Disclosed are a three-dimensional porous structure, a method of preparing the same, and applications thereof. The method includes coating a coating material including coal ash on a surface of a combustible organic particle to form a core-shell particle, wherein the core-shell particle includes a combustible organic particle core, and a coating shell covering at least a portion of the combustible organic particle surface; mixing a plurality of the core-shell particles with an organic or inorganic binder to form a three-dimensional structure in which the core-shell particles are bonded to each other; and performing thermal treatment of the three-dimensional structure, wherein in the thermal treatment of the three-dimensional structure, at least portion of the combustible organic particle in the core-shell particle is removed away, thereby forming a hollow inside the particle core, and forming a number of fine pores in the coating shell.

Disclosed are a three-dimensional porous structure, a method of preparing the same, and applications thereof. The method includes coating a coating material including coal ash on a surface of a combustible organic particle to form a core-shell particle, wherein the core-shell particle includes a combustible organic particle core, and a coating shell covering at least a portion of the combustible organic particle surface; mixing a plurality of the core-shell particles with an organic or inorganic binder to form a three-dimensional structure in which the core-shell particles are bonded to each other; and performing thermal treatment of the three-dimensional structure, wherein in the thermal treatment of the three-dimensional structure, at least portion of the combustible organic particle in the core-shell particle is removed away, thereby forming a hollow inside the particle core, and forming a number of fine pores in the coating shell.

The present application discloses a reinforced and toughened MGO substrate, a preparation method thereof and a composite board having the substrate. The reinforced and toughened MGO substrate includes a middle layer and fiber layers on upper and lower surfaces of the middle layer, wherein the fiber layers are glassfiber surface mats, and the middle layer is prepared from a forming agent, a lightweight filler, a modifier and water in parts by weight as follows: 34-45 parts of light burned magnesium oxide, 23-30 parts of magnesium sulfate heptahydrate, 8-10 parts of granulated lignocellulose, 4-6 parts of xylem fiber, 0.5-2 parts of the modifier, and 18-26 parts of water; the modifier being obtained by mixing citric acid, anhydrous sodium sulfate, dihydrogen phosphate and phosphoric acid in a mass ratio of 10:3:1:6.

Systems and method for curing cementitious products are provided herein. In an example, a pressurized water saturator is used to create a CO.sub.2/H.sub.2O stream. The pressurized water saturator includes a carbon dioxide injection line disposed below a water level in the pressurized water saturator, an exit line disposed above the water level in the pressurized water saturator, and a pressure controller configured to hold a positive pressure of carbon dioxide in the pressurized water saturator.

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.

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.

A composite ultra-high performance porcelain concrete includes cement in an amount between 500 and 680 kg/m.sup.3; and porcelain sand in an amount between 500 and 1200 kg/m.sup.3. The porcelain sand replaces a portion of cement which would normally be needed, thereby reducing environmental impact of the cement, and also creating a beneficial use for waste porcelain source material. The disclosure also relates to a method for producing thin-walled composites CA-UHPPC facade panels and elements for building envelopes.

A method for curing cementitious articles includes flowing dry steam and carbon dioxide (CO.sub.2) simultaneously into a curing chamber containing a cementitious article. A relative humidity within the curing chamber may be between about 50% and about 70% and a temperature within the curing chamber may be between about 50 C. and about 70 C. A dry steam and CO.sub.2 mixture with a CO.sub.2 concentration between 2.5 vol % and 40 vol % is provided in the curing chamber and the cementitious article is cured for a duration between about 4 hours and 16 hours. Cementitious products cured with the method may have a CO.sub.2 uptake of greater than 15 wt % and a mechanical strength at least 10% greater than a cementitious product cured only in dry steam or CO.sub.2.

A method for curing cementitious articles includes flowing dry steam and carbon dioxide (CO.sub.2) simultaneously into a curing chamber containing a cementitious article. A relative humidity within the curing chamber may be between about 50% and about 70% and a temperature within the curing chamber may be between about 50 C. and about 70 C. A dry steam and CO.sub.2 mixture with a CO.sub.2 concentration between 2.5 vol % and 40 vol % is provided in the curing chamber and the cementitious article is cured for a duration between about 4 hours and 16 hours. Cementitious products cured with the method may have a CO.sub.2 uptake of greater than 15 wt % and a mechanical strength at least 10% greater than a cementitious product cured only in dry steam or CO.sub.2.

Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO.sub.2 waste stream, thereby enabling manufacture of the low-carbon concrete product.