Patent ID: 6719956
Filing Date: 2004-04-13
Classification: C01B,C04B,Y02E

Abstract:
A method of making a carbonaceous material for use as a coke substitute comprising:a) selecting a carbon based feed material and feed enhancers for enhancing nucleation having a combined fixed carbon content greater than 25 wt %; b) controlling ash content of the base feed material by measurement and adjustment to a desired ash content; c) heating said carbon based feed material at a temperature in a range of 250Â° C. to 800Â° C. to devolatilize constitutants and to form active nucleation sites for carbon; d) controlling the rate of heating in a range of 1Â° C./min to 1000Â° C./min to adjust reactivity of said active nucleation sites; e) adding a fluidity enhancer selected from the group comprising polymers, tar, pitch and molasses to produce a mixture of fluidity enhanced devolatilized carbon material; f) adding a strength enhancer selected from the group comprising silica and coke breeze to produce a mixture of strength enhanced devolatilized carbon material; g) blending said fluidity enhanced devolatilized carbon and said strength enhanced devolatilized carbon into a blended mixture of carbon material; h) placing said blended mixture of fluidity enhanced and strength enhanced devolatilized carbon material into a compaction mold and compacting at a temperature up to 300Â° C. and a pressure range of 5000 psi to 20,000 psi; i) curing the blended mixture of enhanced devolatilized carbon material at a temperature less than 300Â° C. to produce a carbonaceous material mixture having a molded shape; j) nucleating and adhering the carbon in the carbonaceous material mixture having the molded shape, by heating at a rate in the range of 1Â° C./min to 100Â° C./min up to a temperature in the range of 300Â° C. to 700Â° C.; k) collapsing voids in said carbonaceous material mixture having the molded shape by heating at a rate of about 5Â° C./min to 200Â° C./min to a temperature in the range of about 700Â° C. to 1700Â° C.; and l) cooling said molded and void collapsed carbonaceous material mixture in flue gases so that the maximum difference of temperature between any two locations within said molded shape of said carbonaceous material mixture is less than 500Â° C.