Methods and apparatus for production of electrochemical graphite

Abstract

A method of producing graphite can include beneficiating an amount of coal to form a coal char, grinding the coal char to produce a crushed char and placing the crushed char in a porous container. Then, the method includes immersing the porous container in a molten salt bath. The molten salt bath includes a graphite anode. The method further includes applying an electrical potential across the porous container and the graphite anode such that a graphite deposit forms on the graphite anode. The graphite anode is removed from the molten salt bath and the graphite deposit is separated from the graphite anode to produce graphite fragments.

1 . A method of producing graphite, comprising:
 beneficiating an amount of coal to form a coal char;   grinding the coal char to produce a crushed char;   placing the crushed char in a porous container;   immersing the porous container in a molten salt bath, wherein the molten salt bath includes a graphite anode;   applying an electrical potential across the porous container and the graphite anode such that a graphite deposit forms in the porous container;   removing the graphite anode from the molten salt bath; and   separating the graphite deposit from the porous container to produce graphite fragments.   
     
     
         2 . The method of  claim 1 , wherein beneficiating the amount of coal comprises heating the amount of coal in an inert atmosphere to between about 600° C. and about 1000° C. 
     
     
         3 . The method of  claim 2 , wherein beneficiating the amount of coal comprises heating the amount of coal in an indirectly heated rotary kiln. 
     
     
         4 . The method of  claim 1 , wherein the crushed char comprises a powder or a particle diameter of less than about 100 microns. 
     
     
         5 . The method of  claim 1 , wherein the porous container comprises a mesh comprising a metal having a high resistance to corrosion. 
     
     
         6 . The method of  claim 5 , wherein the porous container comprises at least one of chromium, nickel, aluminum, tin, or alloy. 
     
     
         7 . The method of  claim 1 , wherein the molten salt bath comprises a calcium chloride or a magnesium chloride salt. 
     
     
         8 . The method of  claim 1 , wherein the electrical potential comprises between about 2V to about 3V. 
     
     
         9 . The method of  claim 1 , wherein separating the graphite deposit from the porous container comprises a mechanical separation process. 
     
     
         10 . The method of  claim 9 , wherein the mechanical separation process comprises rinsing the porous container with deionized or distilled water. 
     
     
         11 . The method of  claim 1 , further comprising collecting the graphite deposit from the salt bath and drying the graphite fragments. 
     
     
         12 . The method of  claim 1 , further comprising capturing volatile components of the coal while beneficiating the amount of coal and applying an electrical potential across the porous container and the graphite anode in the molten salt bath. 
     
     
         13 . A method of producing graphite, comprising:
 preparing a molten salt bath;   adding a crushed coal char and a graphite rod to the molten salt bath;   applying an electrical potential between the coal char and the graphite rod; and electrolyzing the molten salt bath to thermally reduce the coal char to produce an electrochemical graphite deposit.   
     
     
         14 . The method of  claim 13 , wherein preparing the molten salt bath comprises heating a salt to 800° C. and electrolyzing the molten salt to form a reaction region. 
     
     
         15 . The method of  claim 13 , wherein electrolyzing the molten salt is continuously performed, and the graphite rod includes a series of graphite rods continuously supplied to reduce the coal char to continuously produce the electrochemical graphite deposit. 
     
     
         16 . The method of  claim 15 , wherein the electrical potential is applied by:
 coupling a conductive container including the coal char to a first wire conveyor and the graphite collector rod from a second wire conveyor, wherein the first wire conveyor and the second wire conveyor are suspended above the molten salt bath;   coupling an electrical tension roller to the first wire conveyor and the second wire conveyor such that the coal char and the graphite collector rod suspend in the molten salt bath;   applying a voltage to the electrical tension roller such that the coal char is cathodic and the graphite collector rod is anodic, wherein carbon in the coal char converts to graphite.   
     
     
         17 . The method of  claim 15 , further comprising:
 conveying the coal char and the graphite collector rod through at least a portion of the molten salt bath;   removing the graphite collector rod and the conductive container from the molten salt bath, wherein the conductive container includes a graphite deposit;   separating the graphite deposit from the conductive container; and   washing the graphite deposit with deionized or distilled water.   
     
     
         18 . The method of  claim 17 , further comprising processing the deionized or distilled water after washing the graphite deposit to capture and recycle salts. 
     
     
         19 . An electrolytic apparatus to produce graphite, comprising:
 a molten salt bath;   an electrical source including a first conveyor and a second conveyor disposed proximal to the molten salt bath, wherein the electrical source produces a voltage potential between the first conveyor and the second conveyor;   at least one coal char cathode contacting he first conveyor;   at least one graphite anode contacting the second conveyor;   an electrical tension roller contact bus configured to couple to the first conveyor and the second conveyor, wherein the electrical tension roller contact bus biases the at least one coal char cathode and at least one graphite anode to be suspended within the molten salt bath; and   an electrolytic cell formed when the voltage is applied to the at least one coal char cathode and the at least one graphite anode to thermally reduce the coal char to produce an electrochemical graphite deposit, wherein the at least one graphite anode includes graphite continuously supplied to reduce the at least one coal char cathode and form a graphite deposit from the coal char cathode.   
     
     
         20 . The electrolytic apparatus of  claim 19 , wherein the molten salt bath includes a calcium chloride or a magnesium chloride salt heated to about 800° C. 
     
     
         21 . The electrolytic apparatus of  claim 19 , wherein the electrical source includes a DC power supply including a voltage between about 2V and about 3V. 
     
     
         22 . The method of  claim 1 , wherein the crushed char comprises a particle diameter of between about 0.5 microns and about 50 microns. 
     
     
         23 . The method of  claim 1 , wherein the porous container comprises a permeable substrate and immersing the porous container comprises spreading the crushed char in a thin layer on the permeable substrate and utilizing a roll-to-roll apparatus including one or more rollers to immerse the porous container in the molten salt bath.