Carbon alloy products and a process for their production

A method of making a carbonaceous material for use as a coke substitute comprising:

• a) selecting a carbon based feed material and feed enhancers for enhancing nucleation having a combined fixed carbon content greater than 25 wt %;
• b) controlling ash content of the base feed material by measurement and adjustment to a desired ash content;
• c) heating said carbon based feed material at a temperature in a range of 250° C. to 800° C. to devolatilize constitutants and to form active nucleation sites for carbon;
• d) controlling the rate of heating in a range of 1° C./min to 1000° C./min to adjust reactivity of said active nucleation sites;
• e) adding a fluidity enhancer selected from the group comprising polymers, tar, pitch and molasses to produce a mixture of fluidity enhanced devolatilized carbon material;
• f) adding a strength enhancer selected from the group comprising silica and coke breeze to produce a mixture of strength enhanced devolatilized carbon material;
• g) blending said fluidity enhanced devolatilized carbon and said strength enhanced devolatilized carbon into a blended mixture of carbon material;
• h) placing said blended mixture of fluidity enhanced and strength enhanced devolatilized carbon material into a compaction mold and compacting at a temperature up to 300° C. and a pressure range of 5000 psi to 20,000 psi;
• i) curing the blended mixture of enhanced devolatilized carbon material at a temperature less than 300° C. to produce a carbonaceous material mixture having a molded shape;
• j) nucleating and adhering the carbon in the carbonaceous material mixture having the molded shape, by heating at a rate in the range of 1° C./min to 100° C./min up to a temperature in the range of 300° C. to 700° C.;
• k) collapsing voids in said carbonaceous material mixture having the molded shape by heating at a rate of about 5° C./min to 200° C./min to a temperature in the range of about 700° C. to 1700° C.;
• and
• l) cooling said molded and void collapsed carbonaceous material mixture in flue gases so that the maximum difference of temperature between any two locations within said molded shape of said carbonaceous material mixture is less than 500° C.