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Carbon Aggregates
Average pricing for conventional lightweight aggregates is approximately US$67.50 per
ton3
, which is by far the lowest pricing of products discussed here, but also represents
the greatest potential for very high volumes and high value.
Carbon aggregate would be a very unique product in this space. Much of the cost and
utilisation of lightweight aggregate depends on transport; manufacture of carbon
aggregate could be located strategically.
Long term, we envision manufacturing would be very similar to methods currently used
for conventional lightweight aggregate. If 5% of the aggregate supplying the markets
described below could be displaced by carbon foam aggregate, the annual coal demand would
be over 400 million tons.
Refractories
Design of refractories often include carbon to enhance properties for use in molten metal
processing, such as MgO brick in the steel industry. Carbon addition improves
performance by inhibiting slag and metal ingress, as well as improving thermal shock
resistance.4 5
Supply of engineered carbon foam aggregate can allow an engineer to
include a relatively clean form of carbon at a specific size range in the refractory design.
Proppant
The global proppant market is projected to be over US$10 billion in 2023. In 2018, 115 million
tons of proppants were supplied 6
, with sand being most often used. Proppant ideally has
a high strength-to-weight ratio. Its strength prevents it from being crushed, while its low
weight enables the proppant to more easily reach the outer limits of the fissure into
which it is pumped, increasing the yield from a given well. Carbon aggregate with 50%
porosity would have a density of only 0.8 g/cc, less than half that of the lightest
commercial proppant.
Concrete
About 10 billion tons of concrete is produced every year, more than one ton per person on the
planet; it is the second most used material next to water.7
Approximately 70% of the volume in concrete is composed of aggregate, putting its demand
at several billion tons per year (which matches global coal production of 7-8 billion tons).
The spectrum of concrete products is quite broad for construction applications and a wide
variety of designs exist.