Development of coal-derived carbon-based structural unit as a potential new building material.

Coal combustion for energy has not only wasted the hydrogen-rich volatile matters but also results in CO₂ emission causing serious environmental issues. An integrated coal pyrolysis and solvent extraction process under elevated temperatures in an inert atmosphere is implemented to convert as-mined coal from Wyoming Powder River Basin to functional carbon elements such as pyrolysis char (PC). This paper presents the development and fabrication of new carbon-based structural unit (CSU) using pulverized PC and two coal-derived pitches (mesophase pitch and tar pitch) to attain high compressive strength greater than 30 MPa, low thermal conductivity less than 0.30 W/m K, and low density less than 1.25 g/cm³. CSUs have the potential to overcome the current challenges with cement and concrete through pressurized fabrication followed by carbonization. This study aims to develop CSU with nearly 100% coal-derived carbon material for structural application in buildings. The effects of pressing pressures, carbonization temperatures, and binder contents on the density and mechanical and thermal properties of CSU samples are investigated. The study concludes that mesophase pitch produces a better performance of CSU samples, a combination of 100 MPa pressing pressure and carbonization temperature of 900 °C yields the highest compressive strength, and a 25% MP content is recommended for low-cost CSU fabrication. CSU has a much lower density, lower thermal conductivity, higher compressive strength, and higher strength-to-density ratio than normal concrete. [ABSTRACT FROM AUTHOR]