Char-based block pavers and brick veneers and methods of making same

Pyrolysis char bricks and pavers, made by mixing pyrolysis char with cement and additives, address the need for eco-efficient coal-derived building materials by offering improved strength and weather resistance.

AU2024208895B2Pending Publication Date: 2026-07-09UNIVERSITY OF WYOMING
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Patent Information

Authority / Receiving Office
AU · AU
Patent Type
Applications
Current Assignee / Owner
UNIVERSITY OF WYOMING
Filing Date
2024-01-17
Publication Date
2026-07-09

AI Technical Summary

Technical Problem

The increasing demand for renewable energy has reduced the production and consumption of coal, leading to a need for environmentally friendly and eco-efficient coal-derived products, particularly bricks, which face performance setbacks compared to conventional clay bricks.

Method used

Pyrolysis char bricks and pavers are produced by mixing pyrolysis char with cement materials, silica fume, and additives like trass or trass lime, resulting in compositions with improved strength, reduced density, and enhanced insulative properties.

Benefits of technology

The resulting pyrolysis char bricks and pavers exhibit compressive strengths of 5-60 MPa, densities of 1.0-2.0 g/cm³, and reduced water absorption, making them suitable for construction applications and resistant to severe weather conditions.

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Abstract

Embodiments of the present disclosure relate to pyrolysis char block pavers (PCBPs), pyrolysis char brick veneers (PCBVs), and methods of forming PCBPs and PCBVs. The PCBP and PCBV includes a composition having a dry mixture and a wet mixture. The dry mixture includes pyrolysis char (PC) and cement materials. The wet mixture includes water, silica fume (SF), and additives. The composition is about 20% to 40% of PC, about 20% to 60% cement materials, about 0.1% to 10% SF, and about 1% to 1.5% additives, by weight. The methods include mixing water and additives to form a wet mixture; mixing pyrolysis char (PC) and cement materials to form a dry mixture; mixing the wet mixture and the dry mixture to form a composition mixture; transferring the composition mixture to a mold; pre-pressing the composition mixture; curing the composition mixture to for a composition; demolding the composition; and curing the composition.
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