Length-Wise Graphitization Furnace for Uniform Coke Heating
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Solution Overview
Problem
Existing graphitization processes for negative electrode material preparation face issues of high energy consumption, non-uniform heating, short furnace life, and high operational costs, particularly in Acheson furnaces and other enclosed furnaces lacking cooling facilities and efficient heat distribution.
Innovation Solution
An apparatus and method utilizing a box-type graphitization device with threaded electrical contacts, graphite boxes, a refractory, and a cooling jacket for uniform heating and temperature regulation, enabling efficient length-wise graphitization with reduced energy use and extended furnace life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If Acheson furnace with graphite crucible is used for graphitization, then graphitization process can be performed, but furnace life is short due to oxidation and handling stress
Solution Approach 1:
The furnace is divided into multiple independent heating zones, each with its own heating elements and control system. This segmentation allows independent operation and maintenance of each zone, extending overall furnace life and improving reliability by isolating damage to specific sections rather than the entire system.
Solution Approach 2:
A refractory material layer is introduced as an intermediary between the heating elements and the graphite crucible. This refractory layer protects the graphite crucible from direct thermal stress and oxidation, thereby extending its service life and improving operational reliability.
2Temperature
If box-type graphite container is used to hold powder material with current passed through coke powder, then graphitization can be performed, but non-uniform heating occurs due to island formation
Solution Approach 1:
The heating system is segmented into multiple independent heating zones distributed throughout the furnace. Each zone has separately controllable heating elements that can be independently regulated to ensure uniform temperature distribution across the entire charge, eliminating island formation and improving product consistency.
Solution Approach 2:
Different regions of the furnace are equipped with heating elements having different power ratings and control characteristics tailored to local thermal requirements. This local optimization ensures that each zone achieves and maintains the desired temperature uniformity, preventing hot spots and cold zones that lead to non-uniform heating.
3Use of energy by moving object
If Acheson process is used for graphitization, then graphitization can be achieved, but energy consumption is high
Solution Approach 1:
The furnace employs continuous heating elements that maintain steady-state temperature throughout the graphitization process, eliminating the need for periodic heating cycles and idle periods. This continuous operation maximizes energy utilization efficiency and reduces operational costs by maintaining optimal processing conditions without interruption.
Solution Approach 2:
The heating system parameters such as voltage, current density, and temperature profiles are dynamically optimized for different stages of graphitization. By adjusting these parameters to match the specific requirements of each processing stage, energy consumption is minimized while maintaining high product quality, thereby improving overall energy efficiency and reducing operational costs.
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 solution achieves uniform heat treatment of powdered coke, reducing energy consumption and operational costs while extending the lifespan of the apparatus, ensuring high-quality product consistency.
Implementation Method 1
a cooling jacket coupled to outer surface of walls of the refractory (104), the cooling jacket pertaining to regulation of surface temperature of the apparatus (100)
Implementation Method 2
one or more heating elements (112) configured to perform uniform heating of the powdered coke
Data Source
AI summary
The present disclosure provides an apparatus and method for preparation of negative electrode material using length-wise graphitization of carbon. The apparatus includes one or more graphite boxes, configured to store powdered coke. The one or more graphite boxes are enabled to be accommodated inside a refractory, encapsulated by a cooling jacket configured to regulate surface temperature of the apparatus. The one or more graphite boxes have one or more openings for refilling of powdered coke and collection of prepared material, the one or more openings being covered by one or more first lids and one or more heat insulating second lids. The apparatus includes one or more graphite electrodes coupled to the one or more graphite boxes and the refractory. One or more heating elements detachably coupled to the one or more graphite electrodes are enabled to receive electric power and uniformly heat the powdered coke.