focused on improving our understanding of the basic operating principles of the lamella classifier. It was determined from testing that product grade is primarily a function of the classifier configuration and operation and the feed grade has relatively minor influence. Additionally, within the range of the testing conducted, the feed density did not seem to have an impact of the yield. Thus, the product composition will not be strongly influenced by the variability of the feed, an important consideration for heterogeneous ponded fly ash. Three types of chemically and functionally different thermoplastic polymers have been chosen for evaluation with the fly ash derived filler: high density polyethylene, thermoplastic elastomer, and polyethylene terphthalate. 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 most ({approx}80%) of 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. A stainless steel mold with cooling capabilities was built in-house to prepare 1 mm thick films for tensile strength and Dynamic Modulus testing. Procedures are being developed to insure a minimum of air voids in the films, which will eventually be evaluated for a variety of physical and mechanical properties