The Acheson process is used to produce synthetic graphite,
typically by heating carbon-containing materials at high
temperatures.
Raw Material Preparation:
Petroleum coke or other carbon-rich materials are mixed with a
binder like coal tar pitch. The mixture is shaped into desired
forms, such as blocks or rods.
Placement in Furnace:
The shaped carbon material is packed with a sand-like material
(silicon carbide) in an electric furnace to help control the
temperature during heating.
Heating (Graphitization):
An electric current is passed through the furnace, heating the
material to temperatures around 2500–3000°C. At these temperatures,
carbon atoms rearrange into graphite’s crystalline structure.
Cooling:
The material is slowly cooled down over a period to ensure proper
crystallization. Rapid cooling can cause cracking or defects in the
graphite structure.
Graphite Extraction:
Once cooled, the synthetic graphite is removed from the furnace,
with impurities being brushed or blasted off.
Final Processing:
The synthetic graphite may undergo further shaping, cutting, or
purification, depending on its intended application, such as
electrodes or battery-grade graphite.
Synthetic Graphite Production is ecologically more damaging. The
Energy intensive Acheson process produces notable amount of NOx,
SOx and particulate matter pollutants.
