Stabilized sulfur binding using activated fillers

1. A method of making a stable, sulfur binding composite comprising:

i) providing a solid aggregate having a surface, the solid aggregate being selected from the group consisting of mineral fillers, ash, silica sand, industrial waste, and combinations thereof;

ii) impregnating the solid aggregate with an organic modifier comprising unsaturated hydrocarbons with at least one double or triple covalent bond between adjacent carbon atoms to create a modifier-impregnated aggregate;

iii) heating and drying the modifier-impregnated aggregate to activate the surface of the modifier-impregnated aggregate for reaction with sulfur;

iv) adding a powdered solid or molten elemental sulfur to the modifier-impregnated aggregate;

v) mixing the elemental sulfur and modifier-impregnated aggregate at a temperature high enough to melt any solid sulfur or maintain a molten state of elemental sulfur in combination with modifier-impregnated aggregate; and

vi) cooling the liquid mixture to form a solid product.

2. A method according to claim 1 , wherein after providing a solid aggregate, the solid aggregate is ground or sieved to provide solid aggregate with desired particle sizes.

3. A method according to claim 1 , wherein the solid aggregate has a maximum particle size of about 1 mm.

4. A method according to claim 1 , wherein the solid aggregate has a maximum 25 particle size of about 200 microns.

5. A method according to claim 1 , wherein the solid aggregate has a maximum particle size of about 150 microns.

6. A method according to claim 1 , wherein the solid aggregate has a maximum particle size of about 100 microns.

7. A method according to claim 1 , wherein the solid aggregate has a minimum particle size of about 10 microns.

8. A method according to claim 1 , wherein the solid aggregate has a minimum particle size of about 1 micron.

9. A method according to claim 1 , wherein the solid aggregate has a minimum particle size of about 0.1 microns.

10. A method according to claim 1 , wherein the solid aggregate are mineral fillers selected from the group consisting of quartz, talc, wollastonite, calcite, dolomite, mica, kaolin, feldspar, barites, and combinations thereof.

11. A method according to claim 10 , wherein the solid aggregate is quartz.

12. A method according to claim 1 , wherein the composite is substantially free of clay-like materials.

13. A method according to claim 1 , wherein the solid aggregate has a filler surface area of greater than about 1,000 cm2/g.

14. A method according to claim 1 , wherein the organic modifier is selected from the group consisting of black oil, gasoil, rubber, or combinations thereof.

15. A method according to claim 1 , wherein heating and drying in step iii) activates unsaturated carbon bonds on the surface of the modifier-impregnated aggregate.

16. A method according to claim 15 , wherein the modifier-impregnated aggregate is heated from about 130° C. to about 200° C.

17. A method according to claim 16 , wherein the modifier-impregnated aggregate is heated from about 150° C. to about 190° C.

18. A method according to claim 1 , wherein the elemental sulfur in step iv) is powdered or molten.

19. A method according to claim 1 , wherein the solid product is in the form of pellets, granules, flakes, or powder.

20. A method according to claim 19 , wherein step vi) further comprises re-melting and combining the solid product with additional modifier-impregnated aggregate to produce sulfur concrete products.

21. A method according to claim 1 , wherein the sulfur and modifier-impregnated aggregate is heated in step v) to a temperature of from about 120° C. to about 210° C.

22. A method according to claim 1 , wherein the mixing in step v) is done using a high shear, vortex, or ultrasonic mixing system capable of introducing sufficient energy into the system to effect a sulfur composite reaction.

23. A method according to claim 1 , wherein the solid aggregate is present in the composite in a minimum amount of about 10 weight percent.

24. A method according to claim 1 , wherein the solid aggregate is present in the 15 composite in a minimum amount of about 20 weight percent.

25. A method according to claim 1 , wherein the solid aggregate is present in the composite in a minimum amount of about 30 weight percent.

26. A method according to claim 1 , wherein the solid aggregate is present in the composite in a maximum amount of about 90 weight percent.

27. A method according to claim 1 , wherein the solid aggregate is present in the composite in a maximum amount of about 80 weight percent.

28. A method according to claim 1 , wherein the solid aggregate is present in the composite in a maximum amount of about 70 weight percent.

29. A method according to claim 1 , wherein the elemental sulfur is present in the composite in a minimum amount of about 10 weight percent.

30. A method according to claim 1 , wherein the elemental sulfur is present in the composite in a minimum amount of about 28 weight percent.

31. A method according to claim 1 , wherein the elemental sulfur is present in the composite in a maximum amount of about 90 weight percent.

32. A method according to claim 1 , wherein the elemental sulfur is present in the composite in a maximum amount of about 68 weight percent.

33. A method according to claim 1 , wherein the organic modifier is present in the composite in a minimum amount of about 1 weight percent.

34. A method according to claim 1 , wherein the organic modifier is present in the composite in a minimum amount of about 1.5 weight percent.

35. A method according to claim 1 , wherein the organic modifier is present in the composite in a maximum amount of about 10 weight percent.

36. A method according to claim 1 , wherein the organic modifier is present in the composite in a maximum amount of about 7 weight percent.

37. A method according to claim 1 , wherein the organic modifier is present in the composite in a maximum amount of about 3 weight percent.