Coal derived carbon-based products with colorant additives and methods of making the same

Abstract

The present disclosure relates to a composition and methods of making the composition. The composition includes a cementitious material, a pyrolysis char (PC), a silica fume, a superplasticizer, and a pigment. The method includes mixing a cementitious material, a pyrolysis char, a silica fume, and a pigment to form a dry mixture and mixing a superplasticizer and water to form a wet mixture. The wet mixture and the dry mixture are mixed to form a pyrolysis char brick (PCB) mixture. The PCB mixture is cured to form a PCB. Another method includes mixing a cementitious material, a pyrolysis char, and a silica fume to form a dry mixture and mixing a superplasticizer, water, and pigments to form a wet mixture. The dry mixture and the wet mixture are mixed to form a pyrolysis char brick (PCB) mixture. The PCB mixture is cured to form a PCB.

Description

Attorney Docket No.: UWYO / 0132PCCOAL DERIVED CARBON-BASED PRODUCTS WITH COLORANT ADDITIVES AND METHODS OF MAKING THE SAMEBACKGROUNDField

[0001] Embodiments of the present disclosure generally relate to thin bricks and stone veneers. In particular, the present disclosure relates to pyrolysis char thin bricks (PCTBs) and pyrolysis char stone veneers (PCSVs) and methods of making PCTBs and PCSVs.Description of the 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 different parts of the United States and the world more generally. Wyoming produces approximately 40% of the coal in the United States, and the coal industry contributes significant revenue to the state of Wyoming (over $798 million in 2018). 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.

[0004] Thin bricks and stone veneers are famous for their aesthetic value and are used to decorate a building or structure exterior fagade. Because of the shape and dimensions of thin bricks and stone veneers, they require comparatively less quantity of materials and less energy for manufacturing. In8781484 1Attorney Docket No.: UWYO / 0132PC addition, the thin bricks and stone veneers facilitate advantageous installation characteristics due to their light weight as compared to conventional bricks and stones. A building composed of wood or other materials can have the appearance of natural stones or brick walls thanks to low-cost goods such as the thin bricks and stone veneers. Thin bricks typically have a maximum thickness of about 44.5 mm, and stone veneers are about 67 mm. Since they are lightweight, the buildings' dead load is not significantly increased.

[0005] Clay and aggregates are common raw materials for manufacturing thin bricks and stone veneers. Thin clay bricks are manufactured using clay and then burnt in a kiln to provide the necessary strength and durability. Stone veneers are made of concrete using cement and natural aggregates. The annual growth rate in the use of thin bricks and stone veneers is around 2%. Increasing production requires increased consumption of natural aggregates, leading to landslides and other hazards. Similarly, burning clay-thin bricks in kilns releases harmful gases, which may contribute to global climate change and global warming. Conventional manufacturing methods and raw materials pose serious environmental concerns, demanding investigating into new and sustainable raw materials.

[0006] Therefore, there is a need for improved thin bricks and stone veneers and methods of fabricating thin bricks and stone veneers for use as building materials.SUMMARY

[0007] In one embodiment, a composition is disclosed. The composition includes a cementitious material, a pyrolysis char (PC), a silica fume, a superplasticizer, and a pigment.

[0008] In another embodiment, a method is disclosed. The method includes mixing a cementitious material, a pyrolysis char, a silica fume, and a pigment to form a dry mixture and mixing a superplasticizer and water to form a wet mixture. The wet mixture and the dry mixture are mixed to form a pyrolysis char brick (PCB) mixture. The PCB mixture is cured to form a PCB.8781484 2Attorney Docket No.: UWYO / 0132PC

[0009] In yet another embodiment, a method of forming a composition is disclosed. The method includes mixing a cementitious material, a pyrolysis char, and a silica fume to form a dry mixture and mixing a superplasticizer, water, and pigments to form a wet mixture. The dry mixture and the wet mixture are mixed to form a pyrolysis char brick (PCB) mixture. The PCB mixture is cured to form a PCB.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] 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, may admit to other equally effective embodiments.

[0011] Figure 1 is a flow chart of a method for processing a pyrolysis char (PC), according to embodiments.

[0012] Figure 2 is a flow chart of a method for forming a composition, according to embodiments.

[0013] Figure 3 is a flow chart of a method for forming a composition, according to embodiments.

[0014] Figure 4 is a graph of the compressive strength of the pyrolysis char brick specimens, according to embodiments.

[0015] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.DETAILED DESCRIPTION

[0016] Embodiments of the present disclosure generally relate to a thin bricks and stone veneers. In particular, the present disclosure relates to8781484 3Attorney Docket No.: UWYO / 0132PC pyrolysis char thin bricks (PCTBs) and pyrolysis char stone veneers (PCSVs) and methods of making PCTBs and PCSVs.

[0017] The inventors have found new and improved methods for fabricating pyrolysis char bricks (PCBs), such as PCTBs and PCSVs. The PCTBs and PCSVs include colorant to achieve a desired aesthetic effect. Briefly, pyrolysis char (PC) is obtained by pyrolyzing coal at a temperature of 500°C to about 900°C, such as about 850°C. The predominant chemical components of PC include fixed carbon (79.9%), ash (16%), moisture (2.9%), and volatile matter (1.2%). The present disclosure incorporates PC into construction products beyond coal’s traditional energy applications. The PCTBs and PCSVs provide alternative usage of coal that avoids the environmental concerns related to the conventional uses of coal. By utilizing PC in the composition of PCTBs and PCSVs, the carbon footprint associated with coal mining and usage can be reduced.

[0018] The use of headings is for purposes of convenience and does not limit the scope of the present disclosure. Embodiments described herein can be combined with other embodiments.

[0019] 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 prepared by suitable mixing process.COMPOSITIONS:

[0020] A composition (e.g., a pyrolysis char brick (PCB)) includes cementitious material, pyrolysis char (PC), silica fume (SF), superplasticizer (SP), pigments, and water. A PCB may include a pyrolysis char thin brick (PCTB) and a pyrolysis char stone veneer (PCSV). The composition includes about 45% to about 60% cementitious materials, about 35% to about 45% PC, about 4% to about 6% silica fume, about 0.7% to about 1.7% SP, and about 3% to about 7% pigment. The water-to-cementitious material ratio is about 0.58781484 4Attorney Docket No.: UWYO / 0132PC to about 1.0, such as about 0.65 to about 0.75, such as about 0.7. The PCB has a compressive strength of about 5 MPa to about 25 MPa. The PCB has a density of about 950 kg / m3to about 1100 kg / m3The PCBs have a water absorption of about 8% to about 14%, such as about 9% to about 12%.

[0021] The PC is derived from coal materials. The coal materials are produced from the Powder River Basin (PRB) coal, which is classified as sub- bituminous coal. In certain embodiments, coal from other deposits or sources may be advantageously utilized according to the embodiments described herein. In some embodiments, the PC is chemically processed from the PRB coal. Despite having a low thermal content, PRB coal has low sulfur content and high carbon content. The PC is formed by pyrolyzing the coal material in a furnace up to a temperature of about 850°C to remove volatiles and tar.

[0022] The cementitious materials may include 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. Other types of cement are contemplated. In some embodiments, the cementitious materials may include ground granulated blast furnace slag (GGBFS), fly ash (e.g., Class C fly ash), ground limestone, and combinations thereof. The ordinary Portland Cement Type II is defined using ASTM C150 / C150M (ASTM 2022). The specific gravity of the cementitious material is about 3.15, in accordance with ASTM C188.

[0023] Silica fume includes BASF Melflux 2651 F in the form of a light yellowish powder, an amorphous micronized grey silicon dioxide pozzolan, a densified SF (e.g., Trinic R-E-D 105WS, Trinic R-E-D 106 pm, Trinic Pozz Plus, Trinic Z3-95, DMI NanoPozz 100-D), or an undensified SF (e.g., Riteks microfume 106 pm).

[0024] The superplasticizer may include polycarboxylic ether polymer (such as BASF Melflux), a polycarboxylate ether, a sulfonated naphthalene8781484 5Attorney Docket No.: UWYO / 0132PC formaldehyde, a sulfonated melamine formaldehyde, a lignosulfate, an acrylic polymer, or combinations thereof. The superplasticizer increases workability and decreases water content, which contributes to the composition’s durability.

[0025] The pigments include iron oxide (yellow powder, brown powder), zinc oxide (white powder), and terra cotta (liquid), natural earth pigments such as Venetian red, raw sienna, and burnt umber, carbon black, ivory black, or combinations thereof although other pigments and mixtures of pigments are contemplated by this disclosure depending on the desired aesthetic appearance of the PCB. The pigments may be formulated according to a yellow:white:black (Y:W:B) ratio. The Y:W:B ratio may be from about 1 :0:0 to about 1 :1 :0, from about 1 :1 :0.015 to about 0:1 :0, from about 0.073:1 :0, from about 0.073:1 :0.015, from about 0.073:0:0 to about 0.073:0:0.015, or any ranges therebetween.

[0026] In some embodiments, the PCB may be coated with a hydrophobic liquid. The hydrophobic liquid includes a polymer-based material, such as a silicone material (e.g., Behr® Concrete & Masonry Protector & Waterproofer), nano-silica, or fluorinated silanes.

[0027] Figure 1 is a flow chart of a method 100 for processing a pyrolysis char (PC). At operation 102, the PC is filtered through a sieve. The sieve is a #50 sieve to a #300 sieve, such as a #150 sieve to a #250 sieve, such as a #190 to a #210 sieve, such as a #200 sieve. The sieve separates coarse PC particles from fine PC particles.

[0028] At operation 104, residual contaminants are removed from the coarse PC particles. The residual contaminants are removed by washing the coarse PC particles within the sieve with water. The washing is repeated until the water runs clean, indicating the removal of pollutants and fine dust. The residual contaminants include tar. Removal of the residual contaminants and fine dust reduces the effect the PC imparts on the hue of other mixed materials, such as the pigments, thus making the PC a color-neutral additive.8781484 6Attorney Docket No.: UWYO / 0132PC

[0029] At operation 106, the fine PC particles and coarse PC particles are dried in an oven. The fine PC particles and coarse PC particles are dried at a temperature from about 60°C to about 110°C.

[0030] Figure 2 is a flow chart of a method 200 for forming a composition. At operation 202, the cementitious material, PC, SF, and pigments are mixed to form a dry mixture. The pigment includes a solid, powder pigment, such as iron oxide or zinc oxide. Other colorant mixtures in the form of powder are also contemplated.

[0031] At operation 204, the superplasticizer and water are mixed to form a wet mixture. At operation 206, the wet mixture and the dry mixture are mixed to form a PCB mixture. At operation 208, the PCB mixture is poured into a mold. The PCB mixture is compacted with a tamping rod and vibrated using a table vibrator for uniform and compact mix.

[0032] At operation 210, the PCB mixture is cured to form pyrolysis char bricks (PCBs). The PCB mixture is cured at room temperature for about 20 to about 28 hours and then cured in a humidity chamber for about 25 days to about 35 days at a humidity of about 85% to about 95% at about 20°C to about 25°C. In some embodiments, the PCB is a pyrolysis char thin brick (PCTB).

[0033] At optional operation 212, the PCB is textured to form a pyrolysis char stone veneer (PCSV). The PCB is chipped using a hammer and chisel to give a stone-like aesthetic look. It is contemplated that other mechanical texturing apparatus may also be utilized to impart texture on the PCSV. Alternatively, the mold utilized in operation 208 may impart a relief on the PCSV, thus imparting a stone-like aesthetic.

[0034] At operation 214, the PCB is coated in a resin to form a resin-coated PCB. The resin includes a vinyl ester resin, an epoxy resin, or other similar types of resin. The resin-coated PCB enables the PCB to be resistant to decolorization at elevated temperatures. In some embodiments, the resin is mixed with a sand and a pigment and the resin / sand / pigment mixture is applied to the PCB to form the resin-coated PCB.8781484 7Attorney Docket No.: UWYO / 0132PC

[0035] At optional operation 216, a pigment is applied to the resin coating. In some embodiments, the pigment is sprinkled, sprayed, or otherwise applied over the resin. In other embodiments, a pigment / sand mixture is sprinkled, sprayed, or otherwise applied over the resin.

[0036] Figure 3 is a flow chart of a method 300 for forming a composition. At operation 302, the cementitious material, PC, and SF are mixed to form a dry mixture. At operation 304, the superplasticizer, water, and pigments are mixed to form a wet mixture. The pigment includes a liquid pigment, such as terra cotta. It is contemplated that other liquid pigments may also be advantageously employed.

[0037] At operation 306, the wet mixture and the dry mixture are mixed to form a PCB mixture. At operation 308, the PCB mixture is poured into a mold. The PCB mixture is compacted with a tamping rod and vibrated using a table vibrator for uniform and compact mix.

[0038] At operation 310, the PCB mixture is cured to form pyrolysis char bricks (PCBs). The PCB mixture is cured at room temperature for about 20 to about 28 hours and then cured in a humidity chamber for about 25 days to about 35 days at a humidity of about 85% to about 95% at a temperature of about 20°C to about 25°C. In some embodiments, the PCB is a pyrolysis char thin brick (PCTB).

[0039] At optional operation 312, the PCB is textured to form a pyrolysis char stone veneer (PCSV). The PCB is chipped using a hammer and chisel to give a stone-like aesthetic look. It is contemplated that other mechanical texturing apparatus may also be utilized to impart texture on the PCSV. Alternatively, the mold utilized in operation 308 may impart a relief on the PCSV, thus imparting a stone-like aesthetic.

[0040] At operation 314, the PCB is coated in a resin to form a resin-coated PCB. The resin includes a vinyl ester resin, an epoxy resin, or other similar types of resin. The resin-coated enables the PCB to be resistant to decolorization at elevated temperatures. In some embodiments, the resin is8781484 8Attorney Docket No.: UWYO / 0132PC mixed with a sand and a pigment and the resin / sand / pigment mixture is applied to the PCB to form the resin-coated PCB.

[0041] At optional operation 316, a pigment is applied the resin coating. In some embodiments, the pigment is sprinkled, sprayed, or otherwise applied over the resin. In other embodiments, a pigment / sand mixture is sprinkled, sprayed, or otherwise applied over the resin.

[0042] At operation 318, the resin-coated PCB is treated with a hydrophobic liquid. The hydrophobic liquid includes a polymer based material, such as a silicone material (e.g., Behr® Concrete & Masonry Protector & Waterproofer), nano-silica, or fluorinated silanes.EXAMPLES:Test Methods

[0043] The compressive strength of the PCBs is measured according to ASTM C1670.

[0044] The water absorption test is performed according to ASTM C67.

[0045] The freeze-thaw test is performed using the freeze-thaw method according to ASTM C67 for the pyrolysis char thin bricks (PCTBs). The freezethaw test is performed using the freeze-thaw method according to ASTM C666 for the pyrolysis char stone veneers (PCSVs).

[0046] Linear dry shrinkage is measured according to ASTM C157.

[0047] The shear bond strength is measured according to ASMT C482.

[0048] The PCTBs satisfy the standards of C1088 and the PCSVs satisfy the standards of C1670.EXPERIMENTALExperiment 1 :8781484 9Attorney Docket No.: UWYO / 0132PC

[0049] Table 1 is a summary of the compositions of pyrolysis char brick (PCB) specimens.Table 1 . Summary of Compositions of Pyrolysis Char Brick Specimens

[0050] Table 2 is a summary of the composition of a yellow-colored pigment mixture.Table 2. Summary of Composition of Yellow Colored Pigment Mixture

[0051] Table 3 is a summary of the mix ratio of resin, hardener, and pigments for coating applications. After application of the resin, three different types of sand are applied to the specimen. The sand is applied in one of three methods: (1 ) a first coat of resin is applied to the PCB specimen and sand is sprinkled over the specimen; (2) a first coat of resin is applied to the PCB specimen and sand and pigment are sprinkled over the PCB specimen; (3) the resin, pigment, and sand are mixed together and a first coat of resin, sand, and pigment are applied to the PCB specimen. In some embodiments, a second coat of resin is applied to the PCB specimen. The pigments may be formulated8781484 10Attorney Docket No.: UWYO / 0132PC according to a yellow:white:black (Y:W:B) ratio. PCB specimen (i) had the most favorable coloration, exhibiting a natural yellowish color and texture that resembled naturally occurring stones.Table 3. Summary of Mix Ratio of Resin, Hardener, and Pigments

[0052] The compressive strength determines the ability of stone veneers to withstand a compressive load. Cylindrical samples, made from the PCB specimens in Table 1 , are tested under a compressive strength testing apparatus until failure. The compressive strength of the stone veneer is determined by calculating the associated stress, which is known as the failure at which the PCB specimen fails.

[0053] Figure 4 is a graph of the compressive strength of the PCB specimens. The Mix-1 PCB specimens have a 7-day compressive strength of 14.67 MPa and reach 19.2 MPa at 28 days. The 7-day compressive strength of the Mix-2 PCB is about 13.44 MPa and increases to 18.07 MPa at 28-days. All the PCB specimens met the standard of 15 MPa, with the exception of the Mix-3 PCB specimen, which replaced gray cement type l / ll with cement type I. The Mix-4 PCB, which included PC, had a 7-day compressive strength of 7.48 MPa and increased to 18.97 MPa at 28-days. The Mix-5 PCB specimen had the highest compressive strength at 28-days of about 23.20 MPa, indicating an improvement from including the powdered pigment. The Mix-6 PCB specimen included terra cotta liquid pigment and has a 7-day compressive strength of8781484 11Attorney Docket No.: UWYO / 0132PC18.35 MPa and 28-days compressive strength of 19.72 MPa, indicating that the liquid pigment may also positively influence the strength of the mixture.

[0054] The PCB specimens are tested to measure their water absorption to evaluate how the PCB specimens withstand variations in weather. The PCTB specimens are 95 mm in length, 90 mm in width, and 13 mm of thickness. The PCSV specimens are 95 mm in length, 90 mm in width, and 40 mm in thickness. The PCB specimens are immersed in room temperature water for 24 hours, then immersed in boiling water for 5 hours. The total water absorption is calculated by dividing the weight of the specimen after five hours in boiling water by the specimen’s original dry weight and multiplying by 100. The Mix-5 specimens have a water absorption of about 11 % and the Mix-6 specimens of about 11 .5%. The maximum water content for bricks, according to ASTM C67, is 18%.

[0055] The PCB specimens are tested to measure their ability to resist crack formation due to cold weather conditions. The PCTB specimens are first kept in a thawing chamber for four hours, then are moved to a freezer and kept in freezing conditions for 20 hours. The freezer is maintained at a temperature of -10°C. The PCTB specimens are thawed and frozen five times over five days, with air drying performed for two days. The process is repeated for 50 cycles. All the PCTB specimens survived the freeze-thaw cycles.

[0056] The PCSV specimens are placed into a freeze-thaw cabinet that switches between -17.78°C and 4.44°C every five hours. The PCSVs spend an average of three to five hours freezing, with the remaining two hours thawing. All the PCSV specimens survived the freeze-thaw cycles.

[0057] The PCB specimens were assessed for linear drying shrinkage. The PCB specimens were placed in lime-saturated water. The PCB specimens have a length of 285 mm, a width of 55 mm, and a thickness of 55 mm. The readings are taken on the 7th day and 35th day after casting are used to compare the length measurements using a length comparator. The shrinkage percentage of the PCB specimen is calculated by multiplying the ratio of the8781484 12Attorney Docket No.: UWYO / 0132PC difference in length measured at 7 days or 35 days with the initial length by 100. The linear shrinkage for all PCB specimens was within the standard of 0.1 %.

[0058] The PCSV specimens are subjected to shear bond testing to ascertain the capacity of the PCSV specimens to adhere to building structures walls when utilizing cement paste and other adhesives. The PCSV specimens had a length of 90 mm, a width of 90 mm, and a thickness of 40 mm. The PCSV specimens are layered over a mortar block using 0.36 w / c ratio cement paste as a bonding agent. A steel framework holds each PCSV specimen upright and prevents the PCSV specimen from tilting while being loaded. The PCSV specimen is subjected to an axial force from the top to separate it from the block. The PCSV specimens bond strength was then measured. The mortar block has dimensions of 152 mm x 114 mm x 51 mm and are formed using cement:sand:water ratio of 1 :3.3:0.5. The Mix-5 PCB specimens and Mix-6 PCB specimens had a 7-day bond strength of 1.18 MPa and 1.11 MPa, respectively. Both the Mix-5 PCB specimens and Mix-6 PCB specimens both exceed the 0.35 MPa minimum standard.

[0059] In summary, the pyrolysis char bricks (PCBs), including pyrolysis char stone veneers (PCSVs) and pyrolysis char thin bricks (PCTBs), give the desired mechanical and durability properties required under the appropriate standards. The raw materials include PC, cementitious materials, superplasticizers, silica fume, and pigments. The pigments include liquid or dry pigments to achieve the desired aesthetic properties.EMBODIMENTS LISTING

[0060] The present disclosure provides, among other things, the following embodiments, each of which can be considered as optionally including any alternate embodiment.

[0061] Clause 1. A composition, comprising: a cementitious material; a pyrolysis char (PC);8781484 13Attorney Docket No.: UWYO / 0132PC a silica fume; a superplasticizer; and a pigment.

[0062] Clause 2. The composition of clause 1 , comprising: about 45% to about 60% cementitious material; about 35% to about 45% PC; about 4% to about 6% silica fume; about 0.7% to about 1 .7% SP; and about 3% to about 7% pigment.

[0063] Clause 3. The composition of clause 1 , wherein the composition has a compressive strength of about 5 MPa to about 25 MPa.

[0064] Clause 4. The composition of clause 1 , wherein the composition has a density of about 950 kg / m3to about 1100 kg / m3

[0065] Clause 5. The composition of clause 1 , wherein the composition has a water absorption of about 8% to about 14%.

[0066] Clause 6. The composition of clause 1 , wherein the superplasticizer comprises polycarboxylic ether polymer, a polycarboxylate ether, a sulfonated naphthalene formaldehyde, a sulfonated melamine formaldehyde, a lignosulfate, an acrylic polymer, or combinations thereof.

[0067] Clause 7. The composition of clause 1 , wherein the pigment comprises iron oxide, zinc oxide, or terra cotta.

[0068] Clause 8. The composition of clause 1 , wherein the silica fume comprises an amorphous micronized grey silicon dioxide pozzolan, a densified SF, or an undensified SF.8781484 14Attorney Docket No.: UWYO / 0132PC

[0069] Clause 9. The composition of clause 1 , further comprising a resin coating.

[0070] Clause 10. The composition of clause 9, wherein the resin coating comprises a vinyl ester resin, an epoxy resin, or a silicone material.

[0071] Clause H . The composition of clause 1 , wherein the PC is derived from coal materials.

[0072] Clause 12. The composition of clause 11 , the coal materials are produced from a sub-bituminous coal.

[0073] Clause 13. The composition of clause 1 , wherein the PC is chemically processed from PRB coal.

[0074] Clause 14. The composition of clause 1 , wherein the PC is formed by pyrolyzing coal materials in a furnace up to a temperature of about 850°C.

[0075] Clause 15. The composition of clause 1 , wherein the cementitious material comprises 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, Portlandpozzolans cement, and pozzolans-modified Portland cement, ground granulated blast furnace slag (GGBFS), fly ash (e.g., Class C fly ash), ground limestone, or combinations thereof.

[0076] Clause 16. The composition of clause 1 , wherein the specific gravity of the cementitious material is about 3.15.

[0077] Clause 17. The composition of clause 1 , wherein the densified SF includes Trinic R-E-D 105WS, Trinic R-E-D 106 pm, Trinic Pozz Plus, Trinic Z3-95, DM I NanoPozz 100-D.8781484 15Attorney Docket No.: UWYO / 0132PC

[0078] Clause 18. The composition of clause 1 , wherein the undensified SF includes Riteks microfume 106 pm.

[0079] Clause 19. The composition of clause 1 , wherein the pigment comprises iron oxide, zinc oxide, or terra cotta.

[0080] Clause 20. The composition of clause 1 , wherein a water-to- cementitious material ratio of the composition is about 0.7.

[0081] Clause 21 . A method of forming a composition, comprising: mixing a cementitious material, a pyrolysis char (PC), a silica fume, and a pigment to form a dry mixture; mixing a superplasticizer and water to form a wet mixture; mixing the wet mixture and the dry mixture to form a pyrolysis char brick (PCB) mixture; and curing the PCB mixture to form a PCB.

[0082] Clause 22. The method of clause 21 , further comprising: coating the PCB with a resin to form a resin-coated PCB.

[0083] Clause 23. The method of clause 23, further comprising: applying the pigment to the resin-coated PCB.

[0084] Clause 24. The method of clause 21 , wherein curing the PCB mixture comprises: curing at room temperature for about 20 to about 28 hours; and curing in a humidity chamber for about 25 days to about 35 days at a humidity of about 85% to about 95% at a temperature of about 20°C to about 25°C.

[0085] Clause 25. The method of clause 21 , further comprising:8781484 16Attorney Docket No.: UWYO / 0132PC texturing the PCB to form a pyrolysis char stone veneer.

[0086] Clause 26. The method of clause 25, wherein the pigment includes an iron oxide or zinc oxide.

[0087] Clause 27. The method of clause 21 , further comprising: pouring the PCB mixture into a mold.

[0088] Clause 28. The method of clause 27, further comprising: compacting the PCB mixture within the mold with a tamping rod; and vibrated the mold using a table vibrator.

[0089] Clause 29. The method of clause 21 , further comprising: texturing the PCB to form a pyrolysis char stone veneer (PCSV).

[0090] Clause 30. The method of clause 29, wherein texturing the PCB further comprises: chipping the PCB is using a hammer and chisel.

[0091] Clause 31 . The method of clause 22, wherein the resin includes a vinyl ester resin, or an epoxy resin.

[0092] Clause 32. The method of clause 30, further comprising: mixing the resin with a sand and a pigment; and applying the resin / sand / pigment mixture to the PCB to form the resin- coated PCB.

[0093] Clause 33. The method of clause 32, further comprising: sprinkling the pigment over the resin.

[0094] Clause 34. The method of clause 33, further comprising:8781484 17Attorney Docket No.: UWYO / 0132PC sprinkling a pigment / sand mixture over the resin.

[0095] Clause 35. The method of clause 21 , further comprising: forming the PC by pyrolyzing a coal material in a furnace up to a temperature of about 850°C.

[0096] Clause 36. A method of forming a composition, comprising: mixing a cementitious material, a pyrolysis char, and a silica fume to form a dry mixture; mixing a superplasticizer, water, and pigment to form a wet mixture; mixing the dry mixture and the wet mixture to form a pyrolysis char brick (PCB) mixture; and curing the PCB mixture to form a PCB.

[0097] Clause 37. The method of clause 36, comprising: coating the PCB with a resin to form a resin-coating PCB.

[0098] Clause 38. The method of clause 37, further comprising: applying the pigment to the resin-coated PCB.

[0099] Clause 39. The method of clause 37, wherein curing the PCB mixture comprises: curing at room temperature for about 20 to about 28 hours; and curing in a humidity chamber for about 25 days to about 35 days at a humidity of about 85% to about 95% at a temperature of about 20°C to about 25°C.

[0100] Clause 40. The method of clause 36, further comprising:8781484 18Attorney Docket No.: UWYO / 0132PC texturing the PCB is textured to form a pyrolysis char stone veneer (PCSV).

[0101] Clause 41. The method of clause 40, wherein texturing the PCB further comprises: chipping the PCB is using a hammer and chisel.

[0102] Clause 42. The method of clause 36, wherein the pigment includes a terra cotta.

[0103] Clause 43. The method of clause 36, further comprising: pouring the PCB mixture into a mold.

[0104] Clause 44. The method of clause 43, further comprising: compacting the PCB mixture within the mold with a tamping rod; and vibrating using a table vibrator for uniform and compact mix.

[0105] Clause 45. The method of clause 37, wherein the resin includes a vinyl ester resin, an epoxy resin, or other similar type of resin.

[0106] Clause 46. The method of clause 37, further comprising: mixing the resin with a sand and a pigment; and the resin / sand / pigment mixture is applied to the PCB to form the resin- coated PCB.

[0107] Clause 47. The method of clause 46, further comprising: sprinkling the pigment over the resin.

[0108] Clause 48. The method of clause 46, further comprising: sprinkling a pigment / sand mixture is sprinkled over the resin.

[0109] Clause 49. The method of clause 37, further comprising:8781484 19Attorney Docket No.: UWYO / 0132PC the resin-coated PCB is treated with a hydrophobic liquid.

[0110] Clause 50. The method of clause 49, wherein the hydrophobic liquid includes a silicone material.

[0111] Clause 51 . The method of clause 36, further comprising: forming the PC by pyrolyzing a coal material in a furnace up to a temperature of about 850°C.

[0112] 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.

[0113] 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 from any upper limit may be combined with any other upper limit to recite a range not explicitly recited.8781484 20Attorney Docket No.: UWYO / 0132PCFor 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.

[0114] 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.8781484 21

Claims

Attorney Docket No.: UWYO / 0132PCWhat is claimed is:

1. A composition, comprising: a cementitious material; a pyrolysis char (PC); a silica fume; a superplasticizer; and a pigment.

2. The composition of claim 1 , comprising: about 45% to about 60% cementitious material; about 35% to about 45% PC; about 4% to about 6% silica fume; about 0.7% to about 1 .7% SP; and about 3% to about 7% pigment.

3. The composition of claim 1 , wherein the composition has a compressive strength of about 5 MPa to about 25 MPa.

4. The composition of claim 1 , wherein the pigment comprises iron oxide, zinc oxide, terra cotta, or combinations thereof.

5. The composition of claim 1 , further comprising: a resin coating.

6. A method of forming a composition, comprising: mixing a cementitious material, a pyrolysis char, a silica fume, and a pigment to form a dry mixture; mixing a superplasticizer and water to form a wet mixture; mixing the wet mixture and the dry mixture to form a pyrolysis char brick (PCB) mixture; and curing the PCB mixture to form a PCB.

7. The method of claim 6, further comprising:8781484 22Attorney Docket No.: UWYO / 0132PC coating the PCB with a resin to form a resin-coated PCB.

8. The method of claim 7, further comprising: applying the pigment to the resin-coated PCB.

9. The method of claim 6, wherein curing the PCB mixture comprises: curing at room temperature for about 20 to about 28 hours; and curing in a humidity chamber for about 25 days to about 35 days at a humidity of about 85% to about 95% at a temperature of about 20°C to about 25°C.

10. The method of claim 6, further comprising: texturing the PCB to form a pyrolysis char stone veneer.

11. A method of forming a composition, comprising: mixing a cementitious material, a pyrolysis char, and a silica fume to form a dry mixture; mixing a superplasticizer, water, and a pigment to form a wet mixture; mixing the dry mixture and the wet mixture to form a pyrolysis char brick (PCB) mixture; and curing the PCB mixture to form a PCB.

12. The method of claim 11 , further comprising: coating the PCB with a resin to form a resin-coated PCB.

13. The method of claim 12, further comprising: applying the pigment to the resin-coated PCB.

14. The method of claim 11 , wherein curing the PCB mixture comprises: curing at room temperature for about 20 to about 28 hours; and curing in a humidity chamber for about 25 days to about 35 days at a humidity of about 85% to about 95% at a temperature of about 20°C to about 25°C.8781484 23Attorney Docket No.: UWYO / 0132PC15. The method of claim 11 , further comprising: texturing the PCB to form a pyrolysis char stone veneer.8781484 24

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