Patent ID: 7897132

Claim:
A process to produce a molded carbon alloy material at process temperatures at or below 1300° C. comprising: selecting a carbon containing feed source as a carbon base for the carbon alloy material to be produced; controlling ash content of the feed source by measurement and adjustment to a desired ash content; adjusting reactivity of the feed source by heating the feed source to a temperature in a range of between about 250° C. and 800° C. to increase the surface area and the internal void volume of the feed source and adjusting the reactivity by adding and blending a carbon containing feed modifier into a homogeneous mixture with the feed source; molding the feed source and the added and blended feed modifier under pressure, after adjusting reactivity of the feed source, and at a temperature below 1300° C. to produce a molded shaped material; curing the molded shaped material; adhering and nucleating the carbon in the shaped material; collapsing voids in the shaped material by heating to a temperature at or below 1300° C.; and cooling of the shaped material to produce the molded carbon alloy.