Pyrolysis Char Brick Composition for Low-Energy Construction
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Solution Overview
Problem
The increasing demand for renewable energy and environmental concerns related to coal combustion have led to a need for sustainable, eco-friendly methods to utilize Wyoming coal, particularly in the production of bricks, which must address issues of energy efficiency, reduced CO2 emissions, and improved material properties compared to conventional bricks.
Innovation Solution
A composition comprising 0-10% sand, 30-70% pyrolysis char, and 30-60% cement, with pyrolysis char having a particle size distribution of 50 μm to 500 μm, is used to fabricate bricks through a process involving mixing dry ingredients, adding water, molding, and curing without the need for an oven, resulting in reduced energy consumption and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional bricks are produced using traditional methods, then structural strength is achieved, but energy consumption is high and environmental impact increases
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating pyrolysis char (30-70% by weight) alongside cement (30-60% by weight), transforming the traditional brick composition to achieve both reduced energy consumption and maintained strength through chemical binding mechanisms
Solution Approach 2:
The patent creates a composite material system combining pyrolysis char with cement and sand, where the composite structure provides both mechanical strength and reduced thermal conductivity, eliminating the need for high-temperature firing while achieving desired performance
2Quantity of substance
If coal is combusted for energy production, then energy needs are met, but CO2 emissions and air pollution increase
Solution Approach 1:
The patent converts coal, traditionally burned for energy and producing CO2 emissions, into pyrolysis char through thermal decomposition without combustion. This char is then used as a structural component in bricks, transforming a harmful substance into a beneficial building material and eliminating CO2 emissions from coal utilization
3Temperature
If pyrolysis char content is increased in brick composition, then insulative properties improve, but structural strength may decrease
Solution Approach 1:
The patent optimizes the composition parameters by maintaining cement content at 30-60% by weight to provide structural binding, while incorporating pyrolysis char at 30-70% by weight for thermal insulation. This balanced parameter selection achieves both improved insulative properties and adequate structural strength
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 resulting pyrolysis char bricks exhibit reduced density, increased strength, lower thermal conductivity, and improved insulative properties, qualifying them as a Class 'A' building material with reduced environmental impact, suitable for construction and recycling, while mitigating CO2 emissions from coal processing.
Implementation Method 1
fabricating bricks from coal. More specifically, embodiments of the present disclosure relate to materials and methods of forming pyrolysis char bricks
Data Source
AI summary
Embodiments of the present disclosure relate to char bricks and methods of making char bricks. A composition (e.g., a char brick) includes about 0% to about 10% sand, about 30% to about 70% pyrolysis char (PC), and about 30% to about 60% cement. The PC has a particle size distribution from about 50 μm to about 500 μm. A method of making the composition includes mixing dry ingredients into a dry mixture, mixing the dry mixture with water to create a wet mixture; molding the wet mixture into a composition; and curing the composition. The dry ingredients include sand, pyrolysis char (PC), and cement. The PC has a particle size distribution from about 50 μm to about 500 μm.