Lined interior board containing pyrolyzed bioaggregates

Abstract

A construction product and a method for manufacturing the construction product are provided. The method includes obtaining a bioaggregate, pyrolyzing the bioaggregate to obtain a pyrolyzed bioaggregate, and mixing a binder including at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide with the pyrolyzed bioaggregate to form a mixture for the construction product. The method further includes forming the mixture into a predetermined geometric shape and providing a planar lining material on one or more outer surfaces of the predetermined geometric shape.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION Embodiments of the present invention relate to construction products. In particular, embodiments of the present invention relate to low-carbon or carbon-negative construction products. [Background technology]

[0002] The Intergovernmental Panel on Climate Change (IPCC) released a report in 2018 detailing the actions governments should take to meet the goal of keeping global temperature rise below 1.5°C above pre-industrial levels. The IPCC report stated that to achieve this goal, global carbon dioxide emissions would need to reach net-zero by the middle of this century. While transitional changes toward reducing greenhouse gas emissions are underway, a rapid increase in the scale and pace of the transition would be necessary to limit warming to 1.5°C. However, some industries are finding it difficult to achieve net-zero emissions. The IPCC suggested that a technique known as carbon dioxide removal (CDR), in which carbon dioxide is removed from the atmosphere, could help limit warming.

[0003] Conventional construction materials emit greenhouse gases during one or more of the manufacturing process, transportation, customer use, and end-of-life. The manufacture of most products involves the generation of greenhouse gas emissions by using raw materials that are mined or manufactured using fossil fuels, and / or by transporting products and / or reagents.

[0004] Therefore, there is a need for construction products that can remove carbon dioxide from the atmosphere. Summary of the Invention [Means for solving the problem]

[0005] The present invention is as defined in the accompanying independent claims. The present invention provides construction products and methods for producing those products. The construction products of the present invention, and related methods for producing those products, may utilize fast carbonation and / or pyrolysis feedstocks (e.g., pyrolysis bioaggregates).

[0006] The construction product may be a low carbon or carbon negative construction product.

[0007] The term "low carbon" is used herein to refer to products whose manufacture results in less carbon dioxide emissions into the atmosphere than corresponding conventional products.

[0008] The term "carbon negative" is used herein to refer to a product that removes more carbon dioxide from the atmosphere than enters the atmosphere during the manufacture of the product.

[0009] The inventive products described herein utilize carbon as a resource (e.g., as carbon dioxide during rapid carbonation and / or as pyrolysis bioaggregates), such that production of the products may reduce atmospheric carbon dioxide.

[0010] The construction products of the invention described herein can have the net effect of removing carbon dioxide from the atmosphere (as measured from resource extraction to completion, i.e., at the factory gate), and therefore can be used to mitigate global warming.

[0011] The construction product of the present invention is preferably composed of natural materials. The construction product preferably comprises at least 80% by weight, preferably at least 90% by weight, preferably at least 95% by weight, for example about 99% by weight, of natural materials relative to the total weight of the mixture. In some embodiments, the construction product is entirely composed of natural materials.

[0012] The term "bioaggregate" is used herein to refer to granules formed from plant material. Each granule in a bioaggregate has a maximum particle size, which is used herein to refer to the granule's maximum dimension. The bioaggregate may be formed from any suitable part of a plant. Preferably, the bioaggregate is formed from plant stems. The bioaggregate may include, for example, pulverized bioaggregates. The bioaggregate may be pulverized using any conventional pulverization mechanism, such as a knife, hammer, rotary, or ball mill. The pulverized bioaggregate may be passed through a screen or sieve having predetermined pores to allow pulverized bioaggregates having predetermined dimensions to pass through. Preferably, the bioaggregate is formed from chemically untreated plant material. The term "chemically untreated" is used herein to refer to plant material in which the cellular structure of the plant material remains unchanged.

[0013] Bioaggregates can be provided by a wide range of plant types. Construction products can be prepared from low-value, readily (preferably locally) available, abundant plant material. Furthermore, construction products of the present invention can be produced at low cost, on a large scale, with low associated energy costs.

[0014] Plant material suitable for use as a bioaggregate can include, for example, perennial plant(s), such as treated perennial plant(s) and / or by-products of treating perennial plant(s). Bioaggregates can include softwood or hardwood. Plant material suitable for use as a bioaggregate includes wood particles of both softwood and hardwood.

[0015] Preferably, the bioaggregate is an agricultural product or by-product, such as a crop, an agricultural by-product, a food crop or a food crop by-product.

[0016] Preferably, the bioaggregate is selected from one or more of maize, wheat (e.g., common wheat (Triticum aestivum)), rice, barley, millet, grass (e.g., horsetail), rice husk, straw, squash, pumpkin, watermelon, cucumber, melon, hops, cannabis, celtis tress, nettle, wildflowers, rape straw, algae, seaweed, bamboo, rapeseed (Brassica napus), barley (Hordeum vulgare), oat (Avena sativa), flax, rice straw, corn straw, giant miscanthus (Miscanthus giganteus), sugarcane bagasse, sisal straw, hemp, or any combination thereof.

[0017] Preferably, the bioaggregate comprises one or more plants having a medium silica content and / or one or more plants having a high silica content.

[0018] The bioaggregate preferably comprises at least one medium (preferably high) silica content plant, preferably having a silica content of 2% or more, for example 4% or more.

[0019] The medium to high silica content of the bioaggregate-forming plant(s) can react with alkaline earth metals (e.g., calcium) in the binder to form strong, durable, crystalline alkaline earth metal silica hydrates, such as calcium silica hydrates. This crystalline structure has been found to be identical to that of calcium silica hydrates found in cement. The alkaline earth metal silica hydrates (e.g., calcium silica hydrates) formed have been found to provide a pozzolanic effect that improves product strength through the use of bioaggregates. Thus, the increased strength of the construction products of the present invention reduces reliance on binders with high carbon content (e.g., cement). Furthermore, the construction products of the present invention have increased strength without the need for, or with reduced amounts of, other mineral-based pozzolans, such as metakaolin and silica fume.

[0020] Preferably, the bioaggregate comprises one or more high-silica plants selected from, for example, one or more of the families Poaceae, Equisetaceae, and / or Cyperaceae, or any combination thereof, and / or one or more medium-silica plants selected from, for example, one or more of the families Cucurbitales, Urticales, and / or Commelinaceae, or any combination thereof. The Poaceae plant family is economically the most important plant family, providing not only staple foods, including cultivated grains, but also feed for meat-producing animals. The Poaceae plant family provides just over half (51%) of total dietary energy through direct human intake. Of the total dietary energy, rice provides 20%, wheat provides 20%, maize (corn) provides 5.5%, and other grains provide 6%. The Poaceae plant family includes, for example, maize, wheat, rice, barley, and millet.

[0021] Some members of the Poaceae plant family, such as bamboo, thatch, and straw, are used as building materials. Other members of the Poaceae family, such as maize, may provide a source of biofuel.

[0022] The family Equisetaceae includes grasses such as horsetail. The family Cyperaceae includes 5,500 known species in about 90 genera. Examples include rice husk and straw.

[0023] The Cucurbitales family, such as the Cucurbitaceae (Gourd) family, includes food species such as squash (Cucurbita spp.), pumpkin (Cucurbita spp.), watermelon (Citrullus vulgaris), cucumber (Cucumis spp.), and melon (Cucumis spp.).

[0024] The Urticales family includes the Cannabaceae family, which includes cultivated species such as hops, cannabis, and Certistresses (e.g., Pteroceltis), known for its high-end rice paper. Cannabis includes not only industrial hemp plants but also varieties high in tetrahydrocannabinol (THC) and other cannabinoids, most commonly cannabidiol (CBD), which are increasingly cultivated for recreational and medicinal use.

[0025] The Urticales family also includes the Urticaceae family, which includes, for example, the common nettle.

[0026] The family Commelinaceae includes, for example, wildflowers.

[0027] The bioaggregates may include organic by-products of food processing. The organic by-products of food or beverage processing may be selected from nut shells, stone fruit, coffee grounds, hops grounds, brewer's grains, or pomace.

[0028] The term "pyrolysis" is used herein to refer to the thermal decomposition of bioaggregates or feedstocks in the absence or near absence of oxygen. Pyrolysis is typically carried out at temperatures above 500°C to provide sufficient heat to break down the biopolymers in the bioaggregates or feedstocks. Because no (or little) oxygen is present, combustion of the bioaggregates or feedstocks does not occur, and the material pyrolyzes into biochar and combustible gases. The combustible gases may condense to provide a flammable liquid called pyrolysis oil or bio-oil. Gases produced during pyrolysis, such as carbon dioxide, carbon monoxide, and light hydrocarbons, may be combusted to provide heat for the process. Pyrolysis conditions, such as temperature and heating rate, may be varied. Varying the pyrolysis conditions may alter the yield of the resulting pyrolyzed bioaggregates or feedstocks. In some embodiments, a slow heating rate is used to increase the production of pyrolytic bioaggregates or feedstocks. In some embodiments, the pyrolysis of bioaggregates or feedstocks may be self-sufficient by utilizing the combustible gases produced during the process to provide thermal energy.

[0029] According to a first aspect of the present disclosure, i) a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide; ii) Bioaggregates and A construction product is provided that includes a fast-carbonating setting mixture of

[0030] In some instances, the construction product is an interior board, and a planar lining material is provided on one or both outer surfaces of the mix. The interior board may be an interior lining board.

[0031] The binder and / or bioaggregate may be as described above.

[0032] Preferably, the binder is selected from one or more of an alkaline earth metal oxide (e.g., magnesium oxide), an alkaline earth metal hydroxide (e.g., calcium hydroxide), cement (e.g., one or more of ordinary Portland cement, white cement, calcium aluminate cement, natural cement, or any combination thereof), lime (e.g., one or more of oxidized lime, hydrated lime, natural hydraulic lime, or any combination thereof), a pozzolanic element (e.g., one or more of metakaolin, silica fume, fly ash, or any combination thereof), or any combination thereof.

[0033] The binder preferably comprises one or more alkaline earth metal oxides and / or alkaline earth metal hydroxides.

[0034] The binder preferably comprises hydrated lime, for example natural hydraulic lime.

[0035] The ratio of the amount of bioaggregate (wt%) to the amount of binder (wt%) in the mixture is preferably at least 1:10, preferably at least 1:8, for example at least 1:6. The ratio of the amount of bioaggregate (wt%) to the amount of binder (wt%) in the mixture is preferably 1:1.5 or less, preferably 1:2 or less, for example 1:3 or less. The ratio of the amount of bioaggregate (wt%) to the amount of binder (wt%) in the mixture is preferably between 1:10 and 1:1.5, preferably between 1:8 and 1:2, preferably between 1:6 and 1:3.

[0036] The maximum particle size of the granules in the bioaggregate is preferably about 100 mm or less, more preferably about 70 mm or less, more preferably about 50 mm or less, more preferably 40 mm or less, for example 30 mm or less.

[0037] The maximum particle size of the granules of the bioaggregate is preferably at least about 0.1 mm, more preferably at least about 0.15 mm, more preferably at least about 0.2 mm, for example at least about 0.25 mm.

[0038] The maximum particle size range of the granules of the bioaggregate is preferably within the range of 0.1 mm to 100 mm, preferably within the range of 0.1 mm to 70 mm, preferably within the range of 0.1 mm to 50 mm.

[0039] The maximum particle size distribution profile of the bioaggregate granules is important to both the manufacturing and structural performance of the resulting product.

[0040] Particle size distribution is conventionally defined by the method by which it is measured.

[0041] One suitable method is sieve analysis, in which powders are separated on sieves of different sizes. The maximum particle size and particle size distribution described herein can be determined by sieve analysis.

[0042] Thus, particle size distributions are measured in terms of discrete size ranges based on the size of the sieve used. Particle size distributions can be presented in cumulative form.

[0043] In some embodiments, the bioaggregates comprise a predetermined particle size distribution ranging from a minimum maximum particle size to a maximum maximum particle size.

[0044] In some embodiments, the cumulative particle size distribution function of the bioaggregates is substantially sigmoidal when measured from the highest maximum particle size to the lowest maximum particle size.

[0045] In some embodiments, the bioaggregates may be fine and may have a maximum particle size of substantially 5 mm. The bioaggregates may have a relatively narrow particle size distribution. In some embodiments, more than 50% of the bioaggregates may be between 1 mm and 4 mm in size, and more than 30% may be less than 1 mm in size. More than 50% of the bioaggregates may be between 1 mm and 4 mm in size. More than 30% of the bioaggregates may be less than 1 mm in size.

[0046] In some embodiments, at least the majority of the particles may have a maximum particle size less than one-third of the thickness of the construction product (measured between the opposing surfaces of the mixture optionally lined with a planar lining material), for example when the construction product is manufactured as a planar sheet such as an interior lining board / plasterboard. In some embodiments, there may be substantially no particles having a maximum particle size greater than one-third of the thickness of the construction product (measured between the opposing surfaces of the mixture optionally lined with a planar lining material), for example when the construction product is manufactured as a planar sheet such as an interior lining board / plasterboard.

[0047] In some embodiments, the bioaggregate comprises a first bioaggregate portion having a fine particle size (e.g., having a maximum particle size of 5 mm or less) to provide increased reactivity for forming crystalline calcium silica hydrate. Preferably, the bioaggregate further comprises a second bioaggregate portion having a larger particle size than the first bioaggregate portion (e.g., the second bioaggregate portion comprises granules having a maximum particle size of 100 mm or less) to provide a product with reduced density and improved thermal and / or moisture absorption properties. The first and second bioaggregate portions can be provided by the same plant or by different plants.

[0048] The bioaggregates are preferably pyrolyzed, allowing the carbon to be sequestered from the atmosphere and permanently trapped in the resulting pyrolyzed biochar. Furthermore, pyrolysis of the bioaggregates increases the density of carbon in the construction product. Pyrolyzed bioaggregate particles are hydrophobic, thus providing improved contact between the binder and the bioaggregate, resulting in improved mechanical strength of the resulting construction product. Pyrolysis of the bioaggregates chemically alters the structure of the bioaggregates, resulting in increased mechanical properties, including, for example, compressive modulus and / or strength and flexural modulus / strength, of the bioaggregates and, in turn, of the resulting construction product. Pyrolysis of the bioaggregates also provides a source of bio-oil and / or biogas for further downstream processing.

[0049] Pyrolysis of bioaggregates preferably produces pyrolyzed bioaggregate particles with a narrow particle size distribution compared to non-pyrolyzed bioaggregates. Bioaggregates are highly siliceous and fibrous in nature, which can make them difficult or cost-effective to break down into small particle sizes. Pyrolyzed bioaggregates are much more brittle in nature, due in part to their high carbon content, and therefore easier to break down.

[0050] The pyrolyzed bioaggregate particles have improved size regularity, resulting in construction products with improved surface finish due to a more regular particle size distribution. The improved surface finish translates into improved edge definition, resulting in more efficient installation of the resulting construction products.

[0051] Preferably, pyrolysis of the bioaggregates produces pyrolyzed bioaggregate particles with reduced moisture content (preferably uniform moisture content).

[0052] Pyrolyzed bioaggregates have an improved ability to sequester volatile organic components (VOCs) from the atmosphere due to the ionic nature of the particle surface and increased surface area compared to non-pyrolyzed particles.

[0053] In some embodiments, negative carbon construction products may include inert, non-biodegradable pyrolytic bioaggregates that permanently sequester biogenic carbon in the pyrolytic bioaggregates.

[0054] In some embodiments, the bioaggregate (or pyrolyzed bioaggregate) has a silica content of at least 2% by weight, preferably at least 4% by weight. The silica in the bioaggregate (or pyrolyzed bioaggregate) can react with binders to form alkaline earth metal silica hydrates (e.g., calcium silica hydrates), providing a pozzolanic effect that has been shown to improve the strength of the resulting construction product. The present invention therefore reduces the product's dependency on the presence of additional high-carbon binders (such as cement) and may eliminate the need for other mineral-based pozzolans, such as metakaolin and silica fume.

[0055] The mixture may further comprise one or more additives selected from viscosity modifiers, and / or coupling agents, and / or water retention agents, or any combination thereof. The one or more additives may comprise one or more carbohydrates, e.g., polysaccharides, such as methylated cellulose ethers. The one or more additives are preferably of plant origin. The mixture may further comprise an air entrainment agent, such as lignin sulfonate.

[0056] The mixture may further comprise a plasticizer. The plasticizer may be present in the mixture in an amount of up to 2% by weight of the binder. Preferably, the plasticizer is present in the mixture in an amount between 0.5% and 1.5% by weight of the binder.

[0057] The construction product can be an interior board, such as an interior lining board, an insulation board, or an acoustic panel. The construction product can be, for example, an interior lining board, an insulation board, an acoustic panel, a tile, a block, or a lintel. The construction product can be, for example, a molded construction product (e.g., a lining board, an insulation board, an acoustic panel, a tile, a block, or a lintel formed at least partially by molding). Water can be added to the mixture before molding. The molded construction product can be formed using extrusion molding, for example, by extruding through a die. The molded construction product can be formed using continuous extrusion molding. The die can be, for example, one or more rollers through which the mixture is continuously extruded. The construction product can be formed by continuously extruding the mixture onto a conveyor, where the mixture is provided on the conveyor and the gap between the conveyor and the rollers defines the die. In some examples, a planar lining material is applied to the outer surface of the mixture by a roller during continuous extrusion. The die can also include static (i.e., non-rolled) elements in addition to the rollers. In other examples, the construction product can be cast or 3D printed. For example, if the construction product is an interior lining board (or another type of interior board such as an insulation board or an acoustic panel), the construction product may include a fast-carbonation setting mixture of binder and bioaggregate provided on a planar lining material, preferably between two opposing sheets of the planar lining material. The planar lining material is preferably provided on one or both outer surfaces of the mixture, e.g., the molding mixture.

[0058] In some embodiments, the planar lining material is paper. In some instances, the paper weighs up to 250 gsm. The paper may weigh at least 150 gsm. The paper may weigh between 170 gsm and 200 gsm, and may be recycled paper.

[0059] The mixture may include a cellulose adhesive, which may be methylcellulose.

[0060] A cellulose adhesive may be used to adhere the lining material to the remaining materials. The cellulose adhesive may contain between 1-2% cellulose in water. The cellulose may be methylcellulose.

[0061] The density of the construction product is at least 400 kg / m 3 The density of the construction product can be 650 kg / m 3 etc., at least 500 kg / m 3 Preferably, the density of the construction product is up to 1000 kg / m 3 The density of the construction product can be up to 700 kg / m 3 The density of the construction product is preferably 650 kg / m 3 etc., 500 kg / m 3 ~750kg / m 3 The density of the construction product can be between 500 kg / m 3 ~700kg / m 3 Preferably, the temperature is between 100°C and 200°C.

[0062] The thickness of the construction product (measured between the opposing surfaces of the mixture, optionally lined with a planar lining material), for example when produced as a planar sheet (e.g. plasterboard), may be at least 5 mm, preferably at least 9 mm, for example about 10 mm. The thickness of the construction product may be up to 50 mm. Preferably, the thickness of the construction product is between 5 mm and 50 mm, preferably between 9 mm and 50 mm, for example between 10 mm and 50 mm. Most preferably, the thickness of the construction product is between 8 mm and 15 mm.

[0063] In some instances, construction products are made from a combination of different board types. For example, the interior surface of the construction product may be insulation board, and the exterior surface of the construction product may be made from interior lining board, which may be thinner and denser than the insulation board.

[0064] In some alternatives, the construction product may be a plaster or render formed by the mixture described herein. The plaster may be an interior plaster for use on the interior walls of a building. The render may be an exterior render for use on the exterior walls of a building.

[0065] In such instances, the plaster or render is not cured during production (using rapid carbonation cure or otherwise). Instead, the plaster / render is cured in situ after being applied to an interior or exterior wall. The plaster or render may be, for example, a dry particulate mixture (e.g., a dry mortar product) to which water is added in situ to allow or cause the plaster / render to set.

[0066] The use of pyrolyzed raw materials in construction products may allow for the use of less water retention agent than would be possible without pyrolysis due to the hydrophobic nature of the pyrolyzed raw materials. The water retention agent (which may include complex carbohydrates) may act as a coupling agent between the binder and raw materials and the cellulose present in the lining material (if used). The use of less water retention agent may result in reduced surface shrinkage and a more uniform finish.

[0067] Construction products have been found to have improved mechanical properties, such as improved flexural strength, improved compressive strength, improved shear strength, improved nail pull resistance, and improved fastener acceptance, compared to the same construction products that have not been subjected to high-speed carbonation. Such interior boards have been found to have improved bonding of planar lining materials (e.g., paper) to the composite / mixture as a result of high-speed carbonation.

[0068] According to a further aspect of the present disclosure, there is provided a construction product comprising a mixture, the mixture comprising: i) a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide; ii) pyrolysis feedstock; Includes:

[0069] In some examples, the raw material is a bioaggregate and a planar lining material is provided on one or both exterior surfaces of the mixture. The interior board can be an interior lining board.

[0070] The pyrolysis feedstock can be, for example, pyrolysis bioaggregates.

[0071] The binder and / or bioaggregate may be as described above. The mixture may further include one or more additives as described above.

[0072] The binder is selected from one or more of an alkaline earth metal oxide (e.g., magnesium oxide), an alkaline earth metal hydroxide (e.g., calcium hydroxide), cement (e.g., one or more of ordinary Portland cement, white cement, calcium aluminate cement, natural cement, or any combination thereof), lime (e.g., one or more of oxidized lime, hydrated lime, natural hydraulic lime, or any combination thereof), a pozzolanic element (e.g., one or more of metakaolin, silica fume, fly ash, or any combination thereof), or any combination thereof.

[0073] The binder preferably comprises one or more alkaline earth metal oxides and / or alkaline earth metal hydroxides.

[0074] The binder preferably comprises hydrated lime, for example natural hydraulic lime.

[0075] The mixture may include a cellulose adhesive, which may be methylcellulose.

[0076] A cellulose adhesive may be used to adhere the lining material to the remaining materials. The cellulose adhesive may contain up to 2% by weight of cellulose in water. The cellulose adhesive may contain between 1 and 2% by weight of cellulose in water. The cellulose may be methylcellulose.

[0077] Pyrolysis of the feedstock can sequester carbon from the atmosphere and permanently trap the sequestered carbon in the resulting pyrolysis feedstock. As a result, the construction products of the present invention can result in the direct removal from the environment and long-term storage of greater amounts of carbon dioxide than required to produce the product. Furthermore, pyrolysis of the feedstock increases the density of the carbon in the construction product. The pyrolysis feedstock particles are hydrophobic, thus providing improved contact between the binder and the feedstock, resulting in improved mechanical strength of the resulting construction product. Pyrolysis of the feedstock chemically and physically alters the structure of the feedstock, resulting in increased mechanical properties, including, for example, compressive modulus and / or strength and flexural modulus / strength, of the feedstock and thus the resulting construction product. Pyrolysis of the feedstock also provides a source of bio-oil and / or biogas for further downstream processing.

[0078] Pyrolysis of the feedstock preferably produces pyrolyzed feedstock particles with a narrow particle size distribution compared to non-pyrolyzed feedstock. The pyrolyzed feedstock particles have improved size regularity, resulting in construction products with improved surface finishes due to the more regular particle size distribution. The improved surface finish translates into improved edge definition, resulting in more efficient installation of the resulting construction products.

[0079] Pyrolysis of the bioaggregates preferably produces pyrolyzed feed particles having a reduced moisture content (preferably uniform moisture content) compared to the non-pyrolyzed feed particles.

[0080] Pyrolyzed feedstocks have an improved ability to sequester volatile organic components (VOCs) from the atmosphere due to the ionic nature of the particle surfaces and increased surface area compared to non-pyrolyzed feedstock particles.

[0081] The construction product comprises an inert, non-biodegradable pyrolysis feedstock that can permanently sequester biogenic carbon in the pyrolysis feedstock.

[0082] The ratio of the amount of pyrolysis raw material (wt%) to the amount of binder (wt%) in the mixture is preferably at least 1:10, preferably at least 1:8, for example at least 1:6. The ratio of the amount of pyrolysis raw material (wt%) to the amount of binder (wt%) in the mixture is preferably 1:1.5 or less, preferably 1:2 or less, for example 1:3 or less. The ratio of the amount of pyrolysis raw material (wt%) to the amount of binder (wt%) in the mixture is preferably between 1:10 and 1:1.5, preferably between 1:8 and 1:2, preferably between 1:6 and 1:3.

[0083] The pyrolysis feedstock comprises pyrolysis bioaggregates. The bioaggregates may be selected from any of the examples of bioaggregates described herein. The pyrolysis feedstock may be obtained from the pyrolysis of post-consumer and / or post-industrial waste. In some examples, the pyrolysis feedstock consists entirely of pyrolysis bioaggregates. Thus, references to pyrolysis feedstock herein may be optionally replaced with references to pyrolysis bioaggregates. In some examples, the pyrolysis feedstock consists entirely of pyrolysis post-consumer and / or post-industrial waste. In some examples, the pyrolysis feedstock comprises both i) pyrolysis bioaggregates and ii) pyrolysis post-consumer and / or post-industrial waste.

[0084] Construction products have been found to have improved performance benefits when using pyrolysis feedstocks due to changes in the structure of the bioaggregates present in the product. Examples of improved performance benefits for construction products include one or more of fire retardancy, and / or thermal insulation / thermal conductivity, and / or VOC removal, and / or moisture buffering capacity, and any combination thereof.

[0085] The maximum particle size of the granules of the pyrolysis feedstock is preferably 100 mm or less, more preferably about 70 mm or less, more preferably about 50 mm or less, more preferably 40 mm or less, for example 30 mm or less.

[0086] The maximum particle size of the granules of pyrolysis feedstock is preferably at least about 0.1 mm, more preferably at least about 0.15 mm, more preferably at least about 0.2 mm, for example at least about 0.25 mm.

[0087] The maximum particle size range of the granules of the pyrolysis raw material is preferably in the range of 0.1 mm to 100 mm, preferably in the range of 0.1 mm to 70 mm, preferably in the range of 0.1 mm to 50 mm.

[0088] The maximum particle size distribution profile of the pyrolysis feedstock granules is important to both the manufacturing and structural performance of the resulting product.

[0089] As mentioned above, particle size distribution is conventionally defined by its measurement method. One suitable method is sieve analysis, in which powder is separated on sieves of different sizes. Therefore, particle size distribution is measured for discrete size ranges based on the size of the sieve used. Particle size distribution can be presented in cumulative form.

[0090] The maximum particle size and particle size distribution described herein may be determined by sieve analysis.

[0091] In some embodiments, the pyrolysis feedstock comprises a predetermined particle size distribution ranging from a minimum maximum particle size to a maximum maximum particle size.

[0092] In some embodiments, the cumulative particle size distribution function of the pyrolysis feedstock is substantially sigmoidal when measured from the highest maximum particle size to the lowest maximum particle size.

[0093] In some embodiments, the pyrolysis feedstock may be finely divided and have a maximum particle size of substantially 5 mm. The pyrolysis feedstock may have a relatively narrow particle size distribution, with more than 50% of the pyrolysis feedstock having a particle size between 1 and 4 mm and more than 30% having a particle size less than 1 mm. More than 50% of the pyrolysis feedstock may have a maximum particle size between 1 and 4 mm. More than 30% of the pyrolysis feedstock may have a maximum particle size less than 1 mm.

[0094] In some embodiments, at least the majority of the particles may have a maximum particle size less than one-third of the thickness of the construction product (measured between the opposing surfaces of the mixture optionally lined with a planar lining material), for example when the construction product is manufactured as a planar sheet such as an interior lining board / plasterboard. In some embodiments, there may be substantially no particles having a maximum particle size greater than one-third of the thickness of the construction product (measured between the opposing surfaces of the mixture optionally lined with a planar lining material), for example when the construction product is manufactured as a planar sheet such as an interior lining board / plasterboard.

[0095] In some embodiments, the pyrolyzed feedstock comprises a first pyrolyzed feedstock portion having a fine particle size (e.g., having a maximum particle size of 5 mm or less) to provide increased reactivity for forming crystalline calcium silica hydrate. Preferably, the pyrolyzed feedstock further comprises a second pyrolyzed feedstock portion having a larger particle size than the first pyrolyzed feedstock portion (e.g., the second pyrolyzed feedstock portion comprises granules having a maximum particle size of 100 mm or less) to provide a product with reduced density and improved thermal properties and / or hygroscopicity. The first and second pyrolyzed feedstock portions can be provided by the same or different feedstocks.

[0096] The pyrolyzed bioaggregates may comprise a mixture of fine and larger particle sizes. The presence of finer pyrolyzed bioaggregate particles increases reactivity and improves calcium silicate hydrate yield. The presence of larger pyrolyzed bioaggregate particles provides a construction product with reduced density and / or improved thermal and / or moisture absorption properties.

[0097] The mixture may further comprise one or more additives selected from viscosity modifiers, and / or coupling agents, and / or water retention agents, or any combination thereof. The one or more additives may comprise one or more carbohydrates, e.g., polysaccharides, such as methylated cellulose ethers. The one or more additives are preferably of plant origin. The mixture may further comprise an air entrainment agent, such as lignin sulfonate.

[0098] The mixture may further comprise a plasticizer. The plasticizer may be present in the mixture in an amount of up to 2% by weight of the binder. Preferably, the plasticizer is present in the mixture in an amount between 0.5% and 1.5% by weight of the binder.

[0099] In some embodiments, the pyrolyzed feedstock has a silica content of at least 2% by weight, preferably at least 4% by weight. The silica present in the pyrolyzed feedstock can react with binders to form alkaline earth metal silica hydrates (e.g., calcium silica hydrates), providing a pozzolanic effect that has been shown to improve the strength of the resulting product. The present invention therefore reduces the product's dependency on the presence of additional high carbon binders (such as cement) and may eliminate the need for other mineral-based pozzolans, such as metakaolin and silica fume.

[0100] The construction product can be an interior board, such as an interior lining board, an insulation board, or an acoustic panel. The construction product can be, for example, an interior lining board, a tile, an insulation board, an acoustic panel, a block, or a lintel. The construction product can be, for example, a molded construction product (e.g., a lining board, an insulation board, an acoustic panel, a tile, a block, or a lintel formed at least partially by molding). The molded construction product can be formed using extrusion, for example, by extruding through a die. The die can be, for example, one or more rollers through which the mixture is continuously extruded. The construction product can be formed by continuously extruding the mixture onto a conveyor, where the mixture is provided on the conveyor and the gap between the conveyor and the rollers defines the die. In some examples, a planar lining material is applied to the outer surface of the mixture by a roller during continuous extrusion. The die can also include static (i.e., non-rolled) elements in addition to the rollers. In other examples, the construction product can be cast or 3D printed. For example, if the construction product is an interior lining board (or insulation board or acoustic panel), the construction product may comprise a fast-carbonation setting mixture of binder and bioaggregate provided on a planar lining material, preferably between two opposing sheets of the planar lining material, which is preferably provided on one or both outer surfaces of the mixture, e.g., the molding mixture.

[0101] In some embodiments, the planar lining material is paper. In some instances, the paper weighs up to 250 gsm. The paper may weigh at least 150 gsm. The paper may weigh between 170 gsm and 200 gsm and may be recycled paper. In further embodiments, the lining material is hessian.

[0102] The mixture may include a cellulose adhesive, which may be methylcellulose.

[0103] A cellulose adhesive may be used to adhere the lining material to the remaining materials. The cellulose adhesive may contain up to 2% by weight of cellulose in water. The cellulose adhesive may contain between 1 and 2% cellulose in water. The cellulose may be methylcellulose.

[0104] The density of the construction product is at least 400 kg / m 3 The density of the construction product can be 650 kg / m 3 etc., at least 500 kg / m 3 Preferably, the density of the construction product is up to 1000 kg / m 3 The density of the construction product can be 650 kg / m 3 etc., up to 700 kg / m 3 The density of the construction product is preferably 650 kg / m 3 etc., 500 kg / m 3 ~750kg / m 3 It can be between.

[0105] The thickness of the construction product when produced in a planar sheet (measured between the opposing surfaces of the mixture optionally lined with a planar lining material) may be at least 5 mm, preferably at least 9 mm, for example about 10 mm. The thickness of the construction product may be 250 mm or less. The thickness of the construction product may be 50 mm or less. The thickness of the construction product is preferably between 5 mm and 50 mm, preferably between 9 mm and 50 mm, for example between 10 mm and 50 mm. Most preferably, the thickness of the construction product is between 8 mm and 15 mm.

[0106] In some instances, construction products are made from a combination of different board types. For example, the interior surface of the construction product may be insulation board, and the exterior surface of the construction product may be made from interior lining board, which may be thinner and denser than the insulation board.

[0107] In some alternatives, the construction product may be a plaster or render formed by the mixture described herein. The plaster may be an interior plaster for use on the interior walls of a building. The render may be an exterior render for use on the exterior walls of a building.

[0108] In such instances, the plaster or render is not cured during production (using rapid carbonation cure or otherwise). Instead, the plaster / render is cured in situ after being applied to an interior or exterior wall. The plaster or render may be, for example, a dry particulate mixture (e.g., a dry mortar product) to which water is added in situ to allow or cause the plaster / render to set.

[0109] According to a further aspect of the present disclosure, there is provided a method of producing a construction product comprising a fast-carbonating setting mixture, the method comprising: Producing a mixture of bio-aggregates and a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide; exposing the mixture to a carbon dioxide containing feed stream for rapid carbonation of the mixture; A method is provided that includes:

[0110] In some examples, the construction product is an interior board, and the method further includes forming the mixture into a predetermined geometric shape and providing a planar lining material on one or more exterior surfaces of the predetermined geometric shape. The interior board can be an interior lining board.

[0111] The binder and / or bioaggregate may be as described above. The mixture may further include one or more additives as described above.

[0112] Exposing the mixture to a carbon dioxide-containing feedstream allows the mixture to absorb carbon dioxide from the feedstream, and has been found to accelerate the setting rate of the mixture (thereby decreasing the setting time) and increase the mechanical properties of the resulting construction product.

[0113] In some embodiments, the mixture is exposed to the carbon dioxide-containing feedstream for a predetermined period of time. In some instances, the predetermined period of exposure is sufficient to ensure that substantially complete carbonation of the mixture (and resulting construction product) is achieved. In other instances, the predetermined period of exposure may only be sufficient to partially carbonate the mixture (and resulting construction product).

[0114] Preferably, the method further comprises forming the mixture into a predetermined geometric shape (eg, molding the mixture), such as a substantially planar shape.

[0115] The mixture can be fed into a mold or form to form a predetermined geometric shape, for example, a planar material, for example, a board (such as an interior lining board, insulation board, or acoustic panel). The mold can be an extrusion mold, such as a die. The die can be, for example, one or more rollers through which the mixture is continuously extruded. A construction product can be formed by continuously extruding the mixture onto a conveyor, where the mixture is provided on the conveyor and the gap between the conveyor and the rollers defines the die. In some examples, a planar lining material is applied to the outer surface of the mixture by rollers during continuous extrusion. The die can also include static (i.e., non-rolling) elements in addition to the rollers.

[0116] In some embodiments, the planar lining material is paper. In some instances, the paper weighs up to 250 gsm. The paper may weigh at least 150 gsm. The paper may weigh between 170 gsm and 200 gsm and may be recycled paper. In further embodiments, the lining material is hessian.

[0117] The mixture may include a cellulose adhesive, which may be methylcellulose.

[0118] A cellulose adhesive may be used to adhere the lining material to the remaining materials. The cellulose adhesive may contain up to 2% by weight of cellulose in water. The cellulose adhesive may contain between 1 and 2% cellulose in water. The cellulose may be methylcellulose.

[0119] The ratio of the amount of bioaggregate (wt%) to the amount of binder (wt%) in the mixture is preferably at least 1:10, preferably at least 1:8, for example at least 1:6. The ratio of the amount of bioaggregate (wt%) to the amount of binder (wt%) in the mixture is preferably 1:1.5 or less, preferably 1:2 or less, for example 1:3 or less. The ratio of the amount of bioaggregate (wt%) to the amount of binder (wt%) in the mixture is preferably between 1:10 and 1:1.5, preferably between 1:8 and 1:2, preferably between 1:6 and 1:3.

[0120] The carbon dioxide-containing feedstream preferably contains an increased concentration of carbon dioxide compared to atmospheric concentration. For example, the concentration of carbon dioxide in the carbon dioxide-containing feedstream may be at least 0.1% by volume, at least 1% by volume, at least 5% by volume, preferably at least 10% by volume, for example at least 20% by volume. The concentration of carbon dioxide in the carbon dioxide-containing feedstream is preferably between 20% and 90% by volume, preferably between 20% and 80% by volume, preferably between 20% and 70%, preferably between 20% and 60% by volume.

[0121] Preferably, the carbon dioxide-containing feedstream further comprises water vapor. The relative humidity of the carbon dioxide-containing feedstream may be at least 50%, at least 65%, preferably at least 70 or 75%, preferably no more than 85%.

[0122] The carbon dioxide-containing feedstream may be provided at a temperature of at least 15° C. Preferably, the carbon dioxide-containing feedstream is provided at above room temperature. Preferably, the carbon dioxide-containing feedstream is provided at a temperature of at least 25° C., preferably at least 30° C. Preferably, the carbon dioxide-containing feedstream is provided at a temperature of 90° C. or less.

[0123] In some embodiments, the carbon dioxide-containing feedstream is obtained from waste gases from one or more industrial processes. For example, the carbon dioxide-containing feedstream can be obtained from one or more of the following sources: directly from flue gas, from calcining limestone in the production of calcium oxide, from calcining limestone clinker in the production of cement, from the combustion of methane to generate heat for an industrial process, from the pyrolysis of bioaggregates (i.e., directly from the pyrolysis of bioaggregates or indirectly as a result of the combustion of biogas and / or bio-oil obtained from the pyrolysis of bioaggregates), from an anaerobic digestion process, from direct air capture, or any combination thereof. The carbon dioxide-containing feedstream can include low-grade carbon dioxide emissions. The costs associated with increasing the carbon dioxide concentration in these low-grade emissions and / or transporting these emissions from their source to the required use point are prohibitive. Therefore, the present method utilizes a source of low-grade carbon dioxide emissions to efficiently remove carbon from the atmosphere. If the carbon dioxide feedstream is obtained from a high-temperature source, the carbon dioxide feedstream can be cooled using a heat exchanger before introducing the carbon dioxide feedstream into the mixture. The heated fluid produced in the heat exchanger during cooling of the carbon dioxide feedstream can be used to heat the mixture during the curing and / or drying steps described herein.

[0124] The mixture may be at a temperature of at least 15°C during exposure of the mixture to the carbon dioxide-containing feed stream. The mixture may be at a temperature in the range of 15°C to 60°C during exposure of the mixture to the carbon dioxide-containing feed stream. The mixture may be heated to a predetermined temperature during exposure of the mixture to the carbon dioxide-containing feed stream. Preferably, the mixture is heated to a temperature of at least 25°C. The mixture may be heated to a temperature in the range of 25°C to 60°C. Preferably, the mixture is heated to a temperature of 40°C or less. Preferably, the mixture is heated to a temperature in the range of 25°C to 40°C.

[0125] Heating of the mixture and / or the carbon dioxide-containing feed stream can be produced by burning biogas or bio-oil (e.g., biogas or bio-oil produced by pyrolysis of bioaggregates). The method reduces the use of fossil fuels and provides a way to use the resulting products of pyrolysis, thereby efficiently sequestering biogenic carbon while further utilizing the heat produced by the pyrolysis process in the production process of a product.

[0126] The step of exposing the mixture to a carbon dioxide-containing feed stream is preferably carried out at atmospheric pressure. In some embodiments, the step of exposing the mixture to a carbon dioxide-containing feed stream is preferably carried out at a pressure greater than 1 atmosphere. The step of exposing the mixture to a carbon dioxide-containing stream is preferably carried out at a pressure of 13 bar or less.

[0127] Increasing the carbon dioxide pressure during the rapid carbonation step has two effects. First, it modifies the density, which has been shown to increase the compressive strength of the product. Second, it accelerates and increases the rate of carbon dioxide uptake by the calcium carbonate, allowing the product to gain strength rapidly while rapidly removing carbon dioxide from the flue gas. Therefore, the use of a rapid carbonation step has been shown to produce construction products with increased shear and flexural strength. The resulting construction products may also provide improved paper adhesion.

[0128] The use of high temperatures, resulting from the exothermic reaction that occurs during the curing phase (fast carbonation), also allows the construction product to achieve the required strength in a shorter time. Active control of temperature in relation to the moisture content and carbon dioxide levels in the air allows for efficient carbonation.

[0129] In some embodiments, during the fast carbonation phase, the concentration of carbon dioxide may be increased over time to control the exothermic carbonation process, e.g., increased steadily (at a predetermined rate) over time, and this may be done dynamically with temperature and humidity.

[0130] The method may further include monitoring the humidity of the feedstream during the step of exposing the mixture to the carbon dioxide-containing feedstream.

[0131] To optimize the rapid carbonation cure time and ensure maximum strength development of the product, it is important to monitor humidity to ensure it remains within predetermined maximum and minimum levels. The minimum humidity during the step of exposing the mixture to the carbon dioxide-containing feed stream is preferably at least 20%, preferably at least 30%, and more preferably at least 40%. The maximum humidity during the step of exposing the mixture to the carbon dioxide-containing feed stream is preferably no more than 50%, preferably no more than 60%, preferably no more than 70%, and more preferably no more than 90% relative humidity. The humidity level during the step of exposing the mixture to the carbon dioxide-containing feed stream is preferably between 20% and 70%.

[0132] In some embodiments, the method further includes controlling the humidity, for example, during the step of exposing the mixture to a carbon dioxide-containing feedstream. The humidity can be controlled in response to determining that the humidity is below a predetermined minimum level or above a predetermined minimum level. The humidity in the chamber in which the mixture is exposed to the carbon dioxide-containing feedstream can be measured by a humidity sensor. A controller can release water vapor into the chamber or feedstream based on a signal from the humidity sensor. The signal can indicate that the measured relative humidity level in the chamber is below a predetermined threshold. Preferably, the predetermined threshold (i.e., minimum) humidity during the step of exposing the mixture to the carbon dioxide-containing feedstream is 20% relative humidity, preferably 30% relative humidity, and more preferably 40% relative humidity. The water vapor can be recycled water from the system, such as from a municipal water supply, condensate recovered from drying the mixture, or water recovered from flue gas scrubbing. A humidifier can be used to increase the humidity to at least a predetermined minimum level, and / or a dehumidifier can be used to reduce the humidity to below a predetermined maximum level. The controller may cause water vapor to be extracted from the chamber or the feedstream based on a signal from the humidity sensor. The signal may indicate that the measured relative humidity level in the chamber exceeds a predetermined threshold. Preferably, the predetermined threshold (i.e., maximum) humidity during the step of exposing the mixture to the carbon dioxide-containing feedstream is 50% relative humidity, preferably 60% relative humidity, preferably 70% relative humidity, and more preferably 90% relative humidity.

[0133] The controller may include at least one processor and at least one memory containing computer program code configured to use the at least one processor to cause the humidifier to emit water vapor and / or the dehumidifier to extract water vapor. The controller is operatively coupled to the humidity sensor(s), the humidifier, and / or the dehumidifier. Any number or combination of intervening elements (including no intervening elements) may exist between the controller and these elements. The controller may be, for example, a chipset. The controller may include at least one processor / processing circuit and at least one memory. The controller may be implemented solely in hardware, have some aspects in software including firmware only, or may be a combination of hardware and software (including firmware). The computer program code may be included in a computer program, a non-transitory computer-readable medium, a computer program product, or a machine-readable medium. In some, but not necessarily all, examples, computer program instructions may be distributed across multiple computer programs.

[0134] It should be understood that the required humidity level will depend on the concentration of carbon dioxide in the carbon dioxide-containing feedstream and the temperature of the feedstream.

[0135] The step of exposing the mixture to the carbon dioxide feed stream can be carried out in a chamber. The chamber can be an oven, such as a cross-flow oven. The chamber can have an inlet that is fed directly from a source of the carbon dioxide feed stream. The chamber can include a fan configured to provide random movement of air around the chamber. The fan can be a rotating plenum fan.

[0136] During the step of exposing the mixture to the carbon dioxide-containing feed stream, the mixture may be periodically agitated or moved to promote evaporation of water that may condense on the mixture.

[0137] The step of producing the mixture may occur before the step of exposing the mixture to a carbon dioxide-containing feedstream.

[0138] In some embodiments, production of a mixture that optionally forms a predetermined geometric shape can occur simultaneously with exposing the mixture to a carbon dioxide-containing feedstream. Production of the mixture can include: i) combining bioaggregates with a binder to form a mixture; ii) adding water to the mixture so that the mixture is in the form of a paste; and iii) mixing the paste. The mixture can be exposed to the carbon dioxide-containing feedstream during any one of these steps, any combination of two of these steps, or all three of these steps. Production of the mixture can be carried out at a pressure between 0.5 bar and 1.5 bar, e.g., substantially atmospheric pressure (1 bar). Production of the mixture can be carried out at a temperature between 15°C and 70°C, e.g., substantially room temperature (25°C).

[0139] When the mixture is exposed to a carbon dioxide-containing feedstream during the mixing stage as described in the paragraph above, the binder may react with the carbon dioxide, thereby allowing carbon dioxide to be captured early in the formation of the construction product. The introduction of carbon dioxide during the production / mixing stage may also reduce the setting time of the mixture. When the mixture is exposed to a carbon dioxide-containing feedstream during the production / mixing stage in water, carbon dioxide may be present in the mixture. The carbon dioxide may react with the binder to form carbonates, which may affect the final strength of the construction product. Therefore, the strength of the final product may be adjusted by adjusting the amount of carbon dioxide introduced into the mixture.

[0140] Furthermore, in instances where pyrolytic bioaggregates are present in the mixture, carbon dioxide may be adsorbed onto the pyrolytic bioaggregates by physical or chemical adsorption, and when an alkaline hydroxide is included in the mixture, the alkaline hydroxide may activate the pyrolytic bioaggregates to adsorb more carbon dioxide.

[0141] The step of forming (e.g., molding) the mixture into a predetermined geometric shape can be performed before and / or during the exposure of the mixture to a carbon dioxide-containing feedstream. The step of forming the mixture into a predetermined geometric shape can be performed before the exposure of the mixture to a carbon dioxide-containing feedstream. The mixture can be formed into the predetermined geometric shape using extrusion, preferably continuous extrusion, for example, by continuously extruding through a die. The die can be, for example, one or more rollers through which the mixture is continuously extruded. The construction product can be formed by continuously extruding the mixture onto a conveyor, where the mixture is provided on the conveyor and the gap between the conveyor and the rollers defines the die. In some examples, a planar lining material is applied to the outer surface of the mixture by rollers during the continuous extrusion. The die can also include static (i.e., non-rolling) elements in addition to the rollers. The mixture can be introduced between two sheets of planar lining material on a conveyor between the rollers to measure the thickness of the predetermined geometric shape.

[0142] In some examples, the mixture may be exposed to a first carbon dioxide-containing feedstream before forming the mixture into a predetermined geometric shape and to a second carbon dioxide-containing feedstream after forming the mixture into a predetermined geometric shape. In such examples, any carbon dioxide not utilized in the first carbon dioxide-containing feedstream (i.e., excess carbon dioxide not incorporated into the mixture during exposure to the first carbon dioxide-containing feedstream) may be recycled and used in the second carbon dioxide-containing feedstream.

[0143] After exposure to the carbon dioxide-containing feedstream(s) (which may be a single carbon dioxide-containing feedstream or multiple carbon dioxide feedstreams as described in the paragraph above), the mixture may contain between 0.1% and 15% by weight of absorbed carbon dioxide. After exposure to the carbon dioxide-containing feedstream, the mixture may contain between 1% and 15% by weight of absorbed carbon dioxide.

[0144] Preferably, the method further includes providing a planar lining material on one or more outer surfaces of the mixture (e.g., a board) of a predetermined geometric shape, e.g., a planar shape. The planar lining material may be provided on each of a pair of opposing outer surfaces of the planar shaped mixture. In some embodiments, the planar lining material may extend over, e.g., around, at least a portion of one or more edges of the outer surface(s) of the planar shaped board. The planar lining material may help to form and shape the edge(s) of the one or more outer surface(s) of the planar shaped board. The planar shaped board provides a high surface area, allowing for effective carbon dioxide uptake during rapid carbonation.

[0145] In some examples, the planar lining material is applied to the outer surface of the mixture by rollers during continuous extrusion. In some embodiments, the mixture can be introduced, e.g., pumped, between two sheets of planar lining material on a conveyor between rollers to measure the thickness of the resulting molded mixture.

[0146] In some embodiments, the mixture can be applied onto one sheet of planar lining material, and then another sheet of lining material can be placed on the opposing surface of the mixture. The combination of the mixture and planar lining material can then be pressed into a desired shape having predetermined dimensions.

[0147] The bioaggregates and binder may be mixed together with water. When water is added to the mixture, the mixture may be in the form of a paste. The binder-to-water ratio may be between 1:1 and 1:2.5. The binder may form 15% to 55% by weight of the paste. Preferably, the binder forms 25% to 50% by weight of the paste, such as 35% to 45% by weight of the paste. The bioaggregates may form 5% to 50% by weight of the paste. Preferably, the bioaggregates form 7% to 20% by weight of the paste, such as 10% by weight of the paste. The water may form 20% to 70% by weight of the paste. Preferably, the water forms 30% to 60% by weight of the paste, such as 40% to 50% by weight of the paste. The paste may then be dried. For example, the paste may be dried at a temperature between 30 and 100°C.

[0148] An adhesive material may be provided on the planar lining material to adhere the planar lining material to the mixture of binder and bio-aggregates. The adhesive material may be a cellulose solution or may be a methylcellulose solution.

[0149] The process is preferably carried out by extrusion, preferably continuous extrusion.

[0150] The method has been found to produce construction products that result in reduced curing times for the formation of construction products, leading to increased throughput and associated reduced costs for manufacturing facilities, and allows the product to develop desired strength properties in a shorter period of time compared to conventional methods for producing bioaggregate-based construction products.

[0151] The construction product formed from the method may in some instances be different from interior lining board / plasterboard, for example the construction product may be tile, insulation board, acoustic panel, block or lintel.

[0152] The combination of fast carbonation and pyrolysis feedstock allows for greater amounts of carbon dioxide to be present in the core of the construction product.

[0153] The method allows for the capture of large amounts of carbon early in the production stage of a construction product. The method provides an efficient way to sequester carbon dioxide-containing emissions from waste sources, such as flue gas emissions, thereby reducing the economic impact resulting from carbon dioxide production. Furthermore, such waste streams typically contain waste heat and water vapor, which can also be utilized in the method to efficiently produce construction products with predetermined strength characteristics. The method enables the production, e.g., continuous production, of construction products that are considered low-carbon or carbon-negative.

[0154] According to a further aspect of the present disclosure, there is provided a method of manufacturing a mixture for a construction product, the method comprising: obtaining a raw material; pyrolyzing the raw material to obtain a pyrolysis raw material; mixing a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide with the pyrolysis feedstock to form a mixture for a construction product; Includes:

[0155] In some examples, the method is a method for manufacturing a construction product, wherein the raw material is bioaggregate, and the construction product is an interior board, and the method further includes forming the mixture into a predetermined geometric shape and providing a planar lining material on one or more exterior surfaces of the predetermined geometric shape. The interior board can be an interior lining board.

[0156] The feedstock may be, for example, a bioaggregate. The binder and / or bioaggregate may be as described above. The pyrolysis feedstock may be as described above. The mixture may further include one or more additives as described above.

[0157] Pyrolyzing the feedstock may include heating the feedstock (e.g., bioaggregates) to an elevated temperature of 500°C or higher in the absence of oxygen. Pyrolysis may include heating the feedstock to between 500°C and 1000°C. Pyrolysis may include heating the feedstock to between 500°C and 800°C. Pyrolysis may include heating the feedstock to between 500°C and 700°C. The feedstock may be heated from substantially room temperature to between 500°C and 1000°C for a period of 5 minutes to 1 hour. The feedstock may be heated from substantially room temperature to between 500°C and 1000°C for a period of 15 minutes to 1 hour. The feedstock may be heated from substantially room temperature to between 500°C and 800°C for a period of 5 minutes to 1 hour. The feedstock may be heated from substantially room temperature to between 500°C and 800°C for a period of 15 minutes to 1 hour. The feedstock may be heated at a temperature ramp rate between 10° C. per minute and 125° C. per minute, such as 30° C. per minute.

[0158] Pyrolysis of bioaggregates produces biogas and / or bio-oil, thermal and pyrolyzed bioaggregates.

[0159] Pyrolysis of the feedstock preferably homogenizes the feedstock.

[0160] The ratio of the amount of pyrolysis raw material (wt%) to the amount of binder (wt%) in the mixture is preferably at least 1:10, preferably at least 1:8, for example at least 1:6. The ratio of the amount of pyrolysis raw material (wt%) to the amount of binder (wt%) in the mixture is preferably 1:1.5 or less, preferably 1:2 or less, for example 1:3 or less. The ratio of the amount of pyrolysis raw material (wt%) to the amount of binder (wt%) in the mixture is preferably between 1:10 and 1:1.5, preferably between 1:8 and 1:2, preferably between 1:6 and 1:3.

[0161] The construction product may be an interior board, such as an interior lining board, an insulation board, or an acoustic panel. The construction product may be an interior lining board, an insulation board, an acoustic panel, a tile, a block, or a lintel. In such instances, the method may preferably further include forming the mixture into a predetermined geometric shape, such as a substantially planar shape (e.g., molding the mixture). Water may be added to the mixture before forming the mixture into the predetermined shape.

[0162] The mixture can be dispensed into a mold, die, or form to form a predetermined geometric shape. The predetermined geometric shape can be formed using extrusion molding. The molded construction product can be formed using continuous extrusion molding. For example, the mixture can be continuously extruded through a die to form the predetermined geometric shape. The die can be, for example, one or more rollers through which the mixture is continuously extruded. The construction product can be formed by continuously extruding the mixture onto a conveyor, where the mixture is provided on the conveyor and the gap between the conveyor and the roller defines the die. In some examples, a planar lining material is applied to the outer surface of the mixture by rollers during continuous extrusion. The die can also include static (i.e., non-rolling) elements in addition to the rollers. The mixture can be introduced between two sheets of planar lining material on a conveyor between the rollers to measure the thickness of the predetermined geometric shape.

[0163] The mixture may be at a temperature of at least 15°C during exposure of the mixture to a carbon dioxide-containing feed stream. The mixture may be at a temperature in the range of 15°C to 60°C during exposure of the mixture to a carbon dioxide-containing feed stream. The mixture may be heated to a predetermined temperature to harden and form a construction product. Preferably, the mixture is heated to a temperature of at least 25°C. The mixture may be heated to a temperature in the range of 25°C to 60°C. Preferably, the mixture is heated to a temperature of 40°C or less. Preferably, the mixture is heated to a temperature in the range of 25°C to 40°C.

[0164] Heating of the mixture (e.g., while the mixture hardens into a predetermined shape) can be achieved by burning biogas or bio-oil (e.g., biogas or bio-oil produced from the pyrolysis of bioaggregates). The methods of the present invention reduce the use of fossil fuels and provide a way to use the products resulting from pyrolysis, thereby efficiently sequestering biogenic carbon while further utilizing the heat generated by the pyrolysis process in the manufacturing process of a product.

[0165] The mixture may be allowed to cure for any suitable period or dwell time.

[0166] It has been found that when the method is run at lower temperatures and for shorter residence times, fewer VOCs are emitted, bio-oil and biogas yields are reduced, and greater yields of pyrolysis bioaggregates are produced.

[0167] The method may include subjecting the mixture to elevated pressure, for example greater than 1 atmosphere, preferably up to 13 bar.

[0168] Increasing the pressure can increase the density and compressive strength of the product, which can result in a construction product with increased shear and flexural strength, which can also provide improved paper adhesion.

[0169] Preferably, the method further comprises providing a planar lining material on one or more outer surfaces of the planar shaped mixture (e.g., board, etc.) of a predetermined geometric shape, for example, a planar shaped mixture. The planar lining material may be provided on each of a pair of opposing outer surfaces of the planar shaped mixture. In some embodiments, the planar lining material may extend over, for example around, at least a portion of one or more edges of the outer surface(s) of the planar shaped board. The planar lining material may help to form and give shape to the edge(s) of the one or more outer surface(s) of the planar shaped board.

[0170] In some examples, the planar lining material is applied to the outer surface of the mixture by rollers during continuous extrusion. In some embodiments, the mixture can be introduced, e.g., pumped, between two sheets of planar lining material on a conveyor between rollers to measure the thickness of the resulting molded mixture.

[0171] In some embodiments, the mixture can be applied onto one sheet of planar lining material, and then another sheet of lining material can be placed on the opposing surface of the mixture. The combination of the mixture and planar lining material can then be pressed into a desired shape having predetermined dimensions.

[0172] In some embodiments, the planar lining material is paper. In some instances, the paper weighs up to 250 gsm. The paper may weigh at least 150 gsm. The paper may weigh between 170 gsm and 200 gsm and may be recycled paper. In further embodiments, the lining material is hessian.

[0173] The mixture may include a cellulose adhesive, which may be methylcellulose.

[0174] A cellulose adhesive may be used to adhere the lining material to the remaining materials. The cellulose adhesive may contain up to 2% by weight of cellulose in water. The cellulose adhesive may contain between 1 and 2% cellulose in water. The cellulose may be methylcellulose.

[0175] The pyrolysis feedstock (e.g., pyrolysis bioaggregates) and binder can be mixed with water to form a paste. The binder can form 15% to 55% by weight of the paste. Preferably, the binder forms 25% to 50% by weight of the paste, such as 35% to 45% by weight of the paste. The pyrolysis feedstock can form 5% to 50% by weight of the paste. Preferably, the pyrolysis feedstock forms 8% to 30% by weight of the paste, such as 12% to 18% by weight of the paste. Water can form 20% to 70% by weight of the paste. Preferably, the water forms 30% to 60% by weight of the paste, such as 40% to 50% by weight of the paste. The binder-to-water ratio can be between 1:1 and 1:2.5. The mixture can then be dried. For example, the mixture can be dried at a temperature of 30 to 100°C.

[0176] The use of pyrolyzed bioaggregates has been found to allow for a larger ratio of raw material to water in the paste when compared to the use of non-pyrolyzed bioaggregates. The ratio of pyrolyzed bioaggregates (wt%) to water (wt%) in the paste is between 1:2 and 1:4. Preferably, the ratio of pyrolyzed bioaggregates (wt%) to water (wt%) in the paste is between 1:2.5 and 1:3.5.

[0177] An adhesive material may be provided on the planar lining material to adhere the planar lining material to the mixture of binder and pyrolysis feedstock. The adhesive material may be a cellulose solution or may be a methylcellulose solution.

[0178] The process may be carried out by extrusion, preferably continuous extrusion.

[0179] In some examples, the construction product can be a plaster or render formed by the mixture described herein. The plaster can be an interior plaster for use on the interior walls of a building. The render can be an exterior render for use on the exterior walls of a building. In such examples, the plaster or render is not cured during production (using rapid carbonation cure or otherwise). Instead, the plaster / render is cured in situ after application to the interior or exterior wall. The plaster or render can be, for example, a dry particulate mixture (e.g., a dry mortar product) to which water is added in situ to allow or harden the plaster / render.

[0180] The presence of pyrolyzed raw materials in the mixture has been found to reduce the viscosity of the extruded (preferably continuously extruded) paste. As a result, the rate at which construction products are produced is significantly reduced, while the amount of water required to produce the product is also reduced. The reduction in the amount of water present in the mixture has resulted in a reduction in the setting time of the product. This results in improved strength development of the product in a shorter period of time.

[0181] The presence of pyrolysis raw materials in the product has been found to provide good thermal and moisture absorption properties during the life of the product.

[0182] According to a further aspect of the present disclosure, there is provided a method for manufacturing a construction product, the construction product being an interior board, the method including the steps of obtaining a bio-aggregate, pyrolyzing the bio-aggregate to obtain a pyrolyzed bio-aggregate, mixing a binder including at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide with the pyrolyzed bio-aggregate to form a mixture for the construction product, forming the mixture into a predetermined geometric shape, and providing a planar lining material on one or more outer surfaces of the predetermined geometric shape. The interior board may be an interior lining board.

[0183] According to a further aspect of the present disclosure, there is provided a construction product comprising a mixture, the construction product being an interior board, the mixture comprising pyrolyzed bioaggregates and a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide, and a planar lining material provided on one or both exterior surfaces of the mixture. The interior board may be an interior lining board.

[0184] According to a further aspect of the present disclosure, there is provided a method for manufacturing a construction product, the construction product being an interior board comprising a rapid carbonation-setting mixture, the method including the steps of producing a mixture of bioaggregates and a binder, the binder comprising an alkaline earth metal oxide or an alkaline earth metal hydroxide, exposing the mixture to a carbon dioxide-containing feedstream to rapid carbonation of the mixture, forming the mixture into a predetermined geometric shape, and providing a planar lining material on one or more exterior surfaces of the predetermined geometric shape. The interior board may be an interior lining board.

[0185] According to a further aspect of the present disclosure, there is provided a construction product, the construction product being an interior board, comprising: i) a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide; and ii) a rapid carbonation setting mixture of bio-aggregates, wherein a planar lining material is provided on one or both exterior surfaces of the mixture. The interior board may be an interior lining board.

[0186] For a better understanding of various examples of embodiments of the present invention, reference will now be made, by way of example only, to the accompanying drawings, in which: [Brief explanation of the drawings]

[0187] [Figure 1] 1 is a flow diagram of a method for producing a product prepared using fast carbonation according to some examples described herein. [Figure 2]1 is a flow diagram of a method for producing a product comprising pyrolyzed bioaggregates according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0188] Referring to FIG. 1, a mixture 101 of bioaggregates and a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide is prepared.

[0189] The bioaggregate is selected from an agricultural product or by-product, such as an agricultural crop, an agricultural crop by-product, a food crop or a food crop by-product.

[0190] Bioaggregates are derived from maize, wheat (e.g., common wheat (Triticum aestivum)), rice, barley, millet, grasses (e.g., horsetail), rice husks, straw, squash, pumpkin, watermelon, cucumber, melon, hops, cannabis, celtissel, nettle, wildflowers, rape straw, algae, seaweed, bamboo, rapeseed (Brassica napus), barley (Hordeum vulgare), oats (Avena sativa), flax, rice straw, corn straw, giant miscanthus (Miscanthus Preferably, the bioaggregate is selected from one or more of: (A. giganteus), sugarcane bagasse, sisal straw, hemp, or any combination thereof. However, it should be understood that other agricultural products or by-products may be used. For example, the bioaggregate may include organic by-products of food and beverage processing. The organic by-products of food processing may be selected from, for example, nut shells, stone fruit, coffee grounds, hops grounds, brewer's grain, or pomace.

[0191] In some embodiments, the bioaggregate is a pyrolyzed bioaggregate. The method may further include pyrolyzing the bioaggregate by heating the bioaggregate to an elevated temperature of at least 250°C in the absence of oxygen. In some examples, the temperature to which the bioaggregate is heated may be at least 350°C, at least 400°C, or at least 500°C. The pyrolysis may include heating the bioaggregate to between 500°C and 1000°C. The pyrolysis may include heating the bioaggregate to between 500°C and 800°C. The pyrolysis may include heating the bioaggregate to between 500°C and 700°C. The bioaggregate may be heated to between substantially room temperature and 500°C and 1000°C for a period of 5 minutes to 1 hour. The bioaggregate may be heated to between substantially room temperature and 500°C and 1000°C for a period of 15 minutes to 1 hour. The bioaggregates may be heated from substantially room temperature to between 500°C and 800°C for a period of 5 minutes to 1 hour. The bioaggregates may be heated from substantially room temperature to between 500°C and 800°C for a period of 15 minutes to 1 hour. During pyrolysis, the bioaggregates may be heated at a temperature ramp rate of between 10°C per minute and 125°C per minute, such as 30°C per minute.

[0192] The bioaggregates may be retained in the pyrolysis process until all bio-oil has been drained from the bioaggregates / char and the char is clean.

[0193] Water may be added to the mixture so that the mixture forms a paste. The paste may be formed in a mixer. The mixer may be at a pressure between 0.5 bar and 1.5 bar, such as substantially atmospheric pressure (1 bar). The mixer may be at a temperature between 15°C and 70°C, such as substantially room temperature (25°C). The mixture may be exposed to a carbon dioxide-containing feedstream before and / or during the addition of water to the mixture. The binder may form 15% to 55% by weight of the paste. Preferably, the binder forms 25% to 50% by weight of the paste, such as 35% to 45% by weight of the paste. The bioaggregates may form 5% to 50% by weight of the paste. Preferably, the bioaggregates form 7% to 20% by weight of the paste, such as 10% by weight of the paste. In instances where the bioaggregates are pyrolyzed, the pyrolyzed bioaggregates may form 8% to 30% by weight of the paste, such as 12% to 18% by weight of the paste. Water may form 20% to 70% by weight of the paste. Preferably, water forms 30% to 60% by weight of the paste, such as 40% to 50% by weight of the paste.

[0194] The mixture in the form of a paste may further comprise one or more additives selected from viscosity modifiers and / or coupling agents, and / or water retention agents, and / or air entraining agents, and / or accelerators, and / or retarders, and / or cellulose adhesives, and / or plasticizers, or any combination thereof. The one or more additives may comprise one or more carbohydrates, e.g., polysaccharides, such as, e.g., methylated cellulose ethers. Preferably, the one or more additives are of plant origin.

[0195] The paste may be mixed in the mixer for a predetermined period of time.

[0196] The mixture can be formed into a predetermined geometric shape, for example, by using a mold or form. The mixture can be formed into a predetermined geometric shape by, for example, extruding the mixture (in paste form) through a die using an extrusion process, which can be a continuous extrusion process. The predetermined geometric shape can be a substantially planar shape. The die can be, for example, one or more rollers through which the mixture is continuously extruded. The construction product can be formed by continuously extruding the mixture onto a conveyor, where the mixture is provided on the conveyor and the gap between the conveyor and the roller defines the die. In some examples, a planar lining material is applied to the outer surface of the mixture by rollers during continuous extrusion. The die can also include static (i.e., non-rolling) elements in addition to the rollers. Preferably, a planar lining material is provided on one or both outer surfaces of the mixture. In some embodiments, the mixture can be introduced, for example, pumped, between two sheets of planar lining material on a conveyor between the rollers to measure the thickness of the resulting molded mixture.

[0197] The mixture is exposed to a carbon dioxide feed stream 102 containing at least 0.1% by volume carbon dioxide for a predetermined period of time to provide a resultant construction product 103. The step of exposing the mixture to the carbon dioxide feed stream may be carried out in a chamber, which may be a mixer in which a paste is formed, or an oven, such as a cross-flow oven.

[0198] The carbon dioxide feed stream 102 may be obtained from waste gases from one or more industrial processes, such as directly from flue gas, from calcining limestone in the production of calcium oxide, from calcining limestone clinker in the production of cement, from the combustion of methane to generate heat for an industrial process, from the pyrolysis of bioaggregates, from an anaerobic digestion process, from direct air capture, or any combination thereof.

[0199] The predetermined period of time is sufficient to ensure that substantially complete carbonation of the mixture is achieved. It should be recognized that this predetermined period of time will depend on several factors, including, for example, the type and concentration of bioaggregates present, the type and concentration of binders present, the flow rate and carbon dioxide concentration of the carbon dioxide-containing feed stream, the temperature of the mixture, and the temperature of the feed stream.

[0200] In some examples, the exposure to the carbon dioxide-containing feedstream occurs during production of the mixture. For example, the mixture can be exposed to the carbon dioxide-containing feedstream while adding water to the mixture in a mixer and / or in the mixer after water has been added (i.e., while the paste is being mixed).

[0201] Additionally or alternatively, exposure to the carbon dioxide-containing feed stream can occur during and / or after the formation of the shape. For example, the mixture can be exposed to the carbon dioxide-containing feed stream after the mixture is formed into a predetermined shape and after a lining material is provided on one or both outer surfaces of the mixture. In that case, the mixture of predetermined shape can be exposed to the carbon dioxide feed stream in an oven, such as a cross-flow oven. The oven can include a fan configured to provide random movement of air around the chamber. The fan can be a rotating plenum fan.

[0202] In examples where the mixture is exposed to a first carbon dioxide-containing feedstream before forming the mixture into a predetermined geometric shape, and the mixture is exposed to a second carbon dioxide-containing feedstream after forming the mixture into a predetermined geometric shape, any carbon dioxide not utilized in the first carbon dioxide-containing feedstream (i.e., excess carbon dioxide not incorporated into the mixture during exposure to the first carbon dioxide-containing feedstream) may be recycled and used in the second carbon dioxide-containing feedstream.

[0203] The mixture and / or the carbon dioxide-containing feed stream may be heated to a predetermined temperature.

[0204] Heating of the mixture and / or the carbon dioxide-containing feed stream can be produced by burning biogas or bio-oil obtained from the pyrolysis of bioaggregates. The method reduces the use of fossil fuels and provides a way to use the products obtained as a result of pyrolysis, thereby efficiently sequestering biogenic carbon while further utilizing the heat generated by the pyrolysis process in the production of products.

[0205] Exposure of the mixture to a carbon dioxide-containing feedstream has been found to increase the rate of hardening and the mechanical properties of the resulting product. Additionally, the resulting construction product sequesters carbon during rapid carbonation through exposure to a carbon dioxide-containing feedstream. As a result, the product removes carbon from the atmosphere and permanently traps it within the product. Furthermore, when the product incorporates pyrolytic bioaggregates, additional carbon is sequestered from the atmosphere and trapped within the product. The manufacturing process has been found to be low-carbon or carbon-negative. Thus, the product is an effective carbon dioxide removal product.

[0206] Referring to FIG. 2, a feedstock is obtained (201) and further pyrolyzed to obtain a pyrolysis feedstock (202).

[0207] The feedstock can be any bioaggregate disclosed herein. Additionally or alternatively, the feedstock can be obtained from the pyrolysis of post-consumer and / or post-industrial waste.

[0208] Pyrolysis can be carried out by heating the feedstock (e.g., bioaggregates) to temperatures above 500°C in the absence of oxygen. Pyrolysis can include heating the feedstock to between 500°C and 1000°C. Pyrolysis can include heating the feedstock to between 500°C and 800°C. Pyrolysis can include heating the feedstock to between 500°C and 700°C. The feedstock can be heated from substantially room temperature to between 500°C and 1000°C for a period of 5 minutes to 1 hour. The feedstock can be heated from substantially room temperature to between 500°C and 1000°C for a period of 15 minutes to 1 hour. The feedstock can be heated from substantially room temperature to between 500°C and 800°C for a period of 5 minutes to 1 hour. The feedstock can be heated from substantially room temperature to between 500°C and 800°C for a period of 15 minutes to 1 hour. The feedstock can be heated at a temperature ramp rate between 10°C per minute and 125°C per minute, such as 30°C per minute.

[0209] Feedstocks that are pyrolyzed at higher temperatures have been found to be more stable, retaining carbon for hundreds of years, thereby slowing the re-release of carbon into the atmosphere by construction products.

[0210] The pyrolyzed feedstock is then mixed (203) with a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide to form a construction product (204). The mixture may be heated to a predetermined temperature to harden and form the construction product. Preferably, the mixture is heated to a temperature of at least 25°C.

[0211] The mixture containing the pyrolysis feedstock may be exposed to a carbon dioxide-containing feedstream as described in connection with FIG. 1 above.

[0212] Heating of the mixture can be achieved by burning biogas or bio-oil produced from the pyrolysis of the feedstock. The method of the present invention reduces the use of fossil fuels and provides a way to use the products resulting from pyrolysis, thereby efficiently sequestering biogenic carbon while further utilizing the heat generated by the pyrolysis process in the production of products.

[0213] Construction products incorporate pyrolysis bioaggregates and optionally further utilize the bio-oil or biogas resulting from pyrolysis for heating, thereby sequestering carbon from the atmosphere and trapping it in the product. The manufacturing process for the products of the present invention has been found to be low-carbon or carbon-negative. Thus, the products of the present invention are effective carbon dioxide removal products.

[0214] The presence of pyrolysis raw materials in the mixture has been found to reduce the viscosity of the mixture, thereby reducing the rate at which construction products are produced.

[0215] The presence of pyrolysis raw materials in the product has been found to provide good thermal and moisture absorption properties during the life of the product.

[0216] The depiction of a particular order for the blocks in Figures 1 or 2 does not necessarily imply that there is a required or preferred order for the blocks, and the order and arrangement of the blocks may vary. Additionally, some steps may be omitted.

[0217] Although embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be understood that modifications to the examples described can be made without departing from the scope of the invention as claimed.

[0218] The features set out in the foregoing description may be used in combinations other than those expressly set out.

[0219] Although functions are described with reference to certain features, those functions may be performed by other features whether or not described.

[0220] Although features are described with reference to certain embodiments, those features may also be present in other embodiments whether or not they are described.

[0221] Although the foregoing specification has attempted to draw attention to those features of the invention which are considered to be particularly important, it is to be understood that the applicant claims protection with respect to any patentable feature or combination of features hereinabove mentioned and / or shown in the drawings, whether or not specifically emphasized.

Claims

1. 1. A method of manufacturing a construction product, the construction product being an interior board, the method comprising: Obtaining a bioaggregate; pyrolyzing the bioaggregate to obtain a pyrolyzed bioaggregate; mixing a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide with the pyrolyzed bio-aggregate to form a mixture for the construction product; forming the mixture into a predetermined geometric shape; providing a planar lining material on one or more exterior surfaces of said predetermined geometric shape; A method comprising:

2. The method of claim 1 , wherein the interior board is an interior lining board.

3. 3. The method of claim 1 or 2, wherein at least a majority of the pyrolyzed bioaggregates in the mixture have a maximum particle size that is less than one-third the thickness of the construction product.

4. 4. The method of any one of claims 1 to 3, wherein greater than 50% of the pyrolyzed bioaggregates in the mixture have a particle size between 1 and 4 millimeters.

5. 5. The method of any one of claims 1 to 4, wherein more than 30% of the pyrolyzed bioaggregates in the mixture have a particle size of less than 1 millimeter.

6. The method of any one of claims 1 to 5, wherein the binder comprises lime.

7. The method of any one of claims 1 to 6, wherein the binder comprises calcium hydroxide.

8. The method of any one of claims 1 to 7, wherein the mixture further comprises a cellulose adhesive.

9. 9. The method of any one of claims 1 to 8, wherein the pyrolysis comprises heating the bioaggregates to between 500°C and 1000°C.

10. 10. The method of claim 9, wherein the bioaggregates are heated from substantially room temperature to between 500°C and 1000°C for a period of between 5 minutes and 1 hour.

11. The method of any one of claims 1 to 10, wherein the predetermined geometric shape is a substantially planar shape.

12. The method according to any one of claims 1 to 11, wherein the planar lining material is paper.

13. The method of any one of claims 1 to 12, further comprising the step of heating the mixture to harden the mixture.

14. 14. The method of claim 13, wherein the heating of the mixture is achieved by burning biogas or bio-oil produced from the step of pyrolyzing the bio-aggregates.

15. 15. The method according to any one of claims 1 to 14, wherein the ratio of the amount of bioaggregate (wt%) to the amount of binder (wt%) in the mixture is between 1:10 and 1:1.

5.

16. 16. The method of claim 15, wherein the ratio of the amount of bioaggregate (wt%) to the amount of binder (wt%) in the mixture is between 1:6 and 1:

3.

17. 17. The method of any one of claims 1 to 16, wherein the bioaggregate is a food crop by-product.

18. 17. The method of any one of claims 1 to 16, wherein the bioaggregates comprise one or more of the following: cereal maize, wheat, rice, millet, grass, rice husk, rice straw, squash, pumpkin, watermelon, cucumber, melon, hops, cannabis, celtissel, nettle, wildflowers, rape straw, algae, seaweed, bamboo, rapeseed (Brassica napus), barley (Hordeum vulgare), oats (Avena sativa), flax, rice straw, corn straw, giant miscanthus (Miscanthus giganteus), sugarcane bagasse, sisal straw, hemp.

19. 17. The method of any one of claims 1 to 16, wherein the bioaggregate comprises one or more high silica content plants selected from one or more of the families Poaceae, Equisetaceae, and / or Cyperaceae, and / or one or more medium silica content plants selected from one or more of the families Cucurbitales, Urticales, and / or Commelinaceae.

20. The method of any one of claims 1 to 19, wherein the mixture is formed into the predetermined geometric shape using extrusion.

21. 21. The method of claim 20, wherein the mixture is formed into the predetermined geometric shape using continuous extrusion.

22. A construction product comprising a mixture, said construction product being an interior board, said mixture comprising pyrolysis bioaggregates; a binder comprising at least one of an alkaline earth metal oxide and / or an alkaline earth metal hydroxide; Including, a planar lining material is provided on one or both outer surfaces of the mixture; construction products.

23. 23. The construction product of claim 22, wherein the interior board is an interior lining board.

24. 24. The construction product of claim 22 or 23, wherein at least a majority of the pyrolyzed bioaggregates in the mixture have a maximum particle size that is less than one-third the thickness of the construction product.

25. 25. The construction product of any one of claims 22 to 24, wherein more than 50% of the pyrolyzed bioaggregates in the mixture have a particle size between 1 and 4 millimeters.

26. 26. The construction product of any one of claims 22 to 25, wherein more than 30% of the pyrolyzed bioaggregates in the mixture have a particle size of less than 1 millimeter.

27. 27. The construction product of any one of claims 22 to 26, wherein the bioaggregate is a food crop by-product.

28. 27. The construction product of any one of claims 22 to 26, wherein the bio-aggregate comprises one or more of maize, wheat, rice, millet, grass, rice husk, straw, squash, pumpkin, watermelon, cucumber, melon, hops, cannabis, celtissel, nettle, wildflower, rape straw, algae, seaweed, bamboo, rapeseed (Brassica napus), barley (Hordeum vulgare), oat (Avena sativa), flax, rice straw, corn straw, giant miscanthus (Miscanthus giganteus), sugarcane bagasse, sisal straw, and hemp.

29. 27. The construction product of any one of claims 22 to 26, wherein the bio-aggregate comprises one or more plants with a high silica content selected from one or more of the families Poaceae, Equisetaceae and / or Cyperaceae, and / or one or more plants with a medium silica content selected from one or more of the families Cucurbitales, Urticales and / or Commelinaceae.

30. 30. The construction product according to any one of claims 22 to 29, wherein the ratio of the amount of bio-aggregate (wt%) to the amount of binder (wt%) in the mixture is between 1:10 and 1:1.

5.

31. 31. The construction product of claim 30, wherein the ratio of the amount of bio-aggregate (wt%) to the amount of binder (wt%) in the mixture is between 1:6 and 1:

3.

32. 32. The construction product of any one of claims 22 to 31, wherein the binder comprises lime.

33. A construction product according to any one of claims 22 to 32, wherein the binder comprises calcium hydroxide.

34. The construction product of any one of claims 22 to 33, wherein the mixture further comprises a cellulose adhesive.

35. A construction product according to any one of claims 22 to 34, wherein the planar lining material is paper.

36. The inner board has a density of 500 kg / m 3 ~750 kg / m 3 The construction product according to any one of claims 22 to 35,

37. Construction product according to any one of claims 22 to 36, wherein the thickness of the product is at least 5 mm.

38. 38. The construction product of claim 37, wherein the thickness of the construction product is between 8 mm and 15 mm.

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