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The correlation between the CO2 reactivity and pore structure of carbon anodes was experimentally investigated. The pore structures of the anodes before and after CO2 oxidation were characterized using image analysis. The porosity, mean pore diameter, and the number of micro-cracks decreased with increasing anode forming pressure, while they increased with over-compaction. With prolonged CO2 oxidation time, the porosity, pore density, mean pore diameter, pore aspect ratio, and the number of micro-cracks increased due to the merging of small pores, increased pore connectivity, and generation of new pores. The activation energy decreased with increasing porosity of the anodes’ pitch phase due to easier CO2 penetration and reaction within the anodes. The results confirm that the fine pitch-coke phase of anodes is preferentially consumed, a cause of carbon dusting. Optimization of the pore structures to balance the pitch, coke, and butt phases may potentially further reduce carbon dusting.

Effects of coke calcination levels on pore structure of carbon anodes have been investigated. Bench anodes were prepared by 3 types of cokes with 4 calcination temperatures (800°C, 900°C, 1000°C and 1100°C). The cokes and anodes were characterized using hydrostatic method, air permeability determination, mercury porosimetry, image analysis and confocal microscopy (CSLM). The cokes with different calcination levels are almost the same in LC values (19–20 A) and real density (1.967–1.985 g/cm3), while the anode containing coke calcined at 900°C has the lowest open porosity and air permeability. Pore size distribution (represented by Anode H sample) can be roughly divided into two ranges: small and medium pores in diameter of 10–400 μm and large pores of 400–580 μm. For the anode containing coke calcined at 800°C, a number of long, narrow pores in the pore size range of 400–580 μm are presented among cokes particles. Formation of these elongated pores may be attributed to coke shrinkages during the anode baking process, which may develop cracking in the anode under cell operations. More small or medium rounded pores with pore size range of 10–400 μm emerge in the anodes with coke calcination temperatures of 900°C, 1000°C and 1100°C, which may be generated due to release of volatiles from the carbon anode during baking. For the anode containing coke calcined at 1100°C, it is found that many rounded pores often closely surround large coke particles, which have potential to form elongated, narrow pores.