Pyrolysis Char Building Materials for Thermal Insulation
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Solution Overview
Problem
The use of coal in its raw form for energy production leads to environmental issues such as carbon dioxide emissions, pollution, and inefficient thermal insulation in building materials, as conventional methods for creating porous materials are costly and carbon-intensive.
Innovation Solution
Thermo-chemical processing of coal to produce pyrolysis char, which is then used to fabricate building materials like char clay plaster, char brick, and foam glass without releasing anthropogenic carbon dioxide, by mixing pyrolysis char with water and other materials and subjecting them to specific temperatures and calcination conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional methods are used to create porous building materials (polyurethane foam, silica gel granules, expanded polystyrene foam), then thermal insulation and noise abatement are improved, but production costs increase and carbon dioxide emissions occur
Solution Approach 1:
The patent utilizes pyrolysis char, a porous carbon-rich material produced from coal, as the core ingredient for creating building materials with inherent porous structure. This natural porosity provides thermal insulation and noise abatement without requiring additional chemical foaming agents or high-energy processing, thereby avoiding CO2 emissions associated with conventional foam materials while achieving the desired energy efficiency.
Solution Approach 2:
The patent converts coal, traditionally burned for energy production that releases CO2, into pyrolysis char through thermal decomposition. This char becomes a valuable building material that sequesters carbon in a stable form while providing thermal insulation. The process transforms a harmful carbon source into a beneficial carbon sink product that reduces overall carbon footprint.
2Loss of energy
If chemically induced pore generation is used (high-temperature swelling or highly-purified reagents), then porosity and thermal insulation are improved, but manufacturing cost increases
Solution Approach 1:
The patent employs readily available, low-cost materials including coal-derived pyrolysis char, clay, sand, and water to create building materials. These inexpensive raw materials are processed through relatively simple thermal decomposition and mixing operations, avoiding the need for expensive chemical reagents or complex manufacturing equipment required by conventional porous material production methods.
Solution Approach 2:
The patent achieves porosity through controlled thermal decomposition (pyrolysis) of coal at elevated temperatures, which transforms the carbon structure into a porous char. This physical-chemical transformation occurs naturally during the heating process without requiring additional chemical treatments, purification steps, or expensive additives, thereby maintaining low manufacturing costs while achieving the desired porous structure for thermal insulation.
3Use of energy by moving object
If coal is combusted directly for energy production, then energy demand is met, but environmental pollution and carbon dioxide emissions increase
Solution Approach 1:
The patent applies thermal energy to decompose coal into pyrolysis char rather than combusting it for energy. This alternative utilization converts coal into a solid building material that sequesters carbon, transforming what would be a pollutant (combusted coal) into a beneficial carbon sink product. The process eliminates CO2 emissions associated with coal combustion while still utilizing thermal energy for material transformation.
Solution Approach 2:
Instead of discarding coal as a fuel source that releases pollution, the patent recovers and preserves the carbon in coal by converting it into stable pyrolysis char for building materials. This recovery process captures carbon that would otherwise be released as CO2, effectively storing it in a permanent solid form within the building structure.
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 building materials exhibit reduced thermal conductivity, enhanced noise abatement, and moisture-buffering properties, while reducing the carbon footprint and production costs, making them environmentally friendly and economically viable alternatives.
Implementation Method 1
The resulting building materials exhibit reduced thermal conductivity
Implementation Method 2
enhanced noise abatement
Implementation Method 3
moisture-buffering properties
Implementation Method 4
heating the coal extraction residue under pyrolysis conditions to form a pyrolysis char
Data Source
AI summary
Embodiments of the present disclosure generally relate to methods and materials for fabricating building materials and other components from coal. More specifically, embodiments of the present disclosure relate to materials and other components, such as char clay plaster, char brick, and foam glass fabricated from coal, and to methods of forming such materials. In an embodiment is provided a building material fabrication method. The method includes mixing an organic solvent with coal, under solvent extraction conditions, to form a coal extraction residue, and heating the coal extraction residue under pyrolysis conditions to form a pyrolysis char, the pyrolysis conditions comprising a temperature greater than about 500° C. The method further includes mixing the pyrolysis char with water and with one or more of clay, cement, or sand to create a mixture, and molding and curing the mixture to form a building material. Pyrolysis char-containing materials are also disclosed.