Evaluation of co-cokes from bituminous coal with vacuum resid or decant oil, and evaluation of anthracites, as precursors to graphite

Graphite is utilized as a neutron moderator and structural component in some nuclear reactor designs. During the reactor operaction the structure of graphite is damaged by collision with fast neutrons. Graphite's resistance to this damage determines its lifetime in the reactor. On neutron irradiation, isotropic or near-isotropic graphite experiences less structural damage than anisotropic graphite. The degree of anisotropy in a graphite artifact is dependent on the structure of its precursor coke. Currently, there exist concerns over a short supply of traditional precursor coke, primarily due to a steadily increasing price of petroleum.;The main goal of this study was to study the anisotropic and isotropic properties of graphitized co-cokes and anthracites as a way of investigating the possibility of synthesizing isotropic or near-isotropic graphite from co-cokes and anthracites. Demonstrating the ability to form isotropic or near-isotropic graphite would mean that co-cokes and anthracites have a potential use as filler material in the synthesis of nuclear graphite. The approach used to control the co-coke structure was to vary the reaction conditions. Co-cokes were produced by coking 4:1 blends of vacuum resid/coal and decant oil/coal at temperatures of 465 and 500 °C for reaction times of 12 and 18 hours under autogenous pressure. Co-cokes obtained were calcined at 1420 °C and graphitized at 3000 °C for 24 hours. Optical microscopy, X-ray diffraction, temperature-programmed oxidation and Raman spectroscopy were used to characterize the products. It was found that higher reaction temperature (500 °C) or shorter reaction time (12 hours) leads to an increase in co-coke structural disorder and an increase in the amount of mosaic carbon at the expense of textural components that are necessary for the formation of anisotropic structure, namely, domains and flow domains. Characterization of graphitized co-cokes showed that the quality, as expressed by the degree of graphitization and crystallite dimensions, of the final product is dependent on the nature of the precursor co-coke.;The methodology for studying anthracites was to select two anthracites on basis of rank, PSOC1515 being semi-anthracite and DECS21 anthracite. The selected anthracites were graphitized, in both native and demineralized states, under the same conditions as co-cokes. Products obtained from DECS21 showed higher degrees of graphitization and larger crystallite dimensions than products obtained from PSOC1515. Demineralization of anthracites served to increase the degree of graphitization, indicating that the minerals contained in these anthracites have no graphitization-enhancing ability. A larger crystallite length for products obtained from native versions, compared to demineralized versions, was attributed to a formation and decomposition of a silicon carbide during graphitization of native versions.;In order to examine the anisotropic and isotropic properties, nuclear-grade graphite samples obtained from Oak Ridge National Laboratory (ORNL) and commercial graphite purchased from Fluka were characterized under similar conditions as graphitized co-cokes and anthracites. These samples served as representatives of "two extremes", with ORNL samples being the isotropic end and commercial graphite being the anisotropic end. Through evaluating relationships between structural parameters, it was observed that graphitized co-cokes are situated, structurally, somewhere between the "two extremes", whereas graphitized anthracites are closer to the anisotropic end. Basically, co-cokes have a better potential than anthracites to transform to isotropic or near-isotropic graphite upon graphitization. By co-coking vacuum resid/coal instead of decant oil/coal or using 500 °C instead of 465 °C, a shift away from commercial graphite towards ORNL samples was attained. Graphitizing a semi-anthracite or demineralizing anthracites before graphitization also caused a shift towards ORNL samples.