Petcoke Cementitious Composition for CO2 Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The cement industry is a significant contributor to carbon dioxide emissions, and existing concrete formulations do not adequately address the need for reduced CO2 footprint while maintaining mechanical properties.

Innovation Solution

A cementitious composition that incorporates petcoke as a replacement for a portion of cement and/or aggregates, with a minimum of 80% of petcoke particles having a particle size of 0.1 μm to 45 μm, and the remaining amount having a size of less than 2 mm, is developed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If conventional concrete formulations are used, then mechanical properties are maintained, but CO2 emissions remain high due to extensive cement production

Engineering Contradiction:

ImproveCO2 emissionsVSAvoidmechanical properties

Core Design Contradiction:

Object-generated harmful factorsVSStrength

Solution Approach 1:

The patent changes the chemical composition parameters of concrete by substituting cement with petcoke (a carbon-containing material), thereby reducing CO2 emissions from cement production while maintaining mechanical properties through optimized petcoke particle size distribution (0.1 μm to 45 μm for at least 80% of particles)

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system by combining petcoke particles with traditional concrete components (cement, aggregates, water), forming a new cementitious composition that leverages the carbon content of petcoke to reduce emissions while maintaining structural integrity

Inventive Principle:

Principle #40Composite materials

2Object-generated harmful factors

If petcoke is added to cementitious composition, then CO2 emissions are reduced, but particle size distribution must be precisely controlled

Engineering Contradiction:

ImproveCO2 emissionsVSAvoidparticle size control

Core Design Contradiction:

Object-generated harmful factorsVSManufacturing precision

Solution Approach 1:

The patent specifies precise particle size parameters for petcoke (at least 80% of particles between 0.1 μm to 45 μm, remaining particles less than 2 mm) to optimize performance while reducing CO2 emissions, transforming the raw petcoke into a controlled material with defined characteristics

Inventive Principle:

Principle #35Parameter changes

3Strength

If petcoke particle size is reduced to 0.1 μm to 45 μm, then durability and mechanical properties are enhanced, but grinding energy consumption increases

Engineering Contradiction:

Improvemechanical properties and durabilityVSAvoidgrinding energy

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent optimizes the particle size parameter of petcoke to a specific range (0.1 μm to 45 μm for at least 80% of particles) that balances mechanical property enhancement with reasonable energy consumption, avoiding excessive fine grinding while achieving improved durability

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250154062A1Utilization of petroleum coke in cementitious materials

Publication Date: 2025.05.15 SAUDI ARABIAN OIL CO

AI summary

Provided is a cementitious composition including a cementitious material; petcoke as particles; aggregates; and water. A minimum of 80% of the petcoke has a particle size of from 0.1 μm to 45 μm, and the remaining amount of the petcoke has a particle size of less than 2 mm. Also provided is a method of producing a cementitious composition and an article including a cementitious composition.