Mechanical, Fire, and Electrical Insulation Properties of Polyurethane Fly Ash Composites

This paper demonstrates that ash composites, comprising fly ash and polyurethane, can be used to develop value-added products that exhibit an effective decrease in the leaching of coal ash inorganics to less than one-third of the Environmental Protection Agency (EPA)’s maximum contaminant level (MCL) when soaked in a water circulation system for 14 months. Furthermore, the composite blocks remain safe even with ruptured surfaces. The concept of encapsulating fly ash within ash composites by using a polar polymer to bind the fine inorganic particles, mimicking how nature does it in the original unburned coal, ensures the safety of the composite. The ash composites can be formulated to have designed mechanical, fire, and electrical properties by controlling the formulation and the density. The properties of typical density composites were produced, measured, and compared with commercial materials. This paper also demonstrates that ash composite technology can be extended to coal ash stored in ponds. Finally, a typical electric utility box cover was designed, fabricated, and test validated. The box cover has less than one-half the weight of the original box cover for the same design limits. Finally, the benefits of this ash-composite technology for product manufacturers, society, and ash producers are summarized.