Building materials and components and methods of making the same
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.
1 . A building material, comprising:
a mixture of pyrolysis char, water, clay, cement, and sand:
cement is present in the mixture in a first amount of about 10 wt % to about 40 wt %, based on a total weight percent of cement, sand, pyrolysis char, and water; and
the water, sand, and pyrolysis char are present in the mixture in a second amount of about 60 wt % to about 90 wt %, based on the total weight percent of cement, sand, pyrolysis char, and water, wherein the total weight percent does not exceed 100 wt %.
2 . The building material of claim 1 , wherein the second amount further comprises about 20 wt % to about 40 wt % water when a weight ratio of the pyrolysis char to sand is about 2:7 to about 4:7.
3 . The building material of claim 1 , wherein the second amount further comprises about 25 wt % to about 40 wt % water when a weight ratio of the pyrolysis char to sand is about 3:6 to about 5:6.
4 . The building material of claim 1 , wherein the second amount further comprises about 30 wt % to about 40 wt % water when a weight ratio of the pyrolysis char to sand is about 0.9:1 to about 1:0.9.
5 . A building material, comprising:
a mixture, comprising:
about 5 wt % to about 80 wt % pyrolysis char (PC);
water;
clay, wherein a weight ratio of water to clay is from about 0.03 to about 0.8; and
about 20 wt % to about 95 wt % sand, wherein the total wt % of PC, clay, and sand does not exceed 100%.
6 . The building material of claim 5 , wherein the mixture further comprises about 10 wt % to about 40 wt % cement.
7 . The building material of claim 5 , wherein the building material has a bulk density of less than about 2 g cm −1 .
8 . The building material of claim 5 , wherein the building material has a thermal conductivity of less than about 1 Wm −1 K −1 .
9 . The building material of claim 5 , wherein the building material has a compressive strength of greater than 6 MPa.
10 . The building material of claim 5 , wherein the building material has a moisture absorption of about 0.01 g H 2 O/g CB at a relative humidity of 75%.
11 . The building material of claim 5 , wherein the building material has a sound absorption coefficient of about 0.2 to about 0.3 for a building material having a thickness of about 40 mm.
12 . The building material of claim 5 , wherein the PC has an average pore channel size of greater than about 1.0 nm.
13 . A building material, comprising:
a mixture, comprising:
about 25 wt % to about 65 wt % pyrolysis char;
about 10 wt % to about 40 wt % cement;
water; and
about 25 wt % to about 60 wt % sand, wherein a total weight percent of cement, sand, and pyrolysis char does not exceed 100 wt %.
14 . The building material of claim 13 , wherein the building material has a bulk density of less than about 2 g cm −1 .
15 . The building material of claim 13 , wherein the building material has a thermal conductivity of less than about 1 Wm −1 K −1 .
16 . The building material of claim 13 , wherein the building material has a compressive strength of greater than 6 MPa.
17 . The building material of claim 13 , wherein the building material has a moisture absorption of about 0.01 g H 2 O/g CB at a relative humidity of 75%.
18 . The building material of claim 13 , wherein the building material has a sound absorption coefficient of about 0.2 to about 0.3 for a building material having a thickness of about 40 mm.
19 . The building material of claim 13 , wherein the mixture is cured in a mold at a temperature of about 25° C. to about 45° C.
20 . The building material of claim 19 , wherein the mixture is cured in the mold at a humidity of greater than about 70%.