Coke with Additives at Yield Points
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Solution Overview
Problem
The existing production methods for carbon products, such as cathode blocks, face challenges in achieving homogeneous mixing of coarse-grained coke and titanium diboride, leading to surface irregularities and reduced lifespan due to mechanical and chemical stresses, as the different particle sizes and densities result in inadequate wetting with aluminum.
Innovation Solution
A coke with additives is developed where the additives are accumulated at the yield points or in the regions surrounded by them, influencing properties like wettability and abrasion resistance, thereby extending the lifespan of carbon products. The additives include acetylene coke, fluid coke, and titanium diboride, which are strategically distributed to enhance mesophase formation and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coarse-grained coke and TiB2 are mixed to improve wettability, then wettability is improved, but homogeneous mixing is difficult due to different particle sizes and densities
Solution Approach 1:
The patent applies local quality by concentrating TiB2 additives specifically at the yield points (boundaries between optically non-anisotropic regions) rather than distributing them uniformly throughout the coke. This localized placement at critical interface regions achieves effective wettability improvement while avoiding the mixing difficulties associated with uniform distribution of particles with different sizes and densities.
2Duration of action of moving object
If TiB2 is added to improve wettability, then lifespan is extended, but technical outlay increases due to considerable mixing requirements
Solution Approach 1:
By targeting TiB2 accumulation specifically at yield points rather than requiring uniform distribution throughout the entire material, the patent reduces the complexity of mixing processes. The localized placement strategy achieves lifespan extension through improved wettability without necessitating complex mixing equipment or procedures.
3Stability of the object's composition
If additives are distributed uniformly, then homogeneous structure is achieved, but wettability is reduced due to formation of islands on surface
Solution Approach 1:
The patent reverses the conventional approach by creating a non-uniform distribution of additives. Instead of uniform distribution, TiB2 is concentrated at yield points (interfaces between anisotropic regions), which are the critical locations for wettability. This localized concentration at boundaries prevents the formation of surface islands while maintaining homogeneous structure in the bulk material.
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 strategic distribution of additives at yield points increases the lifespan of carbon products by improving wettability and abrasion resistance, reducing the need for costly mixing processes and enhancing thermal and electrical conductivity, while maintaining material solidity and isotropy.
Implementation Method 1
When transitioning from liquid to solid phase, a conversion takes place during pyrolysis from an unordered isotropic phase into an ordered, anisotropic phase.
Implementation Method 2
additives are accumulated at the yield points or in the regions surrounded by the yield points
Data Source
AI summary
Coke including additives that are accumulated at the yield points or in the regions surrounded by the yield points. For homogeneous distribution, the additives are continuously dosed into the delayed coker during the filling time. The dosing can be carried out by powdery blowing with an inert gas (nitrogen) or also distributed in a slurry consisting of the reaction components and a partial flow of the coker feed (vacuum resid, pytar, decant oil or coal-tar distillates). According to an advantageous form of embodiment, the additives may optionally have a diameter of between 0.05 mm and 5 mm, preferably between 1 mm and 3 mm. Advantageously, the additives can be selected from at least one of acetylene coke, fluid coke, flexi coke, shot coke, carbon black, non-graphitisable carbons (chars), non-graphitic anthracite, silicon carbide, titanium carbide, titanium diboride or mixtures thereof.