Recycling and regenerating system and method for waste anode carbon blocks

Abstract

The invention relates to the technical field of carbon material recovery, and discloses a waste anode carbon block recovery and regeneration system and method.The system comprises a pretreatment module, a pyrolysis regeneration module, a refining forming module and a central control unit, by establishing a multi-stage impurity separation mechanism, targeted screening is executed step by step according to different metal impurity types, and the metal impurities are separated from one another; ferromagnetic metal and non-ferrous metal impurities are deeply separated; meanwhile, an inert atmosphere protection barrier is constructed in the pyrolysis stage, it is guaranteed that the active structure of carbon particles is not subjected to oxidative damage, the purity and pore integrity of a regenerated carbon matrix are essentially guaranteed, and the defect that in a traditional technology, due to impurity residues, the conductivity of the regenerated carbon block fluctuates greatly is overcome; the cracking risk caused by thermal expansion difference in the roasting stage is avoided, and it is guaranteed that regenerated anode carbon blocks with regular geometrical morphology and compact structure are continuously output.

Description

Technical Field

[0001] This invention relates to the field of carbon material recycling technology, specifically to a recycling and regeneration system and method for waste anode carbon blocks. Background Technology

[0002] Anode carbon blocks refer to carbon blocks produced using petroleum coke and pitch coke as aggregates and coal tar pitch as binders. They are used as anode materials in prebaked aluminum electrolysis cells. These carbon blocks have been roasted and have a stable geometric shape, so they are also called prebaked anode carbon blocks, or conventionally known as carbon anodes for aluminum electrolysis.

[0003] Currently, in the recycling and regeneration of waste anode carbon blocks, the processing technology has multiple limitations, resulting in insufficient stability of the quality of the regenerated carbon blocks. Traditional recycling methods use mechanical crushing followed by direct roasting for regeneration. During the crushing stage, ferromagnetic metals and non-ferrous metal impurities are not fully separated, causing metal residues to form abnormal conductivity points in the regenerated carbon blocks, reducing the uniformity of carbon block resistance. Conventional pyrolysis processes are carried out in open and weak protective atmospheres, and the pore structure of carbon particles is damaged by oxidation, resulting in a decrease in specific surface area, which affects the anode reaction activity in the aluminum electrolysis process.

[0004] Therefore, a recycling system and method for waste anode carbon blocks are proposed to solve the above problems. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a recycling system and method for waste anode carbon blocks, solving the problems mentioned in the background section.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a recycling system and method for waste anode carbon blocks, the method comprising the following steps: S1. The waste anode carbon blocks are physically crushed by crushing equipment to generate coarse crushed material with uneven particle size distribution. S2. Based on electromagnetic separation technology and vibrating screening equipment, the coarsely crushed material is subjected to metal impurity separation and particle size classification to generate ferromagnetic impurity data, non-ferrous metal impurity data and classified carbon particle data. S3. Perform pyrolysis activation pretreatment on the graded carbon particle data, heat to a set temperature range under inert gas protection and maintain the temperature constant to generate pyrolysis regenerated carbon intermediate. S4. The pyrolysis regenerated carbon intermediate is introduced into a refining reactor, and a binder and modifier are added for kneading to generate a plastic carbon paste. S5. The plastic carbon paste is molded and shaped using a high-pressure molding equipment to generate green carbon blocks; S6. Place the green carbon block in a calcination furnace and calcinate it in stages according to a preset heating curve to generate a recycled anode carbon block. S7. The resistivity, compressive strength and ash content of the regenerated anode carbon block are tested using quality testing equipment, and the quality certification data of the regenerated carbon block is generated and marked as qualified product.

[0007] Preferably, S1 includes: S11. A jaw crusher is used for primary crushing of the waste anode carbon blocks, and the crushing particle size is... satisfy:

[0008] in Apply pressure to the jaw plate. For the compressive strength of the carbon block, It is the material's brittleness coefficient, with a value ranging from 1.2 to 1.5; S12. The primary crushed material is further crushed using an impact crusher to produce particles of a certain size. Coarse crushed material ≤10mm.

[0009] Preferably, S2 includes: S21. The coarsely crushed material is conveyed to a strong magnetic separator to separate ferromagnetic impurities and generate ferromagnetic impurity data. S22. Use eddy current separation equipment to separate non-ferrous metals from the crushed material after iron removal, and generate non-ferrous metal impurity data. S23. Based on the multi-layer vibrating screen, the remaining carbon particles are classified into three grades: 2–4 mm, 4–8 mm, and 8–10 mm, and the graded carbon particle data is generated.

[0010] Preferably, S3 includes: S31. Heating the graded carbon particles to the target temperature under nitrogen protection. :

[0011] in: The reference temperature is 650℃; The activation coefficient is 85–95. The target specific surface area is ≥400 m² / g; The temperature holding time t must satisfy t≥30 minutes; S32. Steam is introduced to activate the reaction and generate pyrolysis regenerated carbon intermediate.

[0012] Preferably, S4 includes: S41. The ingredients are prepared according to the following mass ratio: 85–92% pyrolysis recycled carbon intermediate, 5–10% coal tar pitch binder, and 3–5% nano silicon carbide modifier. S42. Knead at 160–180℃ for 40–60 minutes to produce a homogeneous, malleable charcoal paste.

[0013] Preferably, in step S5, the high-pressure molding pressure is 80–120 MPa, the holding time is 60–90 seconds, and a green carbon block with a density ≥1.55 g / cm³ is generated.

[0014] Preferably, the segmented roasting in S6 includes: S61. Heat to 300℃ at a rate of 10–15℃ / h and hold for 8 hours; S62. Heat to 800℃ at a rate of 20–25℃ / h and hold for 12 hours; S63, heat to 1100℃ at a rate of 5–8℃ / h, and hold for 24 hours.

[0015] Preferably, S7 includes: S71. The resistivity of the regenerated anode carbon block is detected by the four-probe method, with a threshold value ≤ 55 μΩ·m; S72. Compressive strength is tested by a universal testing machine, with a threshold value ≥32MPa; S73. Ash content is tested based on GB / T 1429-2009 standard, with a threshold of ≤0.5%.

[0016] Preferred, including: Pre-processing module: includes jaw crusher, impact crusher, high-intensity magnetic separator, eddy current separator and vibrating screen. The jaw crusher applies adjustable pressure through a hydraulic drive system. The impact crusher is equipped with a particle size feedback sensor to adjust the crushing intensity in real time. The high-intensity magnetic separator and eddy current separator are connected in series to achieve the step-by-step removal of ferromagnetic metals and non-ferrous metals. The vibrating screen integrates multiple screens and is connected to an automatic unblocking device to ensure that carbon particles are graded and output according to the preset particle size. The pyrolysis regeneration module includes an inert gas protected pyrolysis furnace, a steam activation reactor, and a temperature controller. The inert gas protected pyrolysis furnace has a built-in nitrogen circulation unit to maintain an oxygen content of less than 0.1%. The steam activation reactor injects steam evenly through a multi-nozzle array. The temperature controller dynamically adjusts the temperature distribution inside the furnace based on a thermocouple array to achieve directional optimization of the pore structure of carbon particles. Refining and molding module: includes a kneader, a high-pressure molding machine, a programmable temperature-controlled calcining furnace and a quality inspection station. The kneader uses a twin-screw agitator to ensure homogeneous composite of the binder and the carbon matrix. The high-pressure molding machine is equipped with a cavity pressure monitoring system to prevent density stratification. The programmable temperature-controlled calcining furnace implements a gradient heating strategy through zoned heating elements. Central control unit: It communicates with the pretreatment module, pyrolysis regeneration module and refining and forming module, collects equipment operating parameters in real time and optimizes the process sequence based on algorithms to ensure that the system maintains stable output in continuous production mode.

[0017] Preferably, the quality inspection station integrates the following components and performs closed-loop quality control: Four-probe resistivity meter: detection accuracy ±0.5μΩ·m. It scans the surface of the carbon block through a multi-point contact probe array, generates a resistance distribution cloud map, and shares the data with the central control unit to calibrate the pyrolysis process. Microcomputer-controlled pressure testing machine: range 0–100kN, equipped with displacement sensor and strain gauge, simulates mechanical load under electrolytic cell working conditions, and dynamically records the compressive strength decay curve; High-temperature ash content analyzer: conforms to GB / T 1429-2009 standard, adopts muffle furnace ignition method combined with electronic balance weighing, automatically calculates ash content and triggers non-conforming product rejection mechanism; Data integration interface: The resistivity, compressive strength and ash content test results are integrated into a quality index. When the test value deviates from the threshold, a feedback signal is sent to the refining and forming module to adjust the mixing ratio and calcination parameters in real time, forming a closed-loop control of the quality of recycled char blocks throughout the entire process.

[0018] Compared with the prior art, the present invention provides a recycling system and method for waste anode carbon blocks, which has the following beneficial effects: 1. In this invention, when recycling and regenerating waste anode carbon blocks, a multi-stage impurity separation mechanism is established, and targeted screening is performed step by step for different types of metal impurities, so that ferromagnetic metals and non-ferrous metal impurities can be deeply separated; at the same time, an inert atmosphere protection barrier is constructed during the pyrolysis stage to ensure that the active structure of carbon particles is not damaged by oxidation, thereby ensuring the purity and pore integrity of the regenerated carbon matrix in essence, and overcoming the defect of large fluctuations in the conductivity of regenerated carbon blocks due to impurity residues in traditional processes.

[0019] 2. In this invention, during the pyrolysis regeneration and molding process of waste anode carbon blocks, a gradient composite strategy of binder phase and carbon matrix is ​​designed, and interface strengthening components are introduced simultaneously based on the kneading process to control the rheological behavior and dispersion homogeneity in the thermoplastic state in real time. This allows the stress distribution and density evolution inside the green carbon block to reach a dynamic balance, avoiding the risk of cracking caused by thermal expansion differences during the roasting stage, and ensuring the continuous output of regenerated anode carbon blocks with regular geometric shape and compact structure.

[0020] 3. In this invention, during the quality monitoring of recycled carbon blocks, a multi-dimensional performance verification system is integrated to correlate resistance characteristics, mechanical strength, and component purity indicators in stages, thereby achieving a hierarchical evaluation of the service capability of recycled carbon blocks. This allows different batches of recycled carbon blocks to be matched with differentiated quality certifications according to the operating conditions of the electrolytic cell, systematically reducing the probability of misjudgment caused by oversights in a single detection dimension, and optimizing the reliability of recycled anode carbon blocks in high-end aluminum smelting scenarios. Attached Figure Description

[0021] Figure 1 This is a flowchart of the method for recycling and regenerating waste anode carbon blocks according to the present invention; Figure 2 This is a schematic diagram of the recycling and regeneration system for waste anode carbon blocks according to the present invention. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Please see Figures 1-2 The recycling and regeneration system and method for the waste anode carbon blocks includes the following steps: S1. The waste anode carbon blocks are physically crushed by crushing equipment to generate coarse crushed material with uneven particle size distribution. S2. Based on electromagnetic separation technology and vibrating screening equipment, the coarsely crushed material is subjected to metal impurity separation and particle size classification to generate ferromagnetic impurity data, non-ferrous metal impurity data and classified carbon particle data. S3. Perform pyrolysis activation pretreatment on the graded carbon particle data, heat to a set temperature range under inert gas protection and maintain the temperature constant to generate pyrolysis regenerated carbon intermediate. S4. The pyrolysis regenerated carbon intermediate is introduced into a refining reactor, and a binder and modifier are added for kneading to generate a plastic carbon paste. S5. The plastic carbon paste is molded and shaped using a high-pressure molding equipment to generate green carbon blocks; S6. Place the green carbon block in a calcination furnace and calcinate it in stages according to a preset heating curve to generate a recycled anode carbon block. S7. The resistivity, compressive strength and ash content of the regenerated anode carbon block are tested using quality testing equipment to generate quality certification data for the regenerated carbon block and mark it as qualified.

[0024] S1 includes: S11. A jaw crusher is used for primary crushing of the waste anode carbon blocks, and the crushing particle size is... satisfy:

[0025] in Apply pressure to the jaw plate. For the compressive strength of the carbon block, It is the material's brittleness coefficient, with a value ranging from 1.2 to 1.5; S12. The primary crushed material is further crushed using an impact crusher to produce particles of a certain size. Coarse crushed material smaller than 10mm.

[0026] S2 includes: S21. The coarsely crushed material is conveyed to a strong magnetic separator to separate ferromagnetic impurities and generate ferromagnetic impurity data. S22. Use eddy current separation equipment to separate non-ferrous metals from the crushed material after iron removal, and generate non-ferrous metal impurity data. S23. Based on the multi-layer vibrating screen, the remaining carbon particles are classified into three grades: 2–4 mm, 4–8 mm, and 8–10 mm, and the graded carbon particle data is generated.

[0027] S3 includes: S31. Heating the graded carbon particles to the target temperature under nitrogen protection. :

[0028] in: The reference temperature is 650℃; The activation coefficient is 85–95. The target specific surface area is greater than 400 m² / g; The temperature holding time t satisfies the condition that t is greater than 30 minutes; S32. Steam is introduced to activate the reaction and generate pyrolysis regenerated carbon intermediate.

[0029] S4 includes: S41. The ingredients are prepared according to the following mass ratio: 92% pyrolysis recycled carbon intermediate, 10% coal tar pitch binder, and 5% nano silicon carbide modifier. S42. Knead at 180℃ for 60 minutes to produce a homogeneous, malleable charcoal paste.

[0030] The S5 medium-pressure molding pressure is 120MPa, the holding time is 90 seconds, and the resulting density is greater than 1.55g / L. Raw charcoal blocks.

[0031] Segmented roasting in S6 includes: S61. Heat to 300℃ at a rate of 15℃ / h and hold for 8 hours; S62. Heat to 800℃ at a rate of 25℃ / h and hold for 12 hours; S63, heat to 1100℃ at a rate of 8℃ / h, and hold for 24 hours.

[0032] S7 includes: S71. The resistivity of the regenerated anode carbon block is detected by the four-probe method, with a threshold value ≤ 55 μΩ·m; S72. Compressive strength is tested by a universal testing machine, with a threshold value ≥32MPa; S73. Ash content is tested based on GB / T 1429-2009 standard, with a threshold of ≤0.5%.

[0033] include: Pre-processing module: includes jaw crusher, impact crusher, high-intensity magnetic separator, eddy current separator and vibrating screen. The jaw crusher applies adjustable pressure through a hydraulic drive system. The impact crusher is equipped with a particle size feedback sensor to adjust the crushing intensity in real time. The high-intensity magnetic separator and eddy current separator are connected in series to achieve the step-by-step removal of ferromagnetic metals and non-ferrous metals. The vibrating screen integrates multiple screens and is connected to an automatic unblocking device to ensure that carbon particles are graded and output according to the preset particle size. The pyrolysis regeneration module includes an inert gas protected pyrolysis furnace, a steam activation reactor, and a temperature controller. The inert gas protected pyrolysis furnace has a built-in nitrogen circulation unit to maintain an oxygen content of less than 0.1%. The steam activation reactor injects steam evenly through a multi-nozzle array. The temperature controller dynamically adjusts the temperature distribution inside the furnace based on a thermocouple array to achieve directional optimization of the pore structure of carbon particles. Refining and molding module: includes a kneader, a high-pressure molding machine, a programmable temperature-controlled calcining furnace and a quality inspection station. The kneader uses a twin-screw agitator to ensure homogeneous composite of the binder and the carbon matrix. The high-pressure molding machine is equipped with a cavity pressure monitoring system to prevent density stratification. The programmable temperature-controlled calcining furnace implements a gradient heating strategy through zoned heating elements. Central control unit: It communicates with the pretreatment module, pyrolysis regeneration module and refining and forming module, collects equipment operating parameters in real time and optimizes the process sequence based on algorithms to ensure that the system maintains stable output in continuous production mode.

[0034] The quality inspection station integrates the following components and performs closed-loop quality control: Four-probe resistivity meter: detection accuracy ±0.5μΩ·m. It scans the surface of the carbon block through a multi-point contact probe array, generates a resistance distribution cloud map, and shares the data with the central control unit to calibrate the pyrolysis process. Microcomputer-controlled pressure testing machine: range 0–100kN, equipped with displacement sensor and strain gauge, simulates mechanical load under electrolytic cell working conditions, and dynamically records the compressive strength decay curve; High-temperature ash content analyzer: conforms to GB / T 1429-2009 standard, adopts muffle furnace ignition method combined with electronic balance weighing, automatically calculates ash content and triggers non-conforming product rejection mechanism; Data integration interface: The resistivity, compressive strength and ash content test results are integrated into a quality index. When the test value deviates from the threshold, a feedback signal is sent to the refining and forming module to adjust the mixing ratio and calcination parameters in real time, forming a closed-loop control of the quality of recycled char blocks throughout the entire process.

[0035] Example 1: Deep regeneration of waste anodes with complex components The decommissioned waste anode carbon blocks received by a large aluminum smelting base were severely aged due to long-term service, with cryolite veins formed by electrolyte infiltration and alloyed iron-aluminum metal nodules embedded in the carbon matrix. When the pretreatment module was activated, the jaw crusher automatically switched hydraulic pressure modes based on the degree of weathering on the carbon block surface, employing a progressive pressure-increasing crushing strategy for high-hardness areas, while simultaneously activating the vibration grinding function of the impact crusher to fully expose the metal nodules encased within the carbon body. A high-intensity magnetic separator scanned the crushed material flow with alternating pulsed magnetic fields, powerfully adsorbing ferromagnetic metal fragments embedded in the carbon gaps; subsequently, an eddy current separator induced non-ferrous metal eddy currents through a high-frequency alternating magnetic field, successfully separating aluminum-copper alloy particles.

[0036] The anti-stick coating on the vibrating screen, aided by a pneumatic tapping device, prevents particle caking caused by fluorine compounds, achieving precise gradation of carbon particles. During the pyrolysis regeneration stage, a nitrogen circulation unit continuously replaces the furnace atmosphere, preventing corrosive gases generated by the high-temperature decomposition of cryolite. The steam activation reactor employs a variable-diameter nozzle design, matching different steam jet velocities according to the carbon particle size to ensure uniform expansion of micron-sized pores. The activated regenerated carbon intermediate exhibits a homogeneous, silky luster, with sufficient adsorption capacity to handle gaseous byproducts generated during electrolysis. At the microscopic level, honeycomb-like pores penetrate the entire carbon matrix, providing ideal ion migration channels for subsequent electrolysis reactions. When this batch of regenerated carbon blocks was applied to a 300kA electrolytic cell, the amount of carbon slag produced decreased by approximately 40% compared to traditional regeneration processes, and the frequency of the anodic effect during electrolysis decreased.

[0037] Example 2: Nano-reinforced regeneration of high-ash waste anodes A recycling plant was processing waste anode carbon blocks, which resulted in an abnormally high ash content due to aluminum molten metal penetration. The carbon matrix surface was covered with a large amount of alumina and aluminum carbide composite hard shell. When the refining and molding module was activated, the twin-screw mixing unit of the kneader switched to reverse rotation mode. At the moment the nano-silicon carbide modifier was injected, a turbulent shear field was created, causing the nanoparticles to penetrate the ash hard shell and anchor to the carbon matrix surface. The coal tar binder, in a hot-melt state, encapsulated the ash particles, forming an isolation and passivation layer.

[0038] The high-pressure molding machine monitors the pressure distribution in the mold cavity in real time using stress sensors. When insufficient density is detected in the edge area, the hydraulic compensation system is automatically triggered to apply gradient pressure, eliminating density discontinuities caused by ash segregation. The programmable temperature-controlled calcining furnace implements a multi-stage synergistic temperature control strategy: the low-temperature section uses infrared radiation homogenization technology to avoid deformation of the green body caused by asphalt softening; the medium-temperature section introduces trace amounts of water vapor to catalyze the solid-phase reaction between nano-silicon carbide and the carbon matrix; and the high-temperature section compensates for heat loss at the edges through zoned temperature control of the furnace wall.

[0039] The calcined recycled carbon blocks exhibited excellent impact resistance in the drop hammer test, with a uniform metallic gray cross-section and no layered peeling. When this batch of products was used in the electrolytic cell, the anodizing consumption rate was basically the same as that of the virgin carbon blocks, and the cell voltage fluctuation range was narrowed to within the allowable threshold of the process. In particular, no local overheating occurred under high current density conditions.

[0040] Example 3: Full-process intelligent closed-loop regeneration system A multinational aluminum group has deployed this system to build a zero-waste reprocessing production line. The central control unit uses deep learning algorithms to predict fluctuations in the composition of waste anodes: when the infrared spectrometer detects excessive cryolite adhesion, it automatically extends the crushing dwell time of the pretreatment module; when X-ray diffraction reveals an abnormal proportion of amorphous carbon, it adjusts the heating curve of the pyrolysis furnace to add a low-temperature holding section.

[0041] The quality inspection station performs collaborative verification: a four-probe resistivity meter generates a three-dimensional conductive model of the carbon block through moving scanning, identifying micro-regions with electrolyte residue; a pressure testing machine simulates the thermal shock cycle of the electrolytic cell using variable frequency loading, recording the microcrack propagation behavior of the carbon block under alternating stress; and an ash analyzer traces the source of pollutants through analysis of the composition of the combustion flue gas. The test data is synchronized to a central database in real time. When the edge ash value of a batch is abnormal, the system automatically traces the calcination parameters at the corresponding location and activates the kneader to increase the concentration of nano-modifiers in that area.

[0042] When uneven density distribution of the green billet is detected, the high-pressure forming machine automatically generates a pressure compensation path diagram. In industrial verification in a 400kA electrolytic cell, the recycled carbon blocks exhibit revolutionary performance: the electrolysis cycle is extended to 1.5 times that of traditional anodes, the power consumption per ton of aluminum is reduced by nearly 1,000 kWh, and the consumption of fluoride salts during electrolysis is reduced by 30%. More importantly, the recycled carbon blocks maintain their complete structural morphology during cell shutdown and maintenance, without the bottom fracture defects commonly found in traditional recycled carbon blocks, verifying the closed-loop control system's ability to guarantee product performance throughout its entire lifecycle.

[0043] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0044] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for recycling and regenerating waste anode carbon blocks, characterized in that: The method includes the following steps: S1. The waste anode carbon blocks are physically crushed by crushing equipment to generate coarse crushed material with uneven particle size distribution. S2. Based on electromagnetic separation technology and vibrating screening equipment, the coarsely crushed material is subjected to metal impurity separation and particle size classification to generate ferromagnetic impurity data, non-ferrous metal impurity data and classified carbon particle data. S3. Perform pyrolysis activation pretreatment on the graded carbon particle data, heat to a set temperature range under inert gas protection and maintain the temperature constant to generate pyrolysis regenerated carbon intermediate. S4. The pyrolysis regenerated carbon intermediate is introduced into a refining reactor, and a binder and modifier are added for kneading to generate a plastic carbon paste. S5. The plastic carbon paste is molded and shaped using a high-pressure molding equipment to generate green carbon blocks; S6. Place the green carbon block in a calcination furnace and calcinate it in stages according to a preset heating curve to generate a recycled anode carbon block. S7. The resistivity, compressive strength and ash content of the regenerated anode carbon block are tested using quality testing equipment, and the quality certification data of the regenerated carbon block is generated and marked as qualified product.

2. The method for recycling and regenerating waste anode carbon blocks according to claim 1, characterized in that: S1 includes: S11. A jaw crusher is used for primary crushing of the waste anode carbon blocks, and the crushing particle size is... satisfy: in Apply pressure to the jaw plate. For the compressive strength of the carbon block, It is the material's brittleness coefficient, with a value ranging from 1.2 to 1.5; S12. The primary crushed material is further crushed using an impact crusher to produce particles of a certain size. Coarse crushed material ≤10mm.

3. The method for recycling and regenerating waste anode carbon blocks according to claim 1, characterized in that: S2 includes: S21. The coarsely crushed material is conveyed to a strong magnetic separator to separate ferromagnetic impurities and generate ferromagnetic impurity data. S22. Use eddy current separation equipment to separate non-ferrous metals from the crushed material after iron removal, and generate non-ferrous metal impurity data. S23. Based on the multi-layer vibrating screen, the remaining carbon particles are classified into three grades: 2–4 mm, 4–8 mm, and 8–10 mm, and the graded carbon particle data is generated.

4. The method for recycling and regenerating waste anode carbon blocks according to claim 1, characterized in that: S3 includes: S31. Heating the graded carbon particles to the target temperature under nitrogen protection. : in: The reference temperature is 650℃; The activation coefficient is 85–95. The target specific surface area is ≥400 m² / g; The temperature holding time t must satisfy t≥30 minutes; S32. Steam is introduced to activate the reaction and generate pyrolysis regenerated carbon intermediate.

5. The method for recycling and regenerating waste anode carbon blocks according to claim 1, characterized in that: S4 includes: S41. The ingredients are prepared according to the following mass ratio: 85–92% pyrolysis recycled carbon intermediate, 5–10% coal tar pitch binder, and 3–5% nano silicon carbide modifier. S42. Knead at 160–180℃ for 40–60 minutes to produce a homogeneous, malleable charcoal paste.

6. The recycling and regeneration system and method for waste anode carbon blocks according to claim 1, characterized in that: The high-pressure molding pressure in S5 is 80–120 MPa, the holding time is 60–90 seconds, and a green carbon block with a density ≥1.55 g / cm³ is generated.

7. The method for recycling and regenerating waste anode carbon blocks according to claim 1, characterized in that: The segmented roasting in S6 includes: S61. Heat to 300℃ at a rate of 10–15℃ / h and hold for 8 hours; S62. Heat to 800℃ at a rate of 20–25℃ / h and hold for 12 hours; S63, heat to 1100℃ at a rate of 5–8℃ / h, and hold for 24 hours.

8. The method for recycling and regenerating waste anode carbon blocks according to claim 1, characterized in that: S7 includes: S71. The resistivity of the regenerated anode carbon block is detected by the four-probe method, with a threshold value ≤ 55 μΩ·m; S72. Compressive strength is tested by a universal testing machine, with a threshold value ≥32MPa; S73. Ash content is tested based on GB / T 1429-2009 standard, with a threshold of ≤0.5%.

9. A recycling and regeneration system for waste anode carbon blocks, used to implement the recycling and regeneration method for waste anode carbon blocks as described in any one of claims 1-8, characterized in that: include: Pre-processing module: includes jaw crusher, impact crusher, high-intensity magnetic separator, eddy current separator and vibrating screen. The jaw crusher applies adjustable pressure through a hydraulic drive system. The impact crusher is equipped with a particle size feedback sensor to adjust the crushing intensity in real time. The high-intensity magnetic separator and eddy current separator are connected in series to achieve the step-by-step removal of ferromagnetic metals and non-ferrous metals. The vibrating screen integrates multiple screens and is connected to an automatic unblocking device to ensure that carbon particles are graded and output according to the preset particle size. The pyrolysis regeneration module includes an inert gas protected pyrolysis furnace, a steam activation reactor, and a temperature controller. The inert gas protected pyrolysis furnace has a built-in nitrogen circulation unit to maintain an oxygen content of less than 0.1%. The steam activation reactor injects steam evenly through a multi-nozzle array. The temperature controller dynamically adjusts the temperature distribution inside the furnace based on a thermocouple array to achieve directional optimization of the pore structure of carbon particles. Refining and molding module: includes a kneader, a high-pressure molding machine, a programmable temperature-controlled calcining furnace and a quality inspection station. The kneader uses a twin-screw agitator to ensure homogeneous composite of the binder and the carbon matrix. The high-pressure molding machine is equipped with a cavity pressure monitoring system to prevent density stratification. The programmable temperature-controlled calcining furnace implements a gradient heating strategy through zoned heating elements. Central control unit: It communicates with the pretreatment module, pyrolysis regeneration module and refining and forming module, collects equipment operating parameters in real time and optimizes the process sequence based on algorithms to ensure that the system maintains stable output in continuous production mode.

10. The waste anode carbon block recycling system according to claim 9, characterized in that: The quality inspection station integrates the following components and performs closed-loop quality control: Four-probe resistivity meter: detection accuracy ±0.5μΩ·m. It scans the surface of the carbon block through a multi-point contact probe array, generates a resistance distribution cloud map, and shares the data with the central control unit to calibrate the pyrolysis process. Microcomputer-controlled pressure testing machine: range 0–100kN, equipped with displacement sensor and strain gauge, simulates mechanical load under electrolytic cell working conditions, and dynamically records the compressive strength decay curve; High-temperature ash content analyzer: conforms to GB / T 1429-2009 standard, adopts muffle furnace ignition method combined with electronic balance weighing, automatically calculates ash content and triggers non-conforming product rejection mechanism; Data integration interface: The resistivity, compressive strength and ash content test results are integrated into a quality index. When the test value deviates from the threshold, a feedback signal is sent to the refining and forming module to adjust the mixing ratio and calcination parameters in real time, forming a closed-loop control of the quality of recycled char blocks throughout the entire process.

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