Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/64—Burning or sintering processes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
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  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
  • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
  • C04B35/632—Organic additives
  • C04B35/636—Polysaccharides or derivatives thereof
  • C04B35/6365—Cellulose or derivatives thereof
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
  • C04B37/003—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts
  • C04B37/005—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts consisting of glass or ceramic material
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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  • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
  • C04B37/008—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
  • H05B3/00—Ohmic-resistance heating
  • H05B3/0004—Devices wherein the heating current flows through the material to be heated
• • H—ELECTRICITY
  • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
  • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
  • H05B7/00—Heating by electric discharge
  • H05B7/02—Details
  • H05B7/06—Electrodes
  • H05B7/08—Electrodes non-consumable
  • H05B7/085—Electrodes non-consumable mainly consisting of carbon
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
  • C04B2237/04—Ceramic interlayers
  • C04B2237/08—Non-oxidic interlayers
  • C04B2237/086—Carbon interlayers
• • C—CHEMISTRY; METALLURGY
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  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
  • C04B2237/32—Ceramic
  • C04B2237/36—Non-oxidic
  • C04B2237/363—Carbon
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
  • C04B2237/59—Aspects relating to the structure of the interlayer
  • C04B2237/592—Aspects relating to the structure of the interlayer whereby the interlayer is not continuous, e.g. not the whole surface of the smallest substrate is covered by the interlayer
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
  • C04B2237/62—Forming laminates or joined articles comprising holes, channels or other types of openings
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
  • C04B2237/70—Forming laminates or joined articles comprising layers of a specific, unusual thickness
  • C04B2237/704—Forming laminates or joined articles comprising layers of a specific, unusual thickness of one or more of the ceramic layers or articles
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
  • C04B2237/70—Forming laminates or joined articles comprising layers of a specific, unusual thickness
  • C04B2237/708—Forming laminates or joined articles comprising layers of a specific, unusual thickness of one or more of the interlayers
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
  • C04B2237/72—Forming laminates or joined articles comprising at least two interlayers directly next to each other
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
  • C04B2237/76—Forming laminates or joined articles comprising at least one member in the form other than a sheet or disc, e.g. two tubes or a tube and a sheet or disc
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
  • C04B2237/78—Side-way connecting, e.g. connecting two plates through their sides

Definitions

• This invention relates to the graphitization of carbon bodies bypassing electric current through the bodies, and in particular to a joint for use in controlling heat loss in the carbon bodies.
• LWG Lengthwise graphitization of carbon bodies to form graphite electrodes for use in electric arc scrap melting furnaces is described in U.S. Patent 5,631,919.
• carbon bodies are placed in end-to-end contact forming an electrically conductive column.
• the carbon bodies are supported by and covered with granular carbon for insulation; and electrical current is passed through the column of carbon bodies heating them to graphitization temperature, e.g., 2500°C -3500°C by the Joule effect.
• the material placed between the pieces typically is low electrical resistivity graphite particles, with or without a binder, or graphite felt.
• the material making up the piece-to-piece connection is sometimes referred to as a "joint".
• a graphite block is machined to shape to accommodate connections to the power source or rectiformer.
• This graphite piece or head electrode is placed at the end of the furnace.
• An example of the location of a type of head electrode can be seen in Figure 1 of U.S. Patent 1,029,121 at G and G 3 (referred to in the specification as terminals).
• the same drawing in the ' 121 patent also shows the joint material at F referred to in the specification, page 1, lines 53-54, as a "... packing F of graphite forming a good electrical connection between them.”
• the connection between the carbon bodies is further described on page 2, lines 1-28 wherein the "joint" nomenclature is used to describe the method of preparing the connection using granular material.
• the carbon bodies that are closest to the head electrodes are subject to higher heat losses by conduction through the ends than the carbon bodies in the internal locations of the furnace. These higher conductive losses are due to the use of graphite - which is a good conductor of heat - for the head electrodes that make the connection between the power source and the column of carbon bodies.
• Water cooling is used for the graphite head electrodes.
• the end of the head electrodes containing the water cooling tubes is connected to the rectiformer by means of copper bars. During the heating and cooling part of the furnace cycle, this end of the electrode must receive sufficient water flow to prevent the copper tubing and copper bars from overheating and even possible melting. Typically, this end of the head, electrodes can reach temperatures in the range of 100- 200°C.
• the electrical connection at the opposite end of the furnace is graphite and also imparts conductive heat losses; causing the end of the carbon body next to the graphite crossover to be significantly cooler than the internally located carbon bodies during firing and at off-fire.
• a further object of the invention is to provide a system which reduces heat loss at the ends of carbon bodies in a LWG furnace.
• a joint for heat treating carbon products comprising at least one layer of a low electrical resistivity material and at least one layer of a high electrical resistivity material.
• the layers of low and high resistivity materials are arranged in alternating relationship and are of a size sufficient to locate between carbon bodies or between a carbon body and an electrode such that an electric current may pass through the layers, the layers being of thickness sufficient to generate a desired amount of heat when the electric current passes through the layers.
• the present invention provides a system for heat treating carbon products comprising a pair of electrodes, a carbon body in electrical contact between the electrodes and a joint between at least one of the electrodes and the carbon body.
• the joint has at least one layer of a low electrical resistivity material and at least one layer of a high electrical resistivity material.
• the layers of low and high resistivity materials are in alternating relationship and of a thickness sufficient such that an electric current passing through the layers may generate a desired amount of heat which flows to the carbon body.
• the present invention provides a system for heat treating carbon products comprising a first carbon body, a second carbon body and a joint between the first and second carbon bodies.
• the joint has at least one layer of a low electrical resistivity material; and at least one layer of a high electrical resistivity material.
• the layers of low and high resistivity materials are in alternating relationship and of a thickness sufficient such that an electric current passing through the layers may generate a desired amount of heat which flows to the carbon bodies.
• the present invention provides a method for heat treating carbon products comprising providing a pair of electrodes, providing a carbon body in electrical contact between the electrodes, and inserting a joint between at least one of the electrodes and the carbon body.
• the joint has at least one layer of a low electrical resistivity material; and at least one layer of a high electrical resistivity material.
• the layers of low and high electrical resistivity materials are in alternating relationship and of a thickness sufficient such that an electric current passing through the layers may generate a desired amount of heat which flows to the carbon body.
• the method then includes passing an electric current through the electrode, joint and carbon body and generating a desired amount of heat in the joint with the electric current to heat a portion of the carbon body adjacent the joint to a desired temperature, preferably graphitizing temperature.
• the layer of low electrical resistivity material comprises graphite, more preferably, flexible graphite foil having a density less than about 0.5g/cc.
• the layer of high electrical resistivity material comprises a cellulose-based material or graphite foil having a density greater than about 0.5g/cc.
• the joint may be disc-shaped.
• the layer of high electrical resistivity material may have openings therein to increase passage of electric current through the at least one layer of low electrical resistivity material.
• the thickness of the layer of high electrical resistivity material may preferably range from about 0.1 to 1.0mm and the thickness of the layer of low electrical resistivity material may preferably range from about 1 to 50mm.
• the joint may include a plurality of layers of the high electrical resistivity material and a plurality of layers of the low electrical resistivity material, with the high and low electrical resistivity layers being in alternating disposition.
• Fig. 1 is an exploded elevational view of one example of the LWG furnace joint of the present invention.
• Fig. 2 is an elevational view of the assembled LWG furnace joint of Fig. 1.
• Fig. 3 is a top plan view of an example of the high electrical resistivity layer used in the LWG furnace joint of Fig. 2.
• Fig. 4 is a perspective view of a LWG furnace utilizing the preferred LWG furnace joint of the present invention.
• Fig. 5 is a graphical representation of the relationship of temperature versus time comparing the joint made in accordance with the present invention with the prior art joint.
• Fig. 6 is a graphical representation of the relationship of specific resistance versus time comparing the joint made in accordance with the present invention with the prior art joint.
• the portions of the carbon pieces located adjacent to the head electrodes and crossovers in a longitudinal or lengthwise graphitizing (LWG) furnace maybe subject to lower conductive heat losses than those of the prior art by using a novel joint at these locations.
• the construction of this invention utilizes alternating layers of flexible graphite and paper which can be varied to increase the Joule effect or I 2 R heating. The increased heat generated by this invention has been found to offset the higher conductive heat losses; resulting in more uniform temperature, both during the heating cycle and at off-fire.
• the subject invention preferably has alternating construction of layers of a material of relatively low electrical and thermal resistivity (or specific resistance), such as flexible graphite, and a material of relatively high electrical and thermal resistivity (or specific resistance), such as paper or other cellulose-based material, that can be used as a packing or joint at the critical head and crossover positions of an LWG furnace in place of the conventional graphite particles to overcome higher heat losses at these locations.
• a material of relatively low electrical and thermal resistivity such as flexible graphite
• a material of relatively high electrical and thermal resistivity or specific resistance
• the terms low resistance and high resistance are, of course, relative, and are used in their ordinary meaning in the art.
• An example of low electrical resistance useful in the present invention is an electrical resistivity of about 1 to 1,000 micro-ohm-meters
• an example of high electrical resistance useful in the present invention is an electrical resistivity higher than about 10,000 micro-ohm-meters.
• This construction helps to reduce the temperature non-uniformity of the carbon bodies during graphitization.
• Figs. 1, 2 and 3 An example of this invention is shown in Figs. 1, 2 and 3.
• Layers of low electrical and thermal resistivity GRAFOIL® flexible graphite 22 (available from UCAR Graph-Tech Inc. of Lakewood, Ohio) and high electrical and thermal resisitvity Kraft paper 24 were cut in a circular or disk shape to form a packing or joint 20.
• the joint layers may be made in other configurations to match the cross section of the electrode column to which the joint is to be mated.
• the multiple graphite and paper layers were alternated across the thickness (Fig. 1), adhesively bonded and compressed to form the final product (Fig. 2).
• the low resistivity graphite layers are exposed at the top 26 and bottom 28 surfaces of the joint 20. More preferably, as shown in Fig. 3, 6mm or other suitable diameter holes 30 are punched in each layer of paper 24 to provide some physical contact between the alternating low electrical resistivity layers 22 to enable current to flow more easily between these layers at furnace start-up.
• low electrical resistivity layer 22 Other exemplary materials which may be used for the low electrical resistivity layer 22 are flexible graphite, monolithic graphite and graphite foams.
• Exemplary materials which may be used for the high electrical resistivity layer 24 are high density graphite foils, carbon paper, cloth and cellulose-based materials such as cardboard. It has been found that in some instances low density GRAFOIL® flexible graphite (e.g., a density of less than about 0.5g/cc, preferably less than about 0.25g/cc) has lower electrical resistivity than higher density flexible graphite (e.g., a density of at least about 0.5g/cc, and preferably at least about 1.0 g/cc), as measured in a direction normal to the plane of the layer. As such, low density flexible graphite layers can be employed as low conductivity layers 22 while higher density flexible graphite layers can be employed as high conductivity layers 24 in Figs. 1-3.
• the layers of low electrical resistivity and high electrical resistivity materials can be varied in number, thickness and density to achieve the desired electrical resistivity (or conductivity) through the thickness of the joint, which in turn generates the desired heat by the Joule effect when current flows through the thickness. While each of the low and high resistivity layers are shown extending completely across the width of the joint (except for paper holes 30), such layers may extend only partially across the joint, depending on the desired resistance across the joint thickness.
• flexible graphite density in the density range of about 0.3 g/cc and thickness of about 2mm along with alternating layers of about 0.15 mm Kraft paper produce the desired electrical and thermal properties. More broadly, the flexible graphite low resistivity layer may be employed in a thickness range of about 1mm to about 50mm, and a paper-based high resistivity layer may be employed in a thickness range of about 0.1mm to about 1mm.
• Fig. 4 depicts the arrangement of carbon bodies and the joint of the present invention in a LWG furnace 40.
• a plurality of cylindrical carbon bodies 32 to be made into graphite electrodes, are connected at their ends to form two pairs of parallel extended lengths.
• Water-cooled, graphite head electrodes 34a, 34b provide electrical power connection to the carbon lengths at one end of the furnace.
• the two lengths of carbon bodies are electrically connected at the opposite end of the furnace by graphite crossover 36.
• Graphite spacers 38 are inserted at the ends of the individual carbon bodies 32 to accommodate any difference in accumulated length of the carbon bodies.
• a granular thermal insulation material (not shown) normally covers the carbon bodies during heating.
• joints 20 made in accordance with the present invention are disposed between head electrodes 34a, b and end portions 32a of the carbon bodies closest to the head electrodes.
• joints 20 are provided between crossover electrical connection 36 and the ends 32b of the carbon bodies adjacent to the crossover.
• the difference in specific resistance between the prior art graphite particle joint and the invention joint during firing of carbon bodies is shown in the graph in Fig. 6.
• the overall specific resistance of the material between the carbon bodies was measured using identical equipment and methods during- the same firing in a LWG furnace as in Fig. 5.
• the plot shows that the invention joint has a higher specific resistance during the initial stages of firing than the prior art joint made from graphite particles.
• the specific resistance of a carbon body electrode length during firing is also shown.
• the present invention achieves the objects described above to provide an improved joint for use in a LWG furnace.
• the system of the present invention reduces heat sink loss at the ends of carbon bodies in a LWG furnace.
• Employing the joint of the present invention results in more uniform graphitization can be achieved when graphitizing carbon bodies using the Joule effect, particularly when heat treating carbon bodies to form graphite electrodes.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Inorganic Chemistry (AREA)
• Physics & Mathematics (AREA)
• Plasma & Fusion (AREA)
• Carbon And Carbon Compounds (AREA)
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• Conductive Materials (AREA)

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• 2000
  • 2000-04-10 EP EP00920231A patent/EP1279319A1/en not_active Withdrawn
  • 2000-04-10 AU AU2000240809A patent/AU2000240809A1/en not_active Abandoned
  • 2000-04-10 WO PCT/US2000/009528 patent/WO2001078460A1/en not_active Application Discontinuation
  • 2000-04-10 BR BR0017204-9A patent/BR0017204A/pt not_active IP Right Cessation
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