Patent ID: 6838024

Claim:
Process for producing carbon blocks, comprising the steps of: a) obtaining an initial carbon aggregate and adjusting grain size distribution of the initial carbon aggregate by separating the initial carbon aggregate into a first fraction having a first size distribution and made up of grains smaller than a predetermined size X and a second fraction having a second size distribution and made up of grains larger than or equal to said predetermined size X, where X is between 0.2 and 2 mm; b) crushing the first fraction and a diverted part of the second fraction to obtain a powder containing a controlled proportion of ultra-fine grains having a size smaller than 30 μm; c) mixing the part of the second fraction which was not diverted and said powder in predetermined proportions; d) hot mixing the mixed carbon aggregate with a predetermined quantity of pitch binder to form a homogeneous paste; e) forming the paste to form at least one crude carbon block, wherein said predetermined proportions result in formation of at least one crude carbon block having a grain size distribution such that a ratio between a proportion Gr of grains larger than 0.3 mm and a proportion S of grains between 30 μm and 0.3 mm in size, Gr/S, is at least equal to 4; and f) baking the at least one crude carbon block to produce said carbon block having a density greater than 1.55.