The manufacturing of graphite involves several key steps, starting from the preparation of raw materials to the final shaping and treatment of the graphite product. Here is a detailed breakdown of the process:
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Preparation of Raw Materials: The primary raw materials used in graphite manufacturing are coke and graphite, which are first milled into fine particles. These particles are then mixed with binder pitch in mixers to create a homogeneous mass.
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Shaping: The mixture is then shaped into the desired form using techniques such as isostatic pressing, extrusion, vibration molding, or die molding. This results in a "green" material, which is the preliminary form of the graphite product.
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Carbonization: The shaped "green" material is subjected to a carbonization process in an oxygen-free environment at about 1000°C. This process forms binder bridges between the solid particles, enhancing the structural integrity of the material.
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Graphitization: Following carbonization, the material undergoes graphitization, a process that transforms the amorphous carbon into a 3-D ordered graphite structure. This is achieved by heating the material to roughly 3000°C in an inert atmosphere. During this process, the carbon atoms rearrange themselves into layers of graphene, forming a perfect graphite crystal.
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Secondary Pulverizing and Isostatic Pressing: After the initial shaping and thermal treatments, the graphite material may undergo further milling to achieve the desired grain size. The fine grains are then subjected to isostatic pressing, where they are placed in molds and exposed to high pressure (over 150 MPa). This ensures uniform distribution and arrangement of the graphite particles, leading to consistent properties throughout the material.
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Machining and Shaping: The graphitized material is then machined into the final product shapes such as tubes, rods, or plates using techniques like extrusion, compression molding, or isostatic pressing. These processes allow for customization of dimensions and properties according to specific applications.
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Purification and Surface Treatment: For applications requiring high purity, such as in the semiconductor industry, the graphite is purified by chemical methods, often involving treatment with halogen gases at high temperatures. The surface of the graphite can also be treated to achieve specific finishes, depending on the intended use.
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Final Inspection and Shipment: After all the processing steps, the graphite product is inspected for quality and then prepared for shipment to the customer.
This comprehensive process ensures that the graphite produced meets the specific requirements of various high-tech applications, leveraging its unique properties such as high thermal resistance and mechanical strength at elevated temperatures.
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