Compositech, Inc.

Demer Corporation

Polysum Technologies, L.l.c.

John C Bayer

Thomas C Gandolfo

A process is provided for making thermoplastic-composites from recycled thermoplastics (polyolefins) together with phosphogypsum waste by-product from the phosphate fertilizer wet process or, in an equally preferred embodiment with fluorogypsum waste by-product from fluorine production wet process to produce lumber profiles. The process involves (a) admixing phosphogypsum (calcium sulfate) and/or fluorogypsum (calcium fluoride) waste byproduct and/or Flue Gas Desulfurization (FGD) gypsum and/or crude gypsum and/or calcined gypsum with thermoplastics and a functionalized compound with or without coupling agents to produce a filled thermoplastic-composite composition, and (b) melt processing the composition to produce a filled thermoplastic-composite article. The articles are preferably in the form of railroad cross ties or construction articles such as common lumber profiles, panels, tiles, poles, utility poles, crossarms for utility poles, roofing tiles, pipeline skids, pilings, marine fender-piles (including light emitting piles), bulkheads, revetments, and are useful for constructing various structures, such as oilfield board roads and equipment mats. The process avoids the accumulation of undesired phosphogypsum/fluorogypsum 'stacks' and provides environmentally friendly useful products which require no chemical preservatives to prevent insect infestation or decay from the elements. Tailings from ore processing can also be used as a filler.

Thermoplastic railroad cross-ties

A composite marine piling is provided comprising (a) a core element comprising filler and a thermoplastic resin and (b) a sheath comprising thermoplastic resin and a light absorbing/emitting material. The filled thermoplastic composition of the core element is melt processed (for example injection or compression molded) to produce the filled thermoplastic composite marine piling core element. The sheath covers top of the core element to provide the top portion of the piling with a light responsive sheath to enhance the visibility of the piling to ship operators. The piling is a useful replacement for wood pilings and has several physical property advantages and preferably being suitable made from recycled plastic and waste byproduct filler.

Thermoplastic photoluminescent pilings and process for making thereof

A composite railroad tie is provided comprising a phosphogypsum filler and a thermoplastic resin. The composite exhibits desirable physical properties for railroad ties. Suitable sources for phospho-gypsum include fertilizer processes involving (a) providing phosphate rock, (b) contacting the phosphate rock with sulphuric acid in the presence of water to produce phosphoric acid and a calcium sulphate, (c) separating at least a portion of the phosphoric acid from the calcium sulphate to produce a phosphoric acid product and a calcium sulphate byproduct, (d) drying the calcium sulphate byproduct to remove water therefrom. The calcium sulphate byproduct (phospho-gypsum) is then admixed with a thermoplastic and a functionalized compound to produce a filled thermoplastic composition. The filled thermoplastic composition is then melt processed (for example injection or compression molded) to produce a filled thermoplastic composite railroad tie. The tie is a useful replacement for wood products having several physical property advantages and being suitable made from recycled plastic and waste byproduct filler.

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Folsom, LA, United States of America

John C Bayer