Carbon alloy products and a process for their production

Abstract

A carbonaceous material, also referred to as a carbon alloy, and a process of making the carbonaceous material is provided. A particulate of partially pyrolyzed carbon (PPC) base is formed on heating a carbon-containing feed material and a nucleating agent in the form of a interactive filler is included. The nucleating agent is adhered together to the PPC particles by application of heat. The material is molded into a shape, voids in the material are collapsed and the resulting carbon alloy is cooled

1 - 30 . (canceled) 
     
     
         31 . A carbon alloy material made by a process comprising:
 selecting a carbon containing feed source based on the property requirements of the carbon alloy material to be produced;   controlling ash content of the feed source;   selectively controlling reactivity of the feed source;   adding a feed modifier to the feed source;   molding the feed source and added feed modifier to produce a shaped material;   curing the molded shaped material;   adhering and nucleating the carbon in the shaped material;   collapsing voids in the shaped carbon material; and   cooling of the shaped material to produce the molded carbon alloy.   
     
     
         32 - 33 . (canceled) 
     
     
         34 . The carbon alloy material made by the process of  claim 31 , wherein selecting the feed source comprises determining thermal behavior and pyrolysis kinetics of the feed source. 
     
     
         35 . (canceled) 
     
     
         36 . The carbon alloy material made by the process of  claim 31 , wherein controlling ash content comprises reducing and modifying ash content of the feed source. 
     
     
         37 . (canceled) 
     
     
         38 . The carbon alloy material made by the process of  claim 36 , wherein reducing and modifying ash content of the feed source results in an ash content no greater than about 8%. 
     
     
         39 . The carbon alloy material made by the process of  claim 38 , wherein the reducing and modifying ash content of the feed source within the range of about 1-4%. 
     
     
         40 . The carbon alloy material made by the process of  claim 31 , wherein selectively controlling reactivity of the feed source comprises altering reactivity using thermal conversion. 
     
     
         41 . (canceled) 
     
     
         42 . The carbon alloy material made by the process of  claim 40 , wherein the thermal conversion comprises a pyrolytic environment. 
     
     
         43 . The carbon alloy material made by the process of  claim 40 , wherein the thermal conversion occurs between about 150° C.-800° C., at a heating rate of about 1° C./min-1000° C./min. 
     
     
         44 . The carbon alloy material made by the process of  claim 31 , further comprising enhancing strength and fluidity of the feed source by adding materials to the feed sources. 
     
     
         45 - 50 . (canceled) 
     
     
         51 . The carbon alloy material made by the process of  claim 31 , wherein molding the feed source and added feed modifier to produce a shaped material comprises molding a shape having a length dimension of about 0.5-9 inches, a width dimension of about 0.5-9 inches and a height dimension of about 0.25-6 inches. 
     
     
         52 . The carbon alloy material made by the process of  claim 31 , wherein curing the molded shaped material comprises heating to a range of about 150-500° C. at a heating rate ranging from about 1° C.-100° C./ minute. 
     
     
         53 . The carbon alloy material made by the process of  claim 31 , wherein curing the molded shaped material comprises heating the material in an inert environment. 
     
     
         54 . The carbon alloy material made by the process of  claim 31 , wherein adhering and nucleating the carbon in said shaped material comprises heating the material to a range of about 300-700° C. at a heating rate ranging from about 1° C.-100° C./minute. 
     
     
         55 . The carbon alloy material made by the process of  claim 31 , wherein collapsing voids in the shaped carbon material comprises heating the shaped carbon material using forced convection. 
     
     
         56 . The carbon alloy material made by the process of  claim 55 , wherein the heating is to a temperature range of about 700-1300° C. at a heating rate ranging from about 1-30° C./minute. 
     
     
         57 . The carbon alloy material made by the process of  claim 55 , wherein collapsing voids is done in a controlled atmosphere of less than about 5% oxygen, less than about 10% CO 2 , and less than about 10% water near the gas-solid interface. 
     
     
         58 . The carbon alloy material made by the process of  claim 55 , wherein collapsing voids is done in a controlled atmosphere of less than about 5% oxygen, more than about 10% CO 2 , and more than about 10% water in the bulk gas phase. 
     
     
         59 . The carbon alloy material made by the process of  claim 31 , wherein cooling the shaped material to produce the carbon alloy comprises forced convection cooling in an inert atmosphere. 
     
     
         60 . (canceled) 
     
     
         61 . A carbonaceous material comprising:
 a particulate of partially pyrolyzed carbon (PPC) base formed on heating a carbon-containing feed material; and a nucleating agent in the form of a interactive filler in said PPC base, said nucleating agent adhered together to said PPC particles by application of heats.   
     
     
         62 .- 63 . (canceled) 
     
     
         64 . The carbonaceous material-of claim  63  wherein ash content is reduced by washing. 
     
     
         65 . The carbonaceous material of  claim 61  wherein said carbon-containing material has an ash content not exceeding 10% by weight. 
     
     
         66 .- 69 . (canceled) 
     
     
         70 . The carbonaceous material of claim  69  wherein the mold shapes have approximate dimensions like length: 1-9 inches, width: 1-9 inches and height: 0.25-6 inches. 
     
     
         71 . The carbonaceous material of  claim 61  wherein the carbonaceous material includes 5-50% by weight of said feed modifiers. 
     
     
         72 - 85 . (canceled) 
     
     
         86 . The process of claim  73  wherein the feed modifiers provide a framework for maintaining nucleation and adhesion of particles of the PPC during initiation, manufacturing and completion of the process. 
     
     
         87 . The process of step  86  takes place in the temperature range of 200-800° C. at a rate of 1-200° C./min. 
     
     
         88 . Wherein the process of step  86  takes place in a controlled atmosphere of oxygen less than 5%, CO 2  more than 10%, water more than 10% in the bulk gas phase. 
     
     
         89 . The process of claim  73  wherein said act of void collapse occurs in the range of 700-1300° C. 
     
     
         90 . The process of  claim 89  occurs at a rate of 0.5-60° C./min. 
     
     
         91 - 97 . (canceled) 
     
     
         98 . A process for the production of carbon alloys, comprising of. providing a refuse or virgin carbonaceous material; reduction of the inorganic from the carbonaceous substance; thermolysis or pyrolysis the refuse or virgin material to form specialty PPC; mixing adhesion and nucleating agent in the form of feed modifiers with the PPC to provide a framework for maintaining adhesion and nucleation of PPC particles during and completion of the process; molding the PPC and feed modifier mix to form a plurality of molds; subjecting the molds for curing stage in a convective process; fractionation of feed modifiers in the thermolytic or pyrolytic environment; pyrolysis of PPC molds; void collapse of the plurality of molds in a forced or natural convective process; controlled cool down of the plurality of molds to produce carbon alloys. 
     
     
         99 - 111 . (canceled)