Process of making carbon electrodes

Abstract

A process for preparing carbon electrodes is presented. In particular, a process for preparing carbon electrodes including the steps of combining calcined coke, a liquid pitch binder and carbon fibers derived from mesophase pitch to form an electrodestock blend; extruding the electrodestock blend to form a green electrodestock; baking the green stock to form a carbonized electrodestock; and graphitizing the carbonized stock by maintaining the carbonized tock at a temperature of at least about 2500.degree. C. for no more than about 18 hours is presented. The electrodes prepared by the inventive process are also presented.

What is claimed is:  
     
         1 . A process for preparing carbon electrodes, the process comprising 
 (a) combining calcined coke, a pitch binder and carbon fibers derived from mesophase pitch or PAN, said fibers having an average length of no more than about 3.25″, to form an electrodestock blend;    (b) extruding the electrodestock blend to form a green electrodestock;    (c) baking the green electrodestock to form a carbonized electrodestock; and    (d) graphitizing the carbonized electrodestock by maintaining the carbonized electrodestock at a temperature of at least about 2500.degree. C. for no more than about 18 hours, to form an electrode.    
     
     
         2 . The process of  claim 1  herein the carbon fibers are present at a level of about 0.5 to about 10 parts by weight of carbon fibers per 100 parts by weight of calcined coke.  
     
     
         3 . The process of  claim 2  wherein the carbon fibers have a tensile strength of at least about 150,000 psi.  
     
     
         4 . The process of  claim 3  wherein the carbon fibers have a Young's modulus of about 15.times.10.sup.6 psi.  
     
     
         5 . A process for preparing carbon electrodes, the process comprising 
 (a) combining calcined coke, a pitch binder and from about 0.5 to about 10 parts by weight carbon fibers, said fibers having an average length of no more than about 3.25″, derived from mesophase pitch or PAN per 100 parts by weight of calcined coke to form an electrodestock blend;    (b) extruding the electrodestock blend to form a green electrodestock;    (c) baking the green electrodestock to form a carbonized electrodestock; and    (d) graphitizing the carbonized electrodestock, to form the electrode.    
     
     
         6 . A process for preparing carbon electrodes, the process comprising 
 (a) combining a filler material, a pitch binder and carbon fibers derived from mesophase pitch, said fibers having an average length of no more than about 3.25″, to form an electrodestock blend; wherein said filler comprises at least one of calcinated coke, petroleum coke, coal derived coke, anthracite coal, and combinations thereof.    (b) extruding the electrodestock blend to form a green electrodestock;    (c) baking the green electrodestock to form a carbonized electrodestock; and    (d) graphitizing the carbonized electrodestock by maintaining the carbonized electrodestock at a temperature of at least about 2500.degree. C. for no more than about 18 hours, to form an electrode.    
     
     
         7 . A carbon electrode comprising calcined coke, a liquid pitch binder and carbon fibers derived from mesophase pitch, said fibers having an average length of no more about 3.25″.  
     
     
         8 . The carbon electrode according to  claim 7  wherein a concentration of said fiber comprises about 10.0% or less of a total mix of components.  
     
     
         9 . A cathode comprising a filler, wherein said filler comprises at least one of calcinated coke, petroleum coke, coal derived coke, anthracite coal, and combinations thereof, a pitch binder and carbon fibers derived from mesophase pitch, said fibers having an average length of no more than about 3.25″.  
     
     
         10 . A process for preparing a carbon cathode, the process comprising 
 (a) combining a filler material, a pitch binder and carbon fibers derived from mesophase pitch, said fibers having an average length of no more than about 3.25″, to form a cathodestock blend, wherein said filler comprises at least one of calcinated coke, petroleum coke, coal derived coke, anthracite coal, and combinations thereof.    (b) extruding the cathodestock blend to form a green cathodestock; and    (c) baking the green cathodestock to form a carbonized cathodestock.