Study of the Molecular-Weight Distribution of Binder Pitches for Carbon Blocks

[Image: see text] The present study aimed to identify the required characteristics of binder pitches in the filler-binder mixing process to effectively manufacture graphite blocks. To this end, a binder pitch was separated into pitch fractions of varying molecular-weight segments. The role and effectiveness of each pitch fraction were then analyzed with respect to their molecular-weight distribution. As a result, the optimal molecular-weight distribution was determined. More specifically, a coal-tar pitch was separated into solvent-soluble and solvent-insoluble fractions. The molecular-weight distribution was determined according to this classification, and the characteristics of each pitch fraction were examined. The pitch separation process was conducted using three solvents: hexane, toluene, and quinoline. The resulting pitch was separated into the following pitch fractions: hexane-soluble (HS), hexane-insoluble-toluene-soluble (HI-TS), toluene-insoluble-quinoline-soluble (TI-QS), and quinoline-insoluble (QI). Fourier transform infrared (FT-IR) spectrum, matrix-assisted laser desorption ionization-time of flight (MALDI-TOF), and softening point of each pitch fraction were measured. Also, pitch samples were refabricated while varying the mixing ratio of these pitch fractions, and carbon blocks were then prepared using them. The compressive strength and porosity of these blocks were measured and compared. The P154_B pitch with a high content of TI-QS was used to fabricate a green block. Due to the high viscosity of the binder used, the fluidity was not sufficiently high, and thus, the green block made of this pitch had relatively low strength. The other blocks had similar levels of strength. After the carbonization process, the carbon block with a high content of HS (P352_B-C) and the carbon block with the HS content removed (P073_B-C) showed lower compressive strength than their respective green-block counterparts (P352_B and P073_B). However, their strength was higher compared to those of the other carbon blocks. In the case of carbon block P073_B-C, the HS content was completely removed, and thus, the content of TI-QS (β-resin) was relatively high. Accordingly, this carbon block ended up with large amounts of components that had high coking values (CVs), and this contributed to limiting the formation of pores. Therefore, the compressive strength of this carbon block was high. In the case of the carbon block with a high content of HS (P352_B-C), a suitable level of viscosity was achieved because the HS components ensured high fluidity. As a result, blocks with higher density and compressive strength could be fabricated. The major findings of the present study confirm that producing carbon blocks with high mechanical properties requires binder pitches with a balanced combination of suitable viscosity to ensure sufficiently high fluidity and a proper level of CV to effectively suppress the formation of pores in the mixing and molding process.