US 11,685,690 B2
Vitreous carbon aggregate for lightweight concrete
Rudolph A. Olson, III, Triadelphia, WV (US)
Assigned to CFOAM LLC, Triadelphia, WV (US)
Appl. No. 17/920,986
Filed by CFOAM, LLC, Triadelphia, WV (US)
PCT Filed May 12, 2021, PCT No. PCT/US2021/031897
§ 371(c)(1), (2) Date Oct. 24, 2022,
PCT Pub. No. WO2021/231515, PCT Pub. Date Nov. 18, 2021.
Claims priority of provisional application 63/025,235, filed on May 15, 2020.
Prior Publication US 2023/0135210 A1, May 4, 2023
Int. Cl. C04B 20/00 (2006.01); C04B 20/02 (2006.01); C04B 20/04 (2006.01); C04B 40/04 (2006.01); C04B 20/10 (2006.01); E04C 5/07 (2006.01); B29C 44/34 (2006.01)
CPC C04B 20/0008 (2013.01) [B29C 44/3403 (2013.01); C04B 20/026 (2013.01); C04B 20/04 (2013.01); C04B 20/1029 (2013.01); C04B 20/1088 (2013.01); C04B 40/04 (2013.01); E04C 5/073 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method for producing a lightweight carbon aggregate, comprising:
pulverizing coal into a fine coal powder;
blending the fine coal powder and at least one additive to form a coal mixture;
pelletizing the coal mixture using a binder to make coal aggregate comprising fine aggregates and course aggregates;
foaming the coal aggregate to cause volatilization and entrapment of volatized gases in a melted liquid phase at atmospheric pressure by heating to a temperature between 250° C. and 500° C. under an inert gas; and
pyroprocessing the coal aggregate to a temperature between 750° C. and 1240° C. under an inert gas to form a vitreous lightweight aggregate having an apparent density of less than 85 pounds per cubic foot.