IC 7481 Methods of Producing Ultra-Clean Coal for Electrode Carbon in Germany

Several processes for the production of ultra-clean coal for electrode carbon were developed in Germany prior to and during World War II . These processes have been investigated since the end of the war by the British and U. S. Government missions . As the reports of the investigations are not readily available to the public , it is the purpose of this paper to present the information which has been obtained regarding the methods by which ultraclean coal was produced . Almost all the ultra-clean coal was used in the manufacture of electrodes for the production of aluminum and magnesium . Standard raw materials for making these electrodes are pitch coke and petroleum coke , which are nearly ashless . The inclusion of ash in the electrode carbon results in lowered efficiency and impure metal from the reduction process . Petroleum coke and pitch coke were in very short supply in Germany during the war , so that it was necessary to augment the supply with carbon produced from coal . In the emergency , methods were developed to clean coal which had never before been economically feasible . However , a demand for nearly ash-free coal might develop in the United States if a shortage of petroleum coke were to occur at the same time as a strong demand for light metals . Other uses of ultraclean coal are in direct hydrogenation of coal , in production of activated carbon, and for special fuels . Specifications for electrode carbon are rather severe owing to the necessity for producing pure metal . Maximum amounts of impurities allowable in American practice are as follows : Total ash , 1.0 percent ( in finished coke , 0.7 percent ) Silica , 0.08 percent Ca or Na, or their sum , 0.12 percent Sulfur , 2.0 percent Ba , Ni , Cr , Mn , Co , and V are objectionable in very small amounts . The most important process for ultra cleaning of coal in Germany was froth flotation . Froth flotation had been used widely there to process washery -water sludges and to recover coking coal from high - ash fines . Its use was indicated , therefore , when the demand for ultra low-ash coal arose . In two plants the coal cleaned by froth flotation was treated with acid or caustic to lower further the ash content . Another process used on an industrial scale was that of dissolving the coal substance in the middle oil from direct hydrogenation of coal under controlled pressure and temperature . The resulting paste was heated, filtered , and the oil distilled off . The residue was a low-ash organic material that could be carbonized for electrode carbon or could be hydrogenated directly . Several other processes had been developed to the laboratory or pilot - plant stage but had never been used on a commercial scale . These processes included cleaning by centrifugal action , cleaning by electrostatic action , and cleaning by forming a paste with oil in water . The coal-preparation plants at the Carl Alexander mine , Augusta Viktoria mine , and Kőenigin Elisabeth mine are described in Bureau of Mines Information Circular 7389 : " Coal Preparation Practice in Western Germany" , by Thomas . Fraser and M. G. Driessen . Most of the special equipment used at these plants is described in the above publication .