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US 2022/0048770 A1Published application
Carbon foam from blended coals
AssigneeTouchstone Research Laboratory, Ltd.
InventorDwayne R. Morgan
Life of this patent
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Abstract
Disclosed are methods for producing carbon foam in which using the vitrinite reflectance values of coals are used to form a blended coal precursor having a targeted vitrinite reflectance value. The targeted vitrinite reflectance value can be used to create similar carbon foam products from one production batch to the next.
Claims10
A method for producing carbon foam, comprising the steps of:
- blending a first comminuted coal having a first vitrinite reflectance value with a second comminuted coal having a second vitrinite reflectance value that is different than the first vitrinite reflectance value to provide a blended coal precursor having an overall vitrinite reflectance value wherein at least one of the first comminuted coal and the second comminuted coal is a swelling coal;
- and
- heating the blended coal precursor in a mold under a non-oxidizing atmosphere and under a pressure ranging of at least about 50 psi to a final temperature ranging from about 300 C to about 700 C, and wherein the resulting carbon foam has an average overall density ranging from 0.1 g/cc to about 1.6 g/cc.
A method for producing carbon foam, comprising the steps of:
- selecting two or more different comminuted coals where at least one comminuted coal is a swelling coal and at least two of the selected comminuted coals have different vitrinite reflectance values;
- blending the selected coal particulates to form a blended coal precursor comprising from about 10 to about 90 weight percent swelling coal particulate such that the blended coal precursor has a predetermined overall vitrinite reflectance;
- heating the blended coal precursor in a mold and under a non-oxidizing atmosphere at a heat up rate of from about 1 to about 20° C./min to a temperature at least above an initial plastic temperature of the swelling coal;
- and
- soaking at a temperature of between about 300 and 700° C. from about 10 minutes up to about 12 hours to form a green foam.
2 more elements
Dependencies are inferred from the claim text.