Mechanical performance of thermoplastic composites using bituminous coal as filler: Study of a potentially sustainable end‐use application for Appalachian coal

Phillips, L.N.; Kappagantula, Keerti; Trembly, Jason

doi:10.1002/pc.24696

Cited by 18 publications

(16 citation statements)

References 20 publications

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“…Other studies by Chaharmhali et al 37 and Ratanawilai and Kampanart 38 found decreasing WPC flexural strength with increasing filler content. A similar decrease in the flexural strength of a polypropylenebased WPC was also reported by Sengupta et al 39 The increase in CPC flexural strength and modulus with the addition of 60 wt % coal was higher than the values reported by Phillips et al Overall, the greater flexural strength of the CPCs in this study, in comparison with prior work, 17 is a result of the stronger HDPE material used in this study in conjunction with optimal composite process parameters, namely, lower compounding temperatures, higher extrusion pressures, and injection molding of coupon samples, resulting in improved dispersion of the filler.…”

Section: ■ Results and Discussionsupporting

confidence: 90%

“…38,40 At high filler content, reinforced polymer composites have been shown to demonstrate lower flexural strength owing to agglomerated filler particles, due to poor dispersion acting as stress concentration sites causing failure. 17,36,40,41 On the other hand, the improved dispersion of coal in the polymer matrix, due to the fabrication processes, described in this paper, allowed better stress transfer to the filler resulting in improved flexural performance of the 60 wt % coal samples compared to that of the 40 wt % coal samples. The increase in the flexural modulus for CPCs may be attributed to the higher stiffness of the coal filler (flexural modulus of 2.2 ± 0.8 GPa measured for bituminous coal) 42 and the restricted movement of the polymer chains due to the filler.…”

Section: ■ Results and Discussionmentioning

confidence: 92%

“…The possibility of using coal as a wood substitute, due to similar organic content, led to a previous research study in this group evaluating coal as a potential filler in thermoplastic materials for similar structural applications. 17 Three types of bituminous coal combined with high-density polyethylene (HDPE) were evaluated to show higher flexural strengths, flexural moduli, and elastic moduli in comparison to the HDPE. That coal plastic composite (CPC) study significantly differed from prior work in other groups 18−20 due to the minimal treatment of either the coal or polymer prior to coal integration into the polymer matrix, a key characteristic for turnkey scalable technologies.…”

Section: ■ Introductionmentioning

confidence: 99%

“…WPCs may use the waste from both wood and polymer industries for applications such as outdoor decking, fencing, and framing and contain up to 80% of the wood filler pending application. The possibility of using coal as a wood substitute, due to similar organic content, led to a previous research study in this group evaluating coal as a potential filler in thermoplastic materials for similar structural applications . Three types of bituminous coal combined with high-density polyethylene (HDPE) were evaluated to show higher flexural strengths, flexural moduli, and elastic moduli in comparison to the HDPE.…”

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Coal-Filler-Based Thermoplastic Composites as Construction Materials: A New Sustainable End-Use Application

Al-Majali¹,

Chirume²,

Marcum³

et al. 2019

ACS Sustainable Chem. Eng.

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This paper reports investigations into coal's viability as an alternative filler to wood flour in wood plastic composites (WPCs)a class of materials used in building applications in lieu of pressure-treated wood coal plastic composites (CPCs) were fabricated with 15−60 wt % coal combined with high-density polyethylene and their physical (mechanical, water absorption, and metal leaching) and chemical (oxidative degradation and flammability) properties were compared with commercial WPCs. In addition, mass and energy balances (10 ton/h basis) and life cycle analyses (60 wt % filler and 1 ton basis) were conducted on CPCs and WPCs to assess environmental impact during manufacturing. At 60 wt %, CPCs had higher flexural strength, slower oxidative degradation and burn rate, and lower water absorption in comparison to commercial WPCs, suggesting better performance and stability in building applications. Furthermore, CPC manufacturing showed 44% lower greenhouse gas emissions and 62% less energy usage in comparison with WPC. These results indicate that the direct utilization of coal as a filler in construction composite applications may yield lower-cost products with lower associated emissions and energy demand compared to that of existing WPC materials, potentially yielding a more sustainable end use for coal than current uses such as power production.

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Section: ■ Results and Discussionsupporting

confidence: 90%

Section: ■ Results and Discussionmentioning

confidence: 92%

Section: ■ Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Coal-Filler-Based Thermoplastic Composites as Construction Materials: A New Sustainable End-Use Application

Al-Majali¹,

Chirume²,

Marcum³

et al. 2019

ACS Sustainable Chem. Eng.

Self Cite

View full text Add to dashboard Cite

show abstract

“…Recently, several types of coal have been investigated to replace wood flour used in polymer composites. 14,15 A former study has shown that coal plastic composite (CPC) outperformed several commercially available WPC products in strength, oxidation, burn rate, ignition, and water absorption. 14 In addition, a preliminary life cycle analysis also indicated CPC manufacturing requires less energy and generates less greenhouse gas emissions than WPC manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Flammability and thermal stability of thermoplastic-based composites filled with natural carbon

Al-Majali

Trembly

2022

Journal of Fire Sciences

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This investigation characterized flammability and thermal stability for a novel sustainable composite engineered for use in building applications. Flammability and thermal stability of coal plastic composites composed of coal (40–60 wt.%) and high-density polyethylene were compared to commercial wood–plastic composites. Pyrolysis thermogravimetric analysis results indicated that coal plastic composites possessed a single-step decomposition and higher char residue, while wood–plastic composites had two-step decomposition, with the first peak occurring at much lower temperatures. Thermogravimetric analyses in air suggest coal plastic composites, compared to wood–plastic composites and neat high-density polyethylene, were more thermally stable. Flash ignition temperatures for coal plastic composites were higher than high-density polyethylene and wood–plastic composites, while self-ignition temperatures were in the same range as wood–plastic composites. Rate of burning data indicated coal plastic composites were slower burning than wood–plastic composites, with increasing coal content slowing burning rate by 19.9%–27.6%. Cone calorimeter testing showed 27% and 59% reduction in total heat release and total smoke release as coal content increased while coal plastic composite with 60 wt.% coal possessed lower overall flammability in comparison with predominant commercially available wood–plastic composite products. Coal improved composite overall thermal stability and flammability by acting as char former and foaming agent.

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Strong, lightweight, thermally stable, and hydrophobic sustainable structural composites produced from coal-based waste and polymer-derived SiOC ceramics

Eterigho-Ikelegbe

Ricohermoso

Harrar

et al. 2023

Clean Techn Environ Policy

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Recycling coal-based waste (CBW) into composites suitable as a building material might be a necessary response to combat its risk to the environment. Therefore, the objective of this study was to investigate the microstructure and performance of coal composites produced from CBW and polysiloxane polymer (SPR-212). Four types of CBW that differ in physicochemical properties were examined. Fourier transform infrared spectroscopy results indicated that the higher the intensity of the C=C bonds in the CBW, the higher the pyrolysis mass loss and shrinkage experienced by the composites during pyrolysis. The continuous operating temperature of the composites is up to 600 °C. However, at temperatures above 600 °C, composites containing carbon content greater than 36% manifested dramatic degradation. Pyrolysis mass loss in the range of 5.28 to 29.62% was obtained for all the composites. The density range of the composites is between 1.5 and 1.9 g per cubic centimetre. The water absorption of all the composites is within the range of 0 to 25% and is comparable to many building materials. Notably, the composites containing total carbon less than 10% registered a water contact angle greater than 90°, indicating the low wettability of their surface. Furthermore, composites that embodied the highest total carbon (63%) displayed the worst structural property. The findings of this study lay the foundation for further development of high-quality structural coal composites from CBW and the SPR-212 preceramic polymer through optimisation of the processing conditions. Graphical abstract

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Mechanical performance of thermoplastic composites using bituminous coal as filler: Study of a potentially sustainable end‐use application for Appalachian coal

Cited by 18 publications

References 20 publications

Coal-Filler-Based Thermoplastic Composites as Construction Materials: A New Sustainable End-Use Application

Coal-Filler-Based Thermoplastic Composites as Construction Materials: A New Sustainable End-Use Application

Flammability and thermal stability of thermoplastic-based composites filled with natural carbon

Strong, lightweight, thermally stable, and hydrophobic sustainable structural composites produced from coal-based waste and polymer-derived SiOC ceramics

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