Calcined Rock Cement Additive from Carbon-Containing Heaps
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Solution Overview
Problem
The cement industry faces significant CO2 emissions and resource inefficiencies in producing cement clinker, which is a major component of cement, and there is a need for a more environmentally sound and resource-sparing method to obtain a further main constituent for cement.
Innovation Solution
A method involving the reworking of carbon-containing heaps containing coal and clay-bearing rock, extracting and calcining the rock to produce fine-grain calcined rock, which can be used as a cement constituent or concrete additive, reducing the need for conventional cement clinker and fly ash.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cement clinker is produced through industrial calcination of limestone and clay, then high-strength cement is achieved, but significant CO2 emissions and energy consumption occur
Solution Approach 1:
The patent converts naturally occurring coal seams containing clay-bearing rock into a beneficial resource. By allowing in-situ combustion of the coal, the process generates heat that calcines the clay minerals directly in the ground, transforming what would be a harmful emissions-intensive industrial process into a beneficial natural phenomenon that produces calcined clay aggregates suitable for cement applications with significantly reduced CO2 emissions
Solution Approach 2:
The naturally occurring coal seams serve as their own fuel source for calcination. The coal combustes in-situ providing the necessary heat to calcine the clay-bearing rock without requiring external energy input or industrial furnaces. This self-service mechanism eliminates the need for energy-intensive industrial calcination processes and associated CO2 emissions
2Manufacturing precision
If industrial calcination processes are used to produce cement constituents, then high-quality calcined clay is obtained, but energy-intensive operations are required
Solution Approach 1:
The in-situ combustion of coal seams provides self-generated heat that calcines the clay-bearing rock directly in the ground. This eliminates the need for external energy input or industrial furnaces, reducing energy consumption while maintaining calcined clay quality suitable for cement applications
Solution Approach 2:
The patent extracts calcined clay aggregates directly from the ground after in-situ combustion, bypassing the need for energy-intensive industrial calcination processes. The calcined material is obtained in-situ and extracted for use in cement and concrete applications
3Quantity of substance
If natural resources are extensively quarried and processed for cement production, then sufficient raw materials are obtained, but resource consumption increases
Solution Approach 1:
Naturally occurring coal seams containing clay-bearing rock serve as the resource base. The in-situ combustion process transforms these natural formations into calcined clay aggregates without requiring extensive quarrying or external resource input, reducing overall resource consumption while maintaining material availability
Solution Approach 2:
The patent merges two naturally occurring resources (coal and clay-bearing rock) into a single beneficial product. The coal serves as both a fuel source and a binding agent that, when combusted in-situ, calcines the clay and creates strong calcined clay aggregates suitable for cement applications
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces CO2 emissions and energy input in cement production, provides a sustainable source of supplementary cementitious materials, and offers a viable alternative to conventional cement compositions, particularly in regions lacking high-quality raw materials.
Implementation Method 1
allowing combustion of the coal seam in situ to a degree that clay-bearing rock in the coal seam is calcined
Implementation Method 2
combustion of the coal seam
Data Source
AI summary
A method of providing a reactive cement constituent or concrete additive includes at least the following steps:a) reworking a carbon-containing heap comprising at least coal and clay-bearing rock;b) extracting at least calcined rock;c) producing fine-grain calcined rock; andd) providing fine-grain calcined rock for use as cement constituent or concrete additive.