Solid Carbon Material Production via Polymerisation

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Solution Overview

Problem

Current methods for producing solid carbon materials face challenges such as the depletion of non-renewable coking coal, high CO2 and pollutant emissions, high sulphur content, and low quality of biomass-derived materials, which limit their application in industries like metallurgy and wastewater treatment.

Innovation Solution

A method involving the heat treatment of carbonaceous feedstock to form a carbon-containing material capable of polymerization, mixed with a polymerization agent and heated to induce polymerization, producing solid carbon materials with high density and low ash yield, suitable for various industrial uses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If coking coal is used to produce metallurgical coke, then high strength carbon materials are obtained, but non-renewable resources are depleted and high sulphur content and ash yield are produced

Engineering Contradiction:

Improvestrength of carbon materialVSAvoidsulphur content and ash yield

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The invention changes the chemical parameters of the feedstock by using low-caking coal or biomass instead of coking coal, and modifies the process parameters through controlled pyrolysis and carbonization at specific temperature ranges (400-1500°C) to produce carbon materials with comparable strength but lower sulphur content and ash yield

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention substitutes expensive, non-renewable coking coal with cheaper, more abundant alternatives such as low-caking coal or biomass, which can be readily available and renewable, thereby reducing resource depletion while maintaining product quality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Adaptability or versatility

If biomass is used to produce solid carbon materials, then renewable resources are utilized, but the quality is insufficient for industrial applications

Engineering Contradiction:

Improverenewability of feedstockVSAvoidquality of carbon material

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The invention creates composite carbon materials by combining biomass-derived carbon with other carbonaceous materials or additives during the carbonization process, enhancing the mechanical strength and structural properties while maintaining the renewable nature of the feedstock

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention optimizes process parameters including temperature (400-1500°C), heating rate, and residence time during pyrolysis and carbonization to transform biomass into high-quality carbon materials with improved strength and structural integrity suitable for industrial applications

Inventive Principle:

Principle #35Parameter changes

3Strength

If coking coal is used for carbon material production, then high strength carbon materials are obtained, but significant CO2 and pollutant emissions are generated

Engineering Contradiction:

Improvestrength of carbon materialVSAvoidCO2 and pollutant emissions

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention substitutes depleting coking coal reserves with abundant, renewable biomass or low-caking coal alternatives, reducing the environmental footprint and greenhouse gas emissions associated with carbon material production while maintaining product quality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention modifies the thermal processing parameters including conducting pyrolysis in controlled atmospheres and optimizing carbonization temperatures to minimize decarboxylation and CO2 emissions while still achieving the desired carbon material strength and properties

Inventive Principle:

Principle #35Parameter changes

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 method produces solid carbon materials with properties similar to metallurgical coke but with lower sulphur content and ash yield, offering a renewable and cost-effective alternative for industries requiring high-strength carbon materials.

Implementation Method 1

heating the material mixture to a temperature at which polymerisation of the material mixture occurs so as to produce the solid carbon material

Methodology Applied

Scientific EffectPolymerisation:

Implementation Method 2

providing a carbon-containing material formed through the heat treatment of carbonaceous feedstock

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS10329490B2Method of and system for producing solid carbon materials

Publication Date: 2019.06.25 RENERGI PTY LTD

AI summary

The present disclosure provides a method of producing a solid carbon material. The method comprises providing a carbon-containing material formed through the heat treatment of carbonaceous feedstock. The carbon-containing material is capable of undergoing polymerisation. The method further comprises mixing the carbon-containing material with a polymerisation agent to form a material mixture. In addition, the method comprises heating the material mixture to a temperature at which polymerisation of the material mixture occurs so as to produce the solid carbon material. The method also comprises adding a further material into the material mixture before polymerisation.