Coal-Ceramic Synthetic Aggregate for Fire-Resistant Concrete
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Solution Overview
Problem
Conventional construction aggregates face limitations in terms of flammability, density, and strength, which can impact the performance and safety of construction materials like concrete.
Innovation Solution
Development of synthetic aggregates comprising coal or coal byproducts coated with polymer-derived ceramic materials, specifically silicon oxycarbide (SiOC), which are non-flammable, have controlled density, and enhanced strength, achieved through a process involving mixing, curing, and pyrolysis to form agglomerations suitable for use in construction materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional aggregates are used in construction materials, then the materials can be produced with standard density and strength, but the materials exhibit flammability and limited high-temperature resistance
Solution Approach 1:
The patent changes the chemical composition parameters of the aggregate by incorporating coal combustion byproducts (fly ash, bottom ash) and reactive silica materials in specific proportions. This compositional parameter change transforms the material's thermal properties, achieving non-flammability and high-temperature resistance while maintaining construction performance
Solution Approach 2:
The patent creates a composite aggregate material by combining coal combustion byproducts with reactive silica materials and binding agents. This composite structure integrates the beneficial properties of each component: the pozzolanic activity of fly ash, the chemical reactivity of silica, and the binding properties of cementitious materials, resulting in a material that resists fire and high temperatures
2Strength
If conventional aggregates are used, then the construction materials achieve standard strength, but the density remains high increasing structural weight
Solution Approach 1:
The patent modifies the density parameter of the aggregate by replacing traditional dense materials with porous coal combustion byproducts and lightweight silica materials. This parameter change reduces the overall density of the concrete while the pozzolanic reactions and binding agents maintain or enhance the compressive strength through chemical bonding and microstructure development
Solution Approach 2:
The patent utilizes the inherent porous structure of coal combustion byproducts (fly ash and bottom ash) as the aggregate material. These porous materials reduce the density and weight of the concrete while the pores can be filled by the binding matrix and reactive silica, maintaining strength. The porous structure also provides space for moisture absorption and reduces thermal mass
3Strength
If synthetic aggregates with enhanced properties are developed, then high-strength and low-weight concrete can be produced, but the manufacturing process complexity increases
Solution Approach 1:
The patent employs self-service mechanisms where the coal combustion byproducts undergo pozzolanic reactions with the binding agents and reactive silica in the concrete mixture. This self-reacting process occurs in-situ during concrete curing, eliminating the need for pre-processing or special handling equipment. The materials automatically react and bond, producing the desired strength enhancement without adding manufacturing complexity
Solution Approach 2:
The patent transforms waste coal combustion byproducts (fly ash and bottom ash) into valuable construction aggregates through a simple mixing and curing process. Instead of requiring complex recovery or refinement systems, the waste materials are directly incorporated into the concrete mixture where they chemically react and contribute to strength development, turning a disposal problem into a performance-enhancing solution
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
The synthetic aggregates provide improved compressive strength, reduced density, and resistance to high temperatures, making them suitable for high-strength, low-weight concrete applications while being environmentally friendly and cost-effective.
Implementation Method 1
heating the mixture to a curing temperature for a curing time to form a cured mixture; pyrolyzing the cured mixture in the presence of an inert gas at a pyrolysis temperature for a pyrolysis time to produce a plurality of agglomerations
Data Source
AI summary
Synthetic aggregate that includes a plurality of agglomerations. Each of the plurality of agglomerations may include a core; and a shell material disposed on the core. According to various embodiments, the construction aggregate may be non-flammable. According to various embodiments, at least one agglomeration of the plurality of agglomerations may have a plurality of cores. The core may include coal, a coal byproduct, and combinations thereof. According to various embodiments, the coal may be a type such as lignite, sub-bituminous, bituminous, and anthracite. The coal byproduct may be fly ash, bottom ash, shale coal, or coal gob.