COAL CORE COMPOSITES FOR LOW COST, LIGHT WEIGHT, FIRE RESISTANT PANELS AND ROOFING MATERIALS (Phase IIB)

Two main problems are targeted by the proposed work: 1 the underutilization of coal, a valuable natural resource, which has led to a catastrophic drop in employment within the coal industry ecosystem in specific geographic areas in the country; and 2 the need within the insurancedriven roof replacement market for a suitable, light weight, low cost, high durability roofing material. These problems will be addressed through the continued development and commercialization of a novel coalbased material developed by Semplastics to serve as lowcost, lightweight, fireresistant roofing tiles. Semplastics manufactures components using a patented process for producing polymerderived ceramics PDCs. PDCs have been used to create many useful end products, from automobile brakes to spacecraft heat shields. Leveraging this technology, Semplastics has developed a novel composite material based on coal. The new coalcore composite CCC material offers promise for the beneficial utilization of large amounts of coal without burning it as fuel. Semplastics will address the problems described above through the application of this technology to the creation of highly durable, lightweight, affordable roofing tiles. The proposed roofing tiles not only provide a highvolume outlet for coal, but also provide an American made option for ceramic tiles. In Phase I, Semplastics produced prototypes of the CCCbased roofing tile. This work included optimization of the blending process to ensure scalability with an eye toward eventual commercial production. In Phase II, Semplastics further refined material formulations to obtain the best cost vs. performance solution. Prototype tiles were subjected to inhouse and commercial laboratory testing in local facilities to characterize the material properties and to show compliance with roofing industry standards. The team produced fullsize tiles in multiple commercially representative configurations and began the work of scaling up roof tile production processes toward fullscale commercialization. Proposed Phase IIB work will support commercialization by adding customerrequested features such as color to the tiles, establishing pilot lines for three different types of roof tiles targeting different sections of the addressable market, and engaging channel partners using the initial output of the pilot lines to begin market penetration. The successful commercialization and market execution of these roofing tiles will produce an immediate impact in the coal industry ecosystem and will contribute to energy diversification across the United States, ultimately impacting the national economy by producing domestic manufacturing jobs. The CCCbased roofing tiles offer a viable, highvolume, highgrowth end market for coal and coal waste, which will yield positive technical, economic, and social benefits. In the long term, the Semplastics team expects that the CCCbased roofing tiles can contribute to the reduction of greenhouse gas emissions worldwide, as the roofing tiles would lock away carbon from coal and subsequently sequester CO2 from the atmosphere.