Coal-derived carbon-based concrete and methods of making the same

Abstract

Embodiments of the present disclosure related to a composition and method of making the composition. The composition includes a dry mixture and water. The dry mixture includes about 15% to about 25% of a cement material, a pyrolysis char (PC), about 35% to about 45% of a coarse aggregate (CA), and about 35% to about 45% of a fine aggregate (FA). In some embodiments, the dry mixture includes a superplasticizer (SP). The PC may replaces about 0.05% to about 1.5% of the cement material or may have an amount of the PC that is about 0.05% to about 1.5% of the cement material. The water to cement ratio is about 0.4 to about 0.6.

Description

COAL-DERIVED CARBON-BASED CONCRETE AND METHODS OF MAKING THE SAMEBACKGROUNDField

[0001] Embodiments of the present disclosure generally relate to concrete materials. In particular, the disclosure relates to pyrolysis char concrete (PCC) and methods of fabricating PCC using coal-derived pyrolysis char (PC).Description of Related Art

[0002] Coal currently serves an important role as an energy source but the increasing demand for renewable energy has reduced the production and consumption of coal in the United States of America (USA). Coal is carbon-rich, and its use in energy generation may affect atmospheric CO2 levels. The air pollution and global environmental issues associated with the combustion of coal have limited the continuous application of coal in energy production. Specifically, according to the Bureau of Safety and Environmental Enforcement (BSEE), global warming that results from various greenhouse gas emissions is partly due to fossil fuel burning, such as the combustion of coal.

[0003] Wyoming Powder River Basin (PRB) coal plays an important role in the Wyoming energy industry as well as other parts of the United States and the world more generally. However, renewable energy is slowly replacing the coal industry, causing the market price of coal to drop. Thus, to attract new investment through technological innovation and support coal mine operations, environmentally friendly methods to create new diversified coal products are needed. In addition, the worldwide demand for concrete is rising.

[0004] Therefore, there is a need for improved concrete and methods of fabricating concrete using coal-derived pyrolysis char.SUMMARY

[0005] In one embodiment, a composition is disclosed. The composition includes a dry mixture and water. The dry mixture includes about 15% to about 25% of a cement material, a pyrolysis char (PC), about 35% to about 45% of a coarse aggregate (CA), and about 35% to about 45% of a fine aggregate (FA). The PC may replace about 0.05% to about 1.5% of the cement material. The water to cement ratio is about 0.4 to about 0.6.

[0006] In another embodiment, a composition is disclosed. The composition includes a dry mixture and water. The dry mixture includes about 15% to about 25% of a cement material, a pyrolysis char (PC), about 35% to about 45% of a coarse aggregate (CA), and about 35% to about 45% of a fine aggregate (FA). The amount of the PC is about 0.05% to about 1.5% of the cement material. The water to cement ratio is about 0.4 to about 0.6.

[0007] In yet another embodiment, a method of making a composition is disclosed. The method includes mixing a coarse aggregate and a first portion of water to form a first wet mixture. A first wet mixture, a fine aggregate, and a second portion of water are mixed to form a second wet mixture. A cement material is mixed with the second mixture and a third portion of water to form a third wet mixture. A fourth portion of water and a PC is mixed to form a PC mixture. The third wet mixture, the PC mixture, and a fifth portion of water are mixed to form a cement mixture. The cement mixture is poured into a mold. The cement mixture is cured into a PC concrete.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] So that the manner in which the above-recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, and may admit to other equally effective embodiments.

[0009] Figure l is a flow diagram of a method of forming a composition, according to embodiments.

[0010] Figure 2 is a graph of the comparison of slump value and the cement mixture, according to embodiments.

[0011] Figure 3 is a graph of the cement mixture consistency among PC types, according to embodiments.

[0012] Figure 4 is a graph of the average density of pyrolysis char concrete (PCC) specimens with different percentages of PC by weight of cement, according to embodiments.

[0013] Figure 5 is a graph of the average density of PCC specimens by PC type, according to embodiments.

[0014] Figure 6A is a graph of the compressive strength of PCC specimens using PC as a replacement, according to embodiments.

[0015] Figure 6B is a graph of the compressive strength of PCC specimens using PC as an additive, according to embodiments.

[0016] Figure 6C is a graph of the percent increment of the compressive strength of the PCC at 28 days of curing, according to embodiments.

[0017] Figure 6D is a graph of the percent increment of the compressive strength of the PCC at 56 days of curing, according to embodiments.

[0018] Figure 7 is a graph of the 28-day cure compressive strength outcomes among PC types, according to embodiments.

[0019] Figure 8 is a graph of the Modulus of Elasticity (MoE) values of PCC specimens, according to embodiments.

[0020] Figure 9 is a graph of the MoE among PC types, according to embodiments.

[0021] Figure 10 is a graph of the Poisson's ratio of PCC specimens cured for 28 days, according to embodiments.

[0022] Figure 11 is a graph of the Poisson’s ratio among PC types, according to embodiments.

[0023] Figure 12A is a graph of the flexural and splitting tensile strength of the PCC replacement specimens, according to embodiments.

[0024] Figure 12B is a graph of the flexural and splitting tensile strength of the PCC additive specimens, according to embodiments.

[0025] Figure 13 A is a graph of the heat of flow of the PCC replacement specimens, according to embodiments.

[0026] Figure 13B is a graph of the cumulative heat of the PCC replacement specimens, according to embodiments.

[0027] Figure 13C is a graph of the heat of flow of the PCC additive specimens, according to embodiments.

[0028] Figure 13D is a graph of the cumulative heat of the PCC additive specimens, according to embodiments.

[0029] Figure 14A is a graph of the x-ray diffraction (XRD) analysis of PCC replacement specimens, according to embodiments.

[0030] Figure 14B is a graph of the XRD analysis of PCC additive specimens, according to embodiments.

[0031] Figure 15 A is a micrograph of scanning electron microscopy (SEM) element analysis of the 56-day-cured control mix at 10 pm, according to embodiments.

[0032] Figure 15B is a micrograph of the SEM element analysis of the 56-day- cured control mix at 5 pm, according to embodiments

[0033] Figure 15C is a micrograph of SEM element analysis of the 56-day-cured CHAR50 at 10 pm, according to embodiments.

[0034] Figure 15D is a micrograph of SEM element analysis of the 56-day-cured CHAR50 at 5 pm, according to embodiments.

[0035] Figure 15E is a micrograph of SEM element analysis of the 56-day-cured CHAR50a at 10 pm, according to embodiments.

[0036] Figure 15F is a micrograph of SEM element analysis of the 56-day-cured CHAR50a at 5 pm, according to embodiments.

[0037] Figure 16 is a graph of the comparison of slump value and the cement mixture, according to embodiments.

[0038] Figure 17 is a graph of the comparison of density and the cement mixture, according to embodiments.

[0039] Figures 18A-18I are graphs of the comparison of uniaxial compressive strength and the cement mixture, according to embodiments.

[0040] Figures 19A-19C are graphs of the effect of water to cement (WC) ratio at varying fine to total aggregate (FA) ratios on the MoE of the cement mixtures, according to embodiments.

[0041] Figures 20A-20C are graphs of the effect of FA ratio at varying WC ratios on the MoE of the cement mixtures, according to embodiments.

[0042] Figures 21A-21C are graphs of the effect of WC ratio at varying FA ratios on the Poisson’s ratio of the cement mixtures, according to embodiments.

[0043] Figures 22A-22C are graphs are graphs of the effect of FA ratio at varying WC ratios on the Poisson’s ratio of the cement mixtures, according to embodiments.

[0044] Figures 23A-23C are graphs of the effect of WC ratio at varying FA ratios on the flexural strength of the cement mixtures, according to embodiments.

[0045] Figures 24A-24C are graphs are graphs of the effect of FA ratio at varying WC ratios on the flexural strength of the cement mixtures, according to embodiments.

[0046] Figures 25A-25C are graphs of the effect of WC ratio at varying FA ratios on the split tensile strength of the cement mixtures, according to embodiments.

[0047] Figures 26A-26C are graphs of the effect of FA ratio at varying WC ratios on the split tensile strength of the cement mixtures, according to embodiments.DETAILED DESCRIPTION

[0048] Embodiments of the present disclosure generally relate to concrete materials. In particular, the disclosure relates to pyrolysis char concrete (PCC) and methods of fabricating PCC using coal -derived pyrolysis char (PC).

[0049] The inventors have found new and improved methods for fabricating pyrolysis char concrete (PCC) from coal-derived pyrolysis char (PC). Briefly, raw coal is thermo-chemically converted to produce PC. The resulting PC is then converted into concrete materials such as pyrolysis char concrete (PCC).

[0050] The desire for environmentally-friendly materials, energy savings, and reduced energy consumption in building materials can be addressed by the building material described herein. Building materials made with PC material have low density, low thermal conductivity, and high insulative properties. These materials, through recycling / reuse and decreasing the amount of energy usage in fabrication, further lessens the environmental impact of the PCC.

[0051] The use of heading is for purposes of convenience and does not limit the scope of the present disclosure. Embodiments described herein can be combined with other embodiments.

[0052] As used herein, “composition” can include component(s) of the composition, reaction product(s) of two or more components of the composition, a remainder balance of remaining starting component(s), or combinations thereof. Compositions of the present disclosure can be prepare by suitable mixing process.COMPOSITIONS

[0053] Embodiments described herein generally relate to concrete materials. In particular, the disclosure relates to pyrolysis char concrete (PCC) and methods of fabricating PCC using coal-derived pyrolysis char.

[0054] A composition (e.g., a pyrolysis char concrete (PCC)) includes pyrolysis char (PC). The composition includes cement material, PC, water, coarse aggregate (CA), and fine aggregate (FA). In some embodiments, the composition includes superplasticizers (SP).

[0055] In some embodiments, the PC is added as a replacement of the cement material (RPCC). The RPCC includes a dry mixture including the cement material, the PC, the CA, the FA, and the SP. The dry mixture is about 15% to about 25% cement material, about 35% to about 45% FA, and about 35% to about 45% CA. The PC replaces about 0.05% of the cement material to about 1.5% of the cement material. E.g., the PC is about 0.005% to about 0.5% of the dry mixture, such as about 0.009% to about 0.3% of the dry mixture. In some embodiments, the dry mixture includes about 0.06% to about 0.2% SP, such as about 0.06% to about 0.14% SP. The water to cement ratio of the RPCC is about 0.4 to about 0.6.

[0056] In other embodiments, the PC is added as an additive to the cement material (APCC). The APCC includes a dry mixture including the cement material, the PC, the CA, the FA, and the SP. The dry mixture is about 15% to about 25% cement material, about 35% to about 45% FA, and about 35% to about 45% CA. The PC is added to the dry mixture as additional cement material at about 0.05% of the cement material to about 1.5% of the cement material. E.g., the PC is about 0.005% to about 0.5% of the dry mixture, such as about 0.009% to about 0.3% of the dry mixture. In some embodiments, the dry mixture includes about 0.06% to about 0.2% SP, such as about 0.06% to about 0.14% SP. The water to cement ratio of the APCC is about 0.4 to about 0.6.

[0057] The PCC has a slump value of about 100 mm to about 200 mm, such as about 100 mm to about 160 mm. The PCC has a density between about 2.0 g / cm3to about 2.5 g / cm3, such as about 2.3 g / cm3to about 2.5 g / cm3. The compressive strengthof the PCC is about 20 MPa to about 70 MPa, such as about 40 MPa to about 70 MPa, such as about 20 MPa to about 50 MPa, such as about 40 MPa to about 50 MPa. The Modulus of Elasticity (MoE) of the PCC is about 10 GPa to about 40 GPa, such as about 30 GPa to about 40 GPa, such as about 15 GPa to about 25 GPa. The Poisson’s ratios of the PCC is about 0.14 to about 0.17, such as about 0.15 to about 0.16. The flexural strength of the PCC is about 3 MPa to about 8 MPa, such as about 5 MPa to about 7 MPa. The split tensile strength of the PCC is about 3 MPa to about 7 MPa, such as about 4 MPa to about 6 MPa.

[0058] The PC was produced from Wyoming's PRB coal by Atlas Carbon. The coal was heated at a high temperature of about 850°C in a nitrogen environment to form the PC. The PC includes about 79.9% fixed carbon, about 16% ash, about 2.9% moisture, and about 1.2% volatile matter. The PC exhibits a Brunauer-Emmett-Teller (BET) specific surface area of 262 m2 / g. In some embodiments, the PC is flash pyrolyzed PC (nPC). The nPC is obtained through a flash pyrolysis, which involved subjecting the coal to rapid, high-temperature decomposition to produce the nPC.

[0059] The cement material includes ordinary Portland cement (Type I, Type II, Type III, Type IV, Type V), slag cement, slag-modified Portland cement, expansive cement, white cement, water-repellant cement, masonry cement Type N or Type S, cement line, Type S, mortar cement, oil well cement, plastic cement, rapid setting cement, Portland blast furnace slag cement, Portland-pozzolans cement, and pozzolans- modified Portland cement, or combinations thereof. In some embodiments, the cementitious materials may include ground granulated blast furnace (GGBFS), fly ash (e.g., Class C fly ash), ground limestone, and combinations thereof. The specific gravity of the cement is about 3.15. The cement materials are about 10% to about 25% of the total composition.

[0060] The superplasticizer may include polycarboxylic ether polymer, a polycarboxylate ether, a sulfonated naphthalene formaldehyde, a sulfonated melamine formaldehyde, a lignosulfate, an acrylic polymer, or combinations thereof.10061] Table 1 is a summary of the properties of the coarse aggregate and the fine aggregate. The coarse aggregate is sieved with a maximum size of about 9.5 mm. After sieving, the coarse aggregate is dried to maintain an oven dry (OD) condition. The fine aggregate has a fineness modulus (FM) of about 2 to about 3, such as about 2.58. The unit weight of the fine aggregate is about 1400 kg / m3to about 1600 kg / m3, such as about 1586.68 kg / m3. The fine aggregate is about 35% to about 50% of the total composition, such as about 42% of the total composition. The coarse aggregate is about 30% to about 45% of the total composition, such as about 38% of the total composition.Table 1. Summary of the Properties of the Coarse and Fine Aggregates.

[0062] Figure 1 is a flow diagram of a method 100 of forming a composition (e.g., a PCC composition. At operation 101, a coarse aggregate (CA) and a first portion of water are mixed to form a first wet mixture. The CA and water are mixed for about 1 minute to about 3 minutes. The first portion of water is about 10% to about 15% of a total water amount.

[0063] At operation 102, the first wet mixture, a fine aggregate (FA), and a second portion of water are mixed to form a second wet mixture. The first wet mixture, FA, and water are mixed for about 1 minute to about 3 minutes. The second portion of water is about 10% to about 15% of the total water. The CA and FA were then oven-dried for at least 24 hours before incorporating them into the first wet mixture and the second wet mixture, respectively.

[0064] At operation 103, a cement material is mixed with the second wet mixture and a third portion of water to form a third wet mixture. The third portion of water is about 45% to about 55% of the total water.

[0065] At operation 104, a fourth portion of water is mixed with a PC to form a PC mixture. The fourth potion of water is about 5% to about 15% of the total water. In some embodiments, the PC is a flash pyrolyzed PC (nPC). In some embodiments, the PC mixture includes a superplasticizer (SP), such as polycarboxylate ether.

[0066] At operation 105, the PC mixture is mixed with the third wet mixture and a fifth portion of water (e.g., about 13% of the total water) to create the cement mixture. The PC mixture is mixed with the third wet mixture and a fourth portion of water for about 2 minutes to about 5 minutes from adding the cement material until incorporating the remaining water.

[0067] In some embodiments, a 1 minute pause may be taken during the mixing to inspect the quality and consistency of the cement mixture, which may enhance ability of the cement mixture to undergo hydration and enhance the workability of the resultant concrete. The mixing may continue for an additional minute.

[0068] At operation 106, the cement mixture is poured into a mold to form molded cement mixture. At operation 107, the molded cement mixture is cured into a PC concrete (PCC). The molded cement mixture is cured for about 1 day to about 60 days.USES

[0069] Embodiments of the present disclosure also generally relate to uses of the compositions described herein. Compositions described herein can also be used for various applications.

[0070] Illustrative, but non-limiting, applications include pyrolysis char cement (PCC) for use in construction and building applications.

[0071] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use embodiments of the present disclosure, and are not intended to limit the scope of embodiments of the present disclosure. Efforts have been made to ensure accuracy with respect to numbers used but some experimental errors and deviations should be accounted for.EXAMPLESTest Methods

[0072] The specific gravity is measured using ASTM Cl 88.

[0073] The cement mixture consistency was measured by how far the cement mixture slumped from the top of the cement mixture-filled cone to the top of cement mixture after removing the cone in accordance with ASTM Cl 43.

[0074] Cylindrical concrete specimens (diameter of 50 mm by height of 100 mm) were prepared following ASTM Cl 92 guidelines. During the preparation of the cylindrical concrete specimens, a tamping rod with a diameter of 9.5 mm was used to compact the cement mixture 25 times in the first half of the cylindrical mold. The second half of the cylinder was then filled with concrete and compacted 25 times as well. Subsequently, a trowel was employed to level the top of the cylinder, and the top was covered with a lid.

[0075] The uniaxial compression tests are performed using servo-controlled compression equipment on the 50 mm by 100 mm concrete specimens for both PC and nPC following the guidelines of ASTM C39. During the compression testing, a pair of axial linear variable differential transformers (LVDTs) and a radial LVDT were incorporated to measure the axial and radial strains.

[0076] The stress-strain responses of the 50 mm specimens obtained from the compression tests were utilized in subsequent analyses to determine both Modulus of Elasticity and Poisson's ratio.

[0077] The indirect split tensile strength test was performed following ASTM C496 guidelines, using the 50 mm by 100 mm concrete specimens in an automatic concrete compression machine.

[0078] The flexure and split tensile strength tests are performed according to ASTM C78. The flexure and split tensile strength tests were done for the four percentages of PC of 0.05%, 0.25%, 0.5% and 0.75% both as a replacement and additive by weight of cement materials. For this test, three rectangular concrete beams measuring 100 mm x 100 mm x 355 mm were prepared and demolded using the same machine as for the split tensile strength test. The beams were supported at their ends, and a load was applied at the midpoint to induce bending.

[0079] The heat of hydration analysis was conducted using an isothermal calorimeter (I-Cal 8000 HPC model manufactured by Calmetrix) in accordance with ASTM Cl 702. A predefined quantity of distilled water, pre-weighed for accuracy, was placed in plastic containers, and stored within the calorimeter. The setup is maintained at a constant temperature of 23 °C for 24 hours to ensure thermal equilibrium. Upon achieving thermal equilibrium, the distilled water was subsequently mixed with PC or nPC. The water mixture was then combined with the dry cement materials for 30 seconds. The water and cement mixture is returned to the calorimeter for measuring the heat of hydration.

[0080] The microstructure of PCC is analyzed using X-ray diffraction (XRD). XRD patterns are generated using monochromate Cu-Kp radiation (with a wavelength of = 1.54 A). The scanning range for 29 was set from 0 to 60 degrees, with a step size of 0.01 degrees.

[0081] For visualizing the microstructure of concrete surface and examining the morphology of hydration crystals, and Scanning Electron Microscope (SEM) images were acquired. These analyses were conducted using a field emission electron microscope (FESEM) equipped with an energy-dispersive X-ray spectrometer.EXPERIMENTALExperiment 1 :

[0082] Table 2 is a summary of the concrete mixture designs for pyrolysis char (PC) as replacement to cement. Table 3 is a summary of the concrete mixture designs for pyrolysis char (PC) as additive to cement. The PCC specimens include a control mix (CHARO), a 0.05% PCC specimen (CHAR5), a 0.10% PCC specimen (CHAR10), a 0.25% PCC specimen (CHAR25), a 0.50% PCC specimen (CHAR50), a 0.75% PCC specimen (CHAR75), a 1.0 % PCC specimen (CHAR100), a 1.5% PCC specimen (CHARI 50).Table 2. Summary of Concrete Mixture Designs for Pyrolysis Char (PC) asReplacement to Cement.

[0083] Table 3 is a summary of the concrete mixture designs for pyrolysis char (PC) as additive to cement. The PCC specimens include a 0.05% PCC specimen (CHAR5a), a 0.10% PCC specimen (CHARI 0a), a 0.25% PCC specimen (CHAR25a), a 0.50% PCC specimen (CHAR50), a 0.75% PCC specimen (CHAR75a), a 1.0 % PCC specimen (CHARI 00a), a 1.5% PCC specimen (CHARI 50a).Table 2. Summary of Concrete Mixture Designs for PC as Additive to Cement.

[0084] The PCC is cast into specimens of 50 mm x 100 mm cylinders for testing the compressive and indirect split tensile strength. The PCC is cast into specimens of 100 mm x 100 mm x 355 mm beams for flexural strength. The cylinder specimens and the beam specimens were cured for 3 days, 7 days, 14 days, 28 days, and 56 days for compressive strength testing and 28 days for split tensile strength and flexural tensile strength testing.

[0085] The C30 in the specimen designation indicates the target compressive concrete strength of 30 MPa. The designation ending with 50 indicates the cylindrical concrete specimen size of 50 mm by 100 mm. The PCC specimens are maintained at a constant water-cement ratio (w / c) of 0.60 with a selected mix proportion of 1 :2.3:2.0 [(Cement + PC): Fine Aggregate (FA): Coarse Aggregate (CA)] by weight.

[0086] Table 4 is a summary of the concrete mixture designs for flash pyrolysis char (nPC) as replacement to cement to prepare flash pyrolysis char concrete (nPCC). The nPCC specimens include a 0.05% nPCC specimen (nCHAR5), a 0.10% nPCC specimen (nCHARlO), a 0.25% nPCC specimen (nCHAR25), a 0.50% nPCC specimen (nCHAR50), a 0.75% nPCC specimen (nCHAR75), a 1.0 % nPCC specimen (nCHARlOO), a 1.5% nPCC specimen (nCHAR150).Table 4. Summary of Concrete Mixture Designs for Flash Pyrolyzed Pyrolysis Char (nPC) as Replacement to Cement.

[0087] Table 5 is a summary of the concrete mixture designs for flash pyrolysis char (nPC) as additive to cement to prepare flash pyrolysis char concrete (nPCC). The PCC specimens include a 0.05% nPCC specimen (nCHAR5a), a 0.10% nPCC specimen (nCHARlOa), a 0.25% nPCC specimen (nCHAR25a), a 0.50% nPCC specimen (nCHAR50a), a 0.75% nPCC specimen (nCHAR75a), a 1.0 % nPCC specimen (nCHARlOOa), a 1.5% nPCC specimen (nCHAR150a).Table 5. Summary of Concrete Mixture Designs for nPC as Additive to Cement.

[0088] The CA and FA were then oven-dried for at least 24 hours before incorporating them into the mixtures. The process started by measuring the FA and CA, along with the cement materials, based on the design mix quantities specified in either Table 2 (for PC replacement); Table 3 (for PC additive), Table 4 (for nPC replacement), or Table 5 (for nPC additive). The CA and a first portion of the water (e.g., about 13% of the total water) is added into a mixing machine to create a first wet mixture. The first portion of water and the CA are mixed for about 2 minutes. Next, the FA was added to the mixture, along with a second portion of water (e.g., an additional 13% of the total water) to create a second wet mixture. The FA, second portion of water, and the first wet mixture are mixed for about 2 minutes. Subsequently, the cement materials were incorporated into the second wet mixture, accompanied by a third portion of water (e.g., about 51% of the total water) to form a third wet mixture. Next, a fourth portion of water (e.g., about 10% of the total water) was placed is mixed with the PC or the nPC to maintain suspension as a PC mixture or an nPC mixture, respectively. The PC mixture or the nPC mixture is mixed with the third wet mixture and a fifth portion of water (e.g., about 13% of the total water) to create the cement mixture. The PC mixture or the nPC mixture is mixed with the third wet mixture and a fifth portion of water is mixed for about 3 minutes, from adding the cement material until incorporating the remaining water. A 1 minute pause may be taken during the mixing to inspect the quality and consistency of the cement mixture, which may enhance ability of the cement mixture to undergo hydration and enhance the workability of the resultant concrete. The mixing may continue for an additional minute. Finally, the cement mixture was poured into a mold to form molded cement mixture. The molded cement mixture is cured into a PC concrete (PCC), e.g., the PCC specimens according to Tables 2-5. The PCC is cured for 3, 7, 14, 28, and 56 days.

[0089] Slump tests were performed on each cement mixture specimen to determine the consistency of cement mixture before curing. The cured cylindrical PCC specimens were stored at room temperature. On the designated days for compressive testing (i.e., 3, 7, 14, 28, and 56 days) or tensile strength testing (i.e., 28 days), the PCC specimens are removed from the molds using air pressure to minimize any potential damage.

[0090] After demolding, all PCC specimens for the compressive strength test undergo a thorough examination to ensure smoothness and levelness on both the top and bottom surfaces. If necessary, the top and bottom faces are polished using a grinding machine to achieve a perpendicular plane with the sides. Additionally, the diameter, length, and mass of each sample were carefully measured before conducting the compressive strength test. The density of each PCC specimen was calculated by dividing the mass by volume.

[0091] Figure 2 is a graph of the comparison of slump value and the cement mixture. As the percentage of PC content increases in the cement mixture specimens as both a replacement and additive, the slump value of the cement mixture specimens remains comparable. The slump values are generally around 120 to 145 mm regardless of the PC percentages. The relatively high slump of about 172.72 mm of C30- CHAR1 00-50 may be due to residual moisture remaining in the CA and FA.

[0092] Figure 3 is a graph of the cement mixture consistency among PC types. The data reveals that nPC exhibits the lowest slump value, which may indicate that nPC absorbs more water compared to PC, resulting in a decreased slump value.

[0093] Figure 4 is a graph of the average density of pyrolysis char concrete (PCC) specimens with different percentages of PC by weight of cement. The PCC specimens are cured for a 28-day period. The specimens are for 50 mm x 100 mm samples using different percentages of PC as both replacement and additive. The densities of the various mix designs are similar, and remains relatively consistent at approximately 2.33 g / cm3after 28 days. This may be due to the minimal presence of PC within the mix. The low concentration of PC in the mixture ensures that the overall density remains comparable to that of ordinary concrete.

[0094] Figure 5 is a graph of the average density of PCC specimens by PC type. The values of the density among different PC types are consistent with one another. This suggests that the different types of CHAR have minimal impact on density.

[0095] Figure 6A is a graph of the compressive strength of PCC specimens using PC as a replacement. Figure 6B is a graph of the compressive strength of PCC specimens using PC as an additive. Figure 6C is a graph of the percent increment of the compressive strength of the PCC at 28 days of curing. Figure 6D is a graph of the percent increment of the compressive strength of the PCC at 56 days of curing. The PCC specimens have a PC percentage and nPC varying from 0% to 1.5% weight of cement material as both a replacement and additive. The compressive strength values generally increase as the curing period increases from 3 to 56 days.

[0096] Regarding PC as a replacement, the compressive strength value of C30- CHAR50-50 exhibits a significant increase, surpassing the target strength of 30 MPa at 14 days. All PC specimens show an increase in compressive strength values with an increasing curing period, eventually exceeding the compressive strength value of C30- CHAR0-50. At the 28-day curing period, C30-CHAR50-50 demonstrates the highest compressive strength value of 37.4 MPa, compared to the control mix of 29.2 MPa, representing a 28.1% increase in compressive strength. The C30-CHAR25-50 specimen exhibits 36.1 MPa compressive strength, followed by C30-CHAR50-50.

[0097] The compressive strength analysis of concrete specimens with varying percentages of PC as an additive indicates a similar trend to PC as a replacement. At the 28-day curing period, C30-CHAR50a-50 specimen has a compressive strength of 38.9 MPa, representing a 33.3% increase over the control mix. Meanwhile, C30- CHAR75a-50 specimen exhibits the highest compressive strength at 56-days curing period of 40.5MPa, which shows 20.6% compressive gain, followed by the C30- CHAR50a-50 specimen with a compressive strength of 40.1 MPa and gain of 20.4%. On the other hand, at 56-days curing period, C30-CHAR150a-50 specimen shows lower compressive strength of 32.9 MPa than the control mix of 33.3 MPa.

[0098] These addition of PC both as a cement replacement and cement additive, especially in specific percentages between 0.5% to 0.75%, may lead to enhancements in the compressive strength of concrete.

[0099] Figure 7 is a graph of the 28-day cure compressive strength outcomes among PC types. The results indicate that PC, regardless of the specific type, yields higher values compared to the control mix. However, among the different PC types, the results are nearly identical, showing minimal variation. For example, C30-CHAR5-50 demonstrates a compressive strength of 31.20 MPa, while C30-nCHAR5-50 exhibits 31.30 MPa.

[0100] Figure 8 is a graph of the Modulus of Elasticity (MoE) values of PCC specimens. The graph illustrates a 28-day curing period and varying percentages of PC (ranging from 0% to 1.5% of cement). This comparison highlights the impact of PC on increasing the stiffness of concrete. Among the PCC specimens, C30-CHAR50-50 had the highest MoE value of 28.38 GPa, which is 60% higher than the control mix MoE value of 17.73 GPa. C30-CHAR75a-50 exhibits a MoE value of 25.48 GPa, further reinforcing the positive impact of PC on the mechanical properties of concrete.

[0101] Figure 9 is a graph of the MoE among PC types. The PC type may have an effect on the concrete's elasticity. A higher MoE value signifies a stiffer material, while a lower MoE value indicates a more flexible material. Among them, nPC exhibits a value closely aligned with the control mix, indicating similar elastic properties. This implies that incorporating nPC into the cement mixture maintains the structural integrity and stiffness of the resulting material. Conversely, PC exhibits a lower MoE value compared to other PC types, indicating a reduction in stiffness. This may be due to the specific characteristics of the PC impact on the concrete's elastic behavior, which may influence factors such as deformation under load and overall structural stability.

[0102] Figure 10 is a graph of the Poisson's ratio of PCC specimens cured for 28 days. Poisson's ratio is a mechanical property representing a material's lateral deformation under axial loading. The Poisson’s ratio ranged from 0.13 to 0.17. The C30-CHAR75a-50 specimen of PCC exhibited the highest value of 0.17, whereas C30-CHAR25a-50 specimen showed a ratio of 0.157. The control mix had a lower Poisson's ratio of 0.15.

[0103] Figure 11 is a graph of the Poisson’s ratio among PC types. In line with Modulus of Elasticity, Poisson's ratio, which measures a material's lateral deformation when subjected to axial loading, reveals that nPC exhibits an identical value of 0.15, mirroring that of the control mix. This may indicate that the lateral deformation characteristics of nPCC resemble those of the control mix. The C30-CHAR5-50 displays a slightly lower Poisson's ratio of 0.133.

[0104] Figure 12A is a graph of the flexural and splitting tensile strength of the PCC replacement specimens. Figure 12B is a graph of the flexural and splitting tensile strength of the PCC additive specimens. The flexural strength at the 28-day curing period showed a positive correlation in strength gain with the percentage of PC, whether used as a replacement or an additive. The C30-CHAR25-50 and C30-CHAR75a-50 specimens demonstrate the maximum improvement compared to the control mix with a value of 4.99 MPa and 5.16 MPa, respectively, where the control mix shows only 4.27 MPa. At the 28-day curing period, all PCC specimens exhibit a consistent increase in tensile strength. The C30-CHAR5-50 and C30-CHAR75a-50 specimens demonstrate the highest values in both scenarios and the values are 4.30 MPa and 4.33 MPa, respectively, whereas control mix shows 4.03 MPa.

[0105] Figures 13A-13D are graphs of the heat generated during cement hydration of PCC specimens. Figure 13 A is a graph of the heat of flow of the PCC replacement specimens. Figure 13B is a graph of the cumulative heat of the PCC replacement specimens. Figure 13C is a graph of the heat of flow of the PCC additive specimens. Figure 13D is a graph of the cumulative heat of the PCC additive specimens. The results demonstrate that as the hydration process progresses, both the PC replacement and the PC additive to the cement material shows a comparable heat release compared to the control mix.

[0106] Figure 14A is a graph of the x-ray diffraction (XRD) analysis of PCC replacement specimens. Figure 14B is a graph of the XRD analysis of PCC additivespecimens. In XRD patterns, amorphous phases are typically represented by broad peaks, while crystalline phases are indicated by sharp peaks. In the context of PCC specimens, the presence of several sharp peaks may indicate an increased content of crystalline phases upon the introduction of PC. The PCC specimens were tested following 56 days of hydration. The XRD spectra were analyzed to identify specific chemical signals associated with the hydration process, leading to the identification of key phases such as portlandite (Ca(0H)2), calcium silicate hydrate (CSH), and ettringite.

[0107] A prominent peak was consistently observed at an angle of 34.3 degrees (29), which may be attributed to the presence of portlandite, which can contribute to rapid early strength development in concrete. Furthermore, two distinct peaks were discerned at 47.15 and 50.80 degrees (29), may also be indicative of portlandite formation.

[0108] While the quantity of hydration products in the PCC did not exhibit significant changes with varying PC concentrations, there were fluctuations in their amounts. The ettringite and CSH phases were detected at angles of 24.7 and 29 degrees (29), respectively. The intensities of the ettringite and CSH phases increased with the addition of PC, ranging from 0.05% to 1.5% by weight of cement material, in both replacement and additive scenarios.

[0109] The incorporation of PC leads to distinct changes in the chemical composition of the hydrated cement matrix. This may indicate that PC accelerates the hydration process, contributes to the formation of a rich crystalline structure, and results in a denser cement matrix. The effects may contribute to the development of a higher- strength cement matrix, demonstrating the benefits of PCC.

[0110] Figure 15A is a micrograph of scanning electron microscopy (SEM) element analysis of the 56-day-cured control mix at 10 pm. Figure 15B is a micrograph of the SEM element analysis of the 56-day-cured control mix at 5 pm. Figure 15C is a micrograph of SEM element analysis of the 56-day-cured CHAR50 at 10 pm. Figure 15D is a micrograph of SEM element analysis of the 56-day-cured CHAR50 at 5 pm.Figure 15E is a micrograph of SEM element analysis of the 56-day-cured CHAR50a at 10 pm. Figure 15F is a micrograph of SEM element analysis of the 56-day-cured CHAR50a at 5 pm. These PC percentages were selected based on the highest compressive strength at 28 days of curing.Experiment 2:

[0111] Table 6 is a summary of the concrete mixture designs for pyrolysis char (PC) as additive to cement. The PC is incorporated as a partial cement additive in concrete mixtures with three water to cement (WC) ratios and three fine to total aggregate (FA) ratios. The WC ratios include 0.6 (W0.60), 0.5 (W0.50), and 0.4 (W0.40). The FA ratios include 0.48 (FAO.48), 0.53 (FAO.53), 0.58 (FAO.58). The percentages of PC used are 0% (CO), 0.25% (C25), 0.5% (C50), and 1.0% (Cl 00).Table 6. Summary of Concrete Mixture Designs for PC as Additive to Cement.

[0112] The PCC is cast into specimens of 50 mm x 100 mm cylinders for testing the compressive and indirect split tensile strength. The PCC is cast into specimens of100 mm x 100 mm x 355 mm beams for flexural strength. The cylinder specimens and the beam specimens were cured for 7 days, 28 days, and 56 days for compressive strength testing and 28 days for split tensile strength and flexural tensile strength testing.

[0113] Table 7 is a summary of the notation conversion of concrete mixture designs between Experiment 1 and Experiment 2. The concrete mixture designs in Experiment 2 are compared against the results of the 0.25%, 0.5% and 1.0% PC mixture designs of Experiment 1.Table 7. Notation Conversions

[0114] Figure 16 is a graph of the comparison of slump value and the cement mixture. In most combinations, an increase in the PC content leads to a decrease in the slump value. For a WC ratio of 0.40 with varying FA ratios, the slump value ranges from about 150 mm to about 170 mm. For a WC ratio of 0.50, the slump value ranges from about 145 mm to about 165 mm. The WC ratio of 0.40 and 0.50 is maintained within this range by the use of SP. In contrast, the WC ratio of 0.60, where no SP is used, the slump values range from about 110 mm to about 125 mm.

[0115] Figure 17 is a graph of the comparison of density and the cement mixture. The densities of the cement mixtures range from about 2.3 g / cm3to about 2.5 g / cm3after 28 days. The similarity in density may be due to a low concentration of PC in the concrete mixtures, which enables the overall density to remain close to that of the control mixture concrete. A lower WC ratio results in higher density, indicating a more compact and solid structure. For different FA ratios, a lower FA leads to a higher density, which may be due to the greater proportion of CA in the concrete mixture.

[0116] Figures 18A-18I are graphs of the comparison of uniaxial compressive strength and the cement mixture. Lower WC ratios result in higher compressivestrength, while lower FA ratios contribute to higher compressive strength. The most significant increase in strength is observed between 0.25% and 0.50% PC as an additive, which aligns with the results in Experiment 1.

[0117] Figures 19A-19C are graphs of the effect of WC ratio at varying FA ratios on the Modulus of Elasticity (MoE) of the cement mixtures. Figures 20A-20C are graphs of the effect of FA ratio at varying WC ratios on the MoE of the cement mixtures. Lower WC ratios consistently results in higher MoE values across all FA ratios. Furthermore, the increase in PC contents leads to a corresponding increase in MoE values. However, FA ratios had a minimal impact on MoE, regardless of the WC ratio used in the cement mixture.

[0118] Figures 21A-21C are graphs of the effect of WC ratio at varying FA ratios on the Poisson’s ratio of the cement mixtures. Figures 22A-22C are graphs are graphs of the effect of FA ratio at varying WC ratios on the Poisson’s ratio of the cement mixtures. The Poisson’s ratio ranged consistently between 0.14 and 0.16 across all cement mixtures. A variation in the Poisson’s ratio with changes in WC ratios is observed, while minimal changes at lower WC ratios is observed with varying FA ratios.

[0119] Figures 23A-23C are graphs of the effect of WC ratio at varying FA ratios on the flexural strength of the cement mixtures. Figures 24A-24C are graphs are graphs of the effect of FA ratio at varying WC ratios on the flexural strength of the cement mixtures. The flexural strength decreases slightly as the PC content increases. Overall, the lower WC ratios result in higher flexural strength, while FA ratios did not affect the flexural strength.

[0120] Figures 25A-25C are graphs of the effect of WC ratio at varying FA ratios on the split tensile strength of the cement mixtures. Figures 26A-26C are graphs are graphs of the effect of FA ratio at varying WC ratios on the split tensile strength of the cement mixtures. The split tensile strength has a similar trend to the flexural strength of the cement mixtures: a slight reduction with increasing PC content. Overall, lower WC and FA ratios yield higher split tensile strengths.

[0121] In summary, a pyrolysis char concrete (PCC) is disclosed to create new coal products. The PCC is a composition that includes a dry mixture and water. The dry mixture includes about 15% to about 25% of a cement material, a pyrolysis char (PC), about 35% to about 45% of a coarse aggregate (CA), and about 35% to about 45% of a fine aggregate (FA). In some embodiments, the dry mixture includes a superplasticizer (SP). The PC may replaces about 0.05% to about 1.5% of the cement material or may have an amount of the PC that is about 0.05% to about 1.5% of the cement material. The water to cement ratio is about 0.4 to about 0.6. The PCC disclosed has comparable mechanical and chemical properties to conventional concrete, and thus can be used in place of conventional concrete.EMBODIMENTS LISTING

[0122] Clause 1. A composition, comprising: a dry mixture, comprising: about 15% to about 25% of a cement material; a pyrolysis char (PC), wherein the PC replaces about 0.05% to about 1.5% of the cement material; about 35% to about 45% of a coarse aggregate (CA); and about 35% to about 45% of a fine aggregate (FA); and water, wherein the water to cement ratio is about 0.4 to about 0.6.

[0123] Clause 2. The composition of clause 1, further comprising about 0.06% to about 0.2% of a superplasticizer (SP).

[0124] Clause 3. The composition of clause 2, wherein the SP includes a polycarboxylic ether polymer, a polycarboxylate ether, a sulfonated naphthalene formaldehyde, a sulfonated melamine formaldehyde, a lignosulfate, an acrylic polymer, or combinations thereof.

[0125] Clause d. The composition of clause 1, wherein the composition has a density between about 2.0 g / cm3 to about 2.5 g / cm3.

[0126] Clause 5. The composition of clause 1, wherein the composition has a compressive strength of the PCC is about 20 MPa to about 70 MPa.

[0127] Clause 6. The composition of clause 1, wherein the composition has a Modulus of Elasticity (MoE) of about 10 GPa to about 40 GPa.

[0128] Clause 7. The composition of clause 1, wherein the composition has a Poisson’s ratios of about 0.14 to about 0.17.

[0129] Clause 8. The composition of clause 1, wherein the composition has a split tensile strength of about 3 MPa to about 7 MPa.

[0130] Clause 9. The composition of clause 1, wherein the composition has a flexural strength of about 3 MPa to about 8 MPa.

[0131] Clause 10. A composition, comprising: a dry mixture, comprising: about 15% to about 25% of a cement material; a pyrolysis char (PC), wherein an amount of the PC is about 0.05% to about 1.5% of the cement material; about 35% to about 45% of a coarse aggregate (CA); and about 35% to about 45% of a fine aggregate (FA); and water, wherein the water to cement ratio is about 0.4 to about 0.6.

[0132] Clause 11. The composition of clause 10, further comprising about 0.06% to about 0.2% of a superplasticizer (SP).

[0133] Clause 12. The composition of clause 11, wherein the SP includes a polycarboxylic ether polymer, a polycarboxylate ether, a sulfonated naphthalene formaldehyde, a sulfonated melamine formaldehyde, a lignosulfate, an acrylic polymer, or combinations thereof.

[0134] Clause 13. The composition of clause 10, wherein the composition has a Modulus of Elasticity (MoE) of about 10 GPa to about 40 GPa.

[0135] Clause 14. The composition of clause 10, wherein the composition has aPoisson’s ratios of about 0.14 to about 0.17.

[0136] Clause 15. The composition of clause 10, wherein the composition has a density between about 2.0 g / cm3to about 2.5 g / cm3.

[0137] Clause 16. The composition of clause 10, wherein the composition has a compressive strength of the PCC is about 20 MPa to about 70 MPa.

[0138] Clause 17. The composition of clause 10, wherein the composition has a split tensile strength of about 3 MPa to about 7 MPa.

[0139] Clause 18. The composition of clause 10, wherein the composition has a flexural strength of about 3 MPa to about 8 MPa.

[0140] Clause 19. A method of making a composition, comprising: mixing a coarse aggregate and a first portion of water to form a first wet mixture; mixing a first wet mixture, a fine aggregate, and a second portion of water to form a second wet mixture; mixing a cement material with the second mixture and a third portion of water to form a third wet mixture; mixing a fourth portion of water and a PC to form a PC mixture; mixing the third wet mixture, the PC mixture, and a fifth portion of water to form a cement mixture; pouring a cement mixture into a mold; curing the cement mixture into a PC cement.

[0141] Clause 20. The method of clause 19, wherein the coarse aggregate, the fine aggregate, a cement material, and PC form a dry mixture, wherein the dry mixture comprises: about 15% to about 25% of a cement material; a pyrolysis char (PC), wherein an amount of the PC is about 0.05% to about 1.5% of the cement material; about 35% to about 45% of a coarse aggregate (CA); andabout 35% to about 45% of a fine aggregate (FA).

[0142] Clause 21. The method of clause 19, wherein the coarse aggregate, the fine aggregate, a cement material, and PC form a dry mixture, wherein the dry mixture comprises: about 15% to about 25% of a cement material; a pyrolysis char (PC), wherein the PC replaces about 0.05% to about 1.5% of the cement material; about 35% to about 45% of a coarse aggregate (CA); and about 35% to about 45% of a fine aggregate (FA).

[0143] Clause 22. The method of clause 20 or clause 21, wherein the dry mixture further comprises about 0.06% to about 0.2% of a superplasticizer (SP).

[0144] Clause 23. The method of clause 22, wherein the SP includes a polycarboxylic ether polymer, a polycarboxylate ether, a sulfonated naphthalene formaldehyde, a sulfonated melamine formaldehyde, a lignosulfate, an acrylic polymer, or combinations thereof.

[0145] Clause 24. The method of clause 19, wherein the water to cement ratio is about 0.4 to about 0.6.

[0146] Clause 25. The method of clause 19, wherein the PC cement has a split tensile strength of about 3 MPa to about 7 MPa.

[0147] Clause 26. The method of clause 19, wherein the PC cement has a flexural strength of about 3 MPa to about 8 MPa.

[0148] Clause 27 The method of clause 19, wherein the PC cement has a Modulus of Elasticity (MoE) of about 10 GPa to about 40 GPa.

[0149] Clause 28. The method of clause 19, wherein the PC cement has a Poisson’s ratios of about 0.14 to about 0.17.

[0150] Clause 29. The method of clause 19, wherein the PC cement has a density between about 2.0 g / cm3to about 2.5 g / cm3.

[0151] Clause 30. The method of clause 19, wherein the PC cement has a compressive strength of the PCC is about 20 MPa to about 70 MPa.

[0152] Clause 31. The method of clause 19, wherein the PC cement has a split tensile strength of about 3 MPa to about 7 MPa.

[0153] Clause 32. The method of clause 19, wherein the PC cement has a flexural strength of about 3 MPa to about 8 MPa.

[0154] As is apparent from the foregoing general description and the specific aspects, while forms of the aspects have been illustrated and described, various modifications can be made without departing from the spirit and scope of the present disclosure. Accordingly, it is not intended that the present disclosure be limited thereby. Likewise, the term “comprising” is considered synonymous with the term “including.” Likewise whenever a composition, process operation, process operations, an element or a group of elements is preceded with the transitional phrase “comprising,” it is understood that we also contemplate the same composition or group of elements with transitional phrases “consisting essentially of,” “consisting of,” “selected from the group of consisting of,” or “Is” preceding the recitation of the composition, process operation, process operations, element, or elements and vice versa, such as the terms “comprising,” “consisting essentially of,” “consisting of’ also include the product of the combinations of elements listed after the term.

[0155] For purposes of this present disclosure, and unless otherwise specified, all numerical values within the detailed description and the claims herein are modified by “about” or “approximately” the indicated value, and consider experimental error and variations that would be expected by a person having ordinary skill in the art. For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges fromany upper limit may be combined with any other upper limit to recite a range not explicitly recited. For example, the recitation of the numerical range 1 to 5 includes the subranges 1 to 4, 1.5 to 4.5, 1 to 2, among other subranges. As another example, the recitation of the numerical ranges 1 to 5, such as 2 to 4, includes the subranges 1 to 4 and 2 to 5, among other subranges. Additionally, within a range includes every point or individual value between its end points even though not explicitly recited. For example, the recitation of the numerical range 1 to 5 includes the numbers 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, among other numbers. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0156] While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof.

Claims

WHAT IS CLAIMED IS:

1. A composition, comprising: a dry mixture, comprising: about 15% to about 25% of a cement material; a pyrolysis char (PC), wherein the PC replaces about 0.05% to about 1.5% of the cement material; about 35% to about 45% of a coarse aggregate (CA); and about 35% to about 45% of a fine aggregate (FA); and water, wherein the water to cement ratio is about 0.4 to about 0.6.

2. The composition of claim 1, further comprising about 0.06% to about 0.2% of a superplasticizer (SP).

3. The composition of claim 2, wherein the SP includes a poly carboxylic ether polymer, a polycarboxylate ether, a sulfonated naphthalene formaldehyde, a sulfonated melamine formaldehyde, a lignosulfate, an acrylic polymer, or combinations thereof.

4. The composition of claim 1, wherein the composition has a density between about 2.0 g / cm3to about 2.5 g / cm3.

5. The composition of claim 1, wherein the composition has a compressive strength of about 20 MPa to about 70 MPa.

6. A composition, comprising: a dry mixture, comprising: about 15% to about 25% of a cement material; a pyrolysis char (PC), wherein an amount of the PC is about 0.05% to about 1.5% of the cement material; about 35% to about 45% of a coarse aggregate (CA); and about 35% to about 45% of a fine aggregate (FA); and water, wherein the water to cement ratio is about 0.4 to about 0.6.

7. The composition of claim 6, further comprising about 0.06% to about 0.2% of a superplasticizer (SP).

8. The composition of claim 7, wherein the SP includes a poly carboxylic ether polymer, a polycarboxylate ether, a sulfonated naphthalene formaldehyde, a sulfonated melamine formaldehyde, a lignosulfate, an acrylic polymer, or combinations thereof.

9. The composition of claim 6, wherein the composition has a Modulus of Elasticity (MoE) of about 10 GPa to about 40 GPa.

10. The composition of claim 6, wherein the composition has a Poisson’s ratios of about 0.14 to about 0.17.

11. A method of making a composition, comprising: mixing a coarse aggregate and a first portion of water to form a first wet mixture; mixing a first wet mixture, a fine aggregate, and a second portion of water to form a second wet mixture; mixing a cement material with the second mixture and a third portion of water to form a third wet mixture; mixing a fourth portion of water and a PC to form a PC mixture; mixing the third wet mixture, the PC mixture, and a fifth portion of water to form a cement mixture; pouring a cement mixture into a mold; and curing the cement mixture into a PC cement.

12. The method of claim 11, wherein the coarse aggregate, the fine aggregate, a cement material, and PC form a dry mixture, wherein the dry mixture comprises: about 15% to about 25% of a cement material; a pyrolysis char (PC), wherein an amount of the PC is about 0.05% to about 1.5% of the cement material; about 35% to about 45% of a coarse aggregate (CA); andabout 35% to about 45% of a fine aggregate (FA).

13. The method of claim 11 , wherein the water to cement ratio is about 0.4 to about 0.6.

14. The method of claim 11, wherein the PC cement has a split tensile strength of about 3 MPa to about 7 MPa.

15. The method of claim 11 , wherein the PC cement has a flexural strength of about 3 MPa to about 8 MPa.

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