Ferrock Basics David Stone, PhD

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

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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

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

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

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