Carbon Foam Anode Manufacturing via Coal Digestion and Graphitization
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Solution Overview
Problem
High temperature fuel cells using coal as a reactant face inefficiencies due to the presence of inorganics and contaminants in coal, which lead to ash deposition and unstable electrolytes, hindering the conversion of coal into electricity effectively.
Innovation Solution
A system for making carbon foam anodes involves pre-digesting coal to remove impurities, molding it into a desired shape, and subjecting it to a stepped temperature program followed by graphitization, resulting in improved power density due to tight packing of carbon atoms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If coal is used as a reactant in high temperature fuel cells, then energy density is improved, but ash deposition and electrolyte instability occur due to inorganics and contaminants
Solution Approach 1:
The patent applies preliminary action by digesting the coal feedstock before it enters the fuel cell to remove inorganics and contaminants. This pre-treatment prevents ash deposition and electrolyte instability that would otherwise occur during fuel cell operation, allowing the system to maintain both high energy density and reliable stable operation.
2Quantity of substance
If coal contains inorganics and contaminants, then ash is produced and deposited in the fuel cell, but this requires routine cleaning effort
Solution Approach 1:
The digestion process is performed as a preliminary action before the coal enters the fuel cell. This pre-treatment removes inorganics and contaminants that would otherwise require routine cleaning of the fuel cell, thereby reducing maintenance effort while maintaining effective coal utilization.
3Power
If carbon atoms are tightly packed in the anode, then power density is improved, but manufacturing complexity increases due to stepped temperature program and graphitization
Solution Approach 1:
The patent applies parameter changes by implementing a stepped temperature program with graphitization to achieve tight packing of carbon atoms in the anode. This controlled thermal processing transforms the carbon structure to maximize power density, accepting the increased manufacturing process complexity as necessary to achieve the desired performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The carbon foam anodes produced exhibit enhanced power density and reduced ash deposition, leading to more efficient conversion of coal into electricity with improved fuel cell stability.
Implementation Method 1
coal is digested in accordance with the present invention and then placed into a mold having a desirable shape or form. Pressure is increased within the mold and then it is subjected to a stepped or ramped temperature program to a desirable temperature as disclosed herein. Once at a maximum temperature, the pressure within the mold is decreased quickly to produce an ungraphitized carbon foam anode.
Implementation Method 2
After this, it is placed into a graphitization oven where it is turned into a graphitized carbon foam anode. Once the carbon foam electrode has been graphitized, it can then be inserted into a carbon fuel cell. The present invention produces carbon foam anodes of improved or having improved power density due to the tight packing of the carbon atoms.
Data Source
AI summary
A system for making carbon foam anodes including a digestion vessel in communication with a coal feedstock unit for producing a digested coal; a mold having an interior for accepting the digested coal to produce an ungraphitized carbon foam anode having a desired shape; a pressure unit in communication with the mold for producing an increased pressure within the interior of said mold; a heating element in communication with the mold to provide heat to the mold sufficient to convert the digested coal into the ungraphitized carbon foam anode; and a graphitization oven for graphitizing the ungraphitized carbon foam anode to produce the carbon foam anode. The present invention further includes methods for making carbon foam anodes.