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Ferrock Basics David Stone, PhD
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Status of Ferrock • One patent, one application, one provisional
• Five scientific papers on characteristics • Basic testing on strength and other qualities • Prototype products and demonstration structures
(a) (b)
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Comparison with Portland Cement
• Higher compressive strength • Greater flexural strength • Better crack resistance • Resists high heat much better • Lower cost at large scale operations
(a) (b)
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Potential Product Applications
• Blocks, pavers, tiles, other small modular units • Walls, slabs, roofs, and columns • Structural panels, thin shells, and backer sheets • Pipe, culverts, vaults and other precast products
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Ferrock’s Green Qualities
• Recycles steel dust as its iron source • Recycles fly ash as its silica source • Captures CO2 during hardening • Releases hydrogen as by-product
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Methods of CO2 Capture
• Pre-cast products in a gas-filled autoclave • Pumping through embedded perforated pipes • Injecting under pressure into a wet mix • Mixing in saturated CO2 adsorbent
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CO2
SCHEMATICDIAGRAMOFTHEIRONCARBONATEPROCESSATANEXISTINGPLANT
CURINGCHAMBER
MIXER
SPENT STEEL ABRASIVES, MACHINE SHOP SHAVINGS, OR DIRECT REDUCED IRON
FLY ASH OR CRUSHED GLASS
LIMESTONE OR OTHER CaCO3 (RAW)
KAOLIN OR OTHER MICA CLAY
PROMOTERS, STABILIZERS, CATALYSTS FORM
WATER (EFFLUENT OR SEAWATER)
GREEN PRE-CAST PRODUCTS
DECREASING CO2 AND TEMPERATURE CURED PRODUCTS
OR: SIMPLE AGGREGATE FOR MULTIPLE USES
H2 CHXOy
FURNACE / BOILER / KILN