Ceramic Brick Firing With High TIC Retention and Lower CO2
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Solution Overview
Problem
Current brick production methods release significant amounts of CO2 due to carbonate decomposition during the firing process, which is not accounted for in existing climate neutrality efforts.
Innovation Solution
The production process involves forming a ceramic building product from a plastic mass using only solid and liquid components, excluding exposure to any atmosphere other than air, and controlling the firing process to limit the conversion of free metal oxides into silicates, thereby reducing CO2 emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbonate decomposition is allowed during firing to complete the sintering process, then the brick achieves proper hardness and structural stability, but CO2 emissions increase significantly
Solution Approach 1:
The patent applies this principle by creating a CO2-rich atmosphere in the firing kiln through the decomposition of organic matter and controlled carbonate decomposition. This atmosphere suppresses further carbonate decomposition and prevents CO2 escape, while still allowing the sintering process to complete. The inert-like environment maintains high TIC content in the final product.
Solution Approach 2:
The patent changes the chemical parameters of the firing atmosphere by controlling the decomposition of organic matter and carbonates to establish a specific CO2 partial pressure. This parameter change suppresses carbonate decomposition equilibrium, allowing sintering to proceed while retaining TIC and reducing CO2 emissions to the environment.
2Object-generated harmful factors
If carbonate decomposition is suppressed to reduce CO2 emissions, then TIC content is maintained, but the sintering process may be incomplete affecting brick hardness
Solution Approach 1:
The patent uses organic matter decomposition as an intermediary process. The decomposition of organic materials generates CO2 and heat, creating a reducing atmosphere that suppresses carbonate decomposition while providing the thermal energy needed for sintering. This intermediary mechanism allows both sintering completion and TIC retention.
Solution Approach 2:
The patent utilizes phase transitions of organic matter (dehydration, decomposition, combustion) to generate the necessary thermal energy and atmospheric conditions. These phase transitions occur in controlled stages, providing heat for sintering while maintaining a CO2-rich atmosphere that suppresses carbonate decomposition and preserves TIC.
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 approach significantly reduces CO2 emissions by maintaining a high Total Inorganic Carbon (TIC) content and preventing excessive carbonate decomposition, achieving a more environmentally friendly brick production method.
Implementation Method 1
In the subsequent firing zone, the heated brick blanks undergo a significant transformation process, in which adjacent clay particles are fused together through sintering, i.e., surface melting.
Implementation Method 2
The carbonate content also decomposes. The CO2 emissions from TIC (Clay Tendered Clay) brick production result primarily from the carbonate decomposition of the calcite and dolomite it contains. This carbonate decomposition is an endothermic reaction
Data Source
AI summary
The invention relates to a ceramic building product for the production of a wall and/or for the cladding of a building envelope, e.g. in the form of a brick or a facade element, in particular a brick, wherein the fired building product has a TIC content (Total Inorganic Carbon) of more than 0.3 wt.%, and cannot be converted into a plastic state of the material by the addition of water, and to a method for the production of such a building product.