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Graphite Electrodes

Graphite electrodes are mainly used in electric arc furnace. They are presently the only products available that have the high levels of electrical conductivity and the capability of sustaining the extremely high levels of heat generated in EAF. Graphite electrodes are also used to refine steel in ladle furnaces and in other smelting processes. Graphite electrodes are divided into 4 Types: RP Graphite electrodes, HP Graphite electrodes, SHP Graphite electrodes, UHP Graphite electrodes.

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NY TWO GLOBAL has strong presence at refractory & abrasive industry since ten years ago. By combining sources and optimized expert team, we are widening our business into Alloy, Big Bag and retail industries.We have two 100% owned BFA plants and one big bag plant. By investing some other refractory plants, we enhance our position of production and quality control for a better price.Refractory & Abrasive Raw Material: Brown Fused Alumina, White Fused Alumina, White Tabular Alumina, Black Silicon Carbide, Fused Mullite, Bauxite,Fused Magnesia ,Dead Burned Magnesia, Calcined Alumina etc. Alloy: High-Medium-Low Carbon Ferro Manganese, High Carbon Ferro Chrome, Low Carbon Ferro Chrome, Silico Manganese, Ferro Silicon, Silicon Metal, manganese Metal, Cored Wires,Incoulants,etc.

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NY TWO GLOBAL has strong presence at refractory & abrasive industry since ten years ago. By combining sources and optimized expert team, we are widening our business into Alloy, Big Bag and retail industries.

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All our plants meet ISO 9001:2015, ISO 14001:2015 & OHSAS 18001:2007.

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By strong presence in China, India, Turkey, Europe and U.S., we have tight connections with main player in each Industries.

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What is Graphite Electrodes

Benefits of Graphite Electrodes

Processing speed is faster: Under normal circumstances, graphite machining speed can be 2 to 5 times faster than copper; and discharge processing speed is 2 to 3 times faster than copper.

The material is more difficult to deform: Obvious advantages in the thin-walled electrode processing.

lighter weight: The density of graphite is only 1/5 of copper, large electrode for electrical discharge machining, can effectively reduce the machine tool (EDM) burden; more suitable for large mold applications.

Types of Graphite Electrodes

UHP Graphite Electrode
It is made of high-grade needle coke and treated with Lengthwise Graphitization (LWG). The graphitization temperature can be up to 2800 °C -3000 °C. Finished products have lower electrical resistance & linear expansion, good thermal shock resistance and allow a larger current density.

HP Graphite Electrode
It adopts quality petroleum coke or low grade needle coke as raw material. Its physical and mechanical properties are higher than RP graphite electrode such as lower electrical resistance and allowing a greater current density.

RP Graphite Electrode
Ordinary grade petroleum coke is adopted for production. This type of graphite electrode is treated with low graphitization temperature. The allowable current density is lower than HP graphite electrode's. Regular power graphite electrodes are specified with allowable current density less than 17 A/cm2.

Application of Graphite Electrodes

For electric arc steelmaking furnace

Electric furnace steelmaking is a big user of graphite electrodes. The output of electric furnace steel in my country accounts for about 18% of the output of crude steel, and graphite electrodes for steelmaking account for 70% to 80% of the total consumption of graphite electrodes. Electric furnace steelmaking uses graphite electrodes to introduce current into the furnace, and uses the high temperature heat source generated by the arc between the electric part and the charge for smelting.

Used for submerged electric furnace

The submerged electric furnace is mainly used for the production of industrial silicon and yellow phosphorus. Its characteristic is that the lower part of the conductive electrode is buried in the charge to form an arc in the charge layer, and the heat energy from the resistance of the charge itself is used to heat the charge, which requires current High-density submerged electric furnaces need graphite electrodes. For example, about 100 kg of graphite electrodes are consumed for every 1 ton of silicon produced, and about 40 kg of graphite electrodes are consumed for every production of 1 ton of yellow phosphorus.

For resistance furnace

Graphitization furnaces for producing graphite products, melting furnaces for melting glass, and electric furnaces for producing silicon carbide are all resistance furnaces. The materials in the furnace are both heating resistors and objects to be heated. Generally, conductive graphite electrodes are embedded at the end of the resistance furnace. In the furnace head wall of the part, the graphite electrode used here is discontinuously consumed.

Used to prepare special-shaped graphite products

The blanks of graphite electrodes are also used for processing into various crucibles, molds, boats and heating elements and other special-shaped graphite products. For example, in the quartz glass industry, 10t of graphite electrode blanks are required to produce 1t of fused tubes; 100kg of graphite electrode blanks are required to produce 1t of quartz bricks.

Raw Materials For Producing Graphite Electrodes

Petroleum coke

Petroleum coke is a combustible solid product obtained from coking of petroleum residue and petroleum asphalt. Black porous, the main element is carbon, ash content is very low, generally less than 0.5%. Petroleum coke is a kind of graphitized carbon. Petroleum coke is widely used in chemical and metallurgical industries. It is the main raw material for producing artificial graphite products and carbon products for electrolytic aluminium.

Needle coke

Needle coke is a kind of high-quality coke with obvious fibrous texture, especially low thermal expansion coefficient and easy graphitization. When the coke block breaks down, it can be divided into slender strips (the aspect ratio is generally more than 1.75). Anisotropic fibrous structure can be observed under polarizing microscope, so it is called needle coke.The anisotropy of the physical and mechanical properties of needle coke is very obvious. It has good conductivity and thermal conductivity parallel to the long axis of the particle. The thermal expansion coefficient is low. During extrusion, the long axis of most particles is arranged in the direction of extrusion.

Coal tar pitch

Coal tar pitch is one of the main products of coal tar deep processing. It is a mixture of various hydrocarbons. It is a black semi-solid or solid with high viscosity at room temperature. It has no fixed melting point. It softens after heating and then melts. Its density is 1.25-1.35g/cm3. According to its softening point, it can be divided into three types: low temperature, medium temperature and high temperature asphalt. The yield of medium temperature asphalt is 54-56% of coal tar. Coal tar pitch is used as binder and impregnating agent in carbon industry. Its performance has great influence on the production process and product quality of carbon products. Binder asphalt is generally modified at medium temperature or medium temperature with moderate softening point, high coking value and high beta resin.

How to Choose Graphite Electrodes

Average particle diameter of graphite electrode

The average particle diameter of the material directly affects the discharge condition of the material. The smaller the average particle, the more uniform the discharge, the more stable the discharge condition and the better the surface quality. For forging and die-casting molds with low surface and precision requirements, it is usually recommended to use materials with coarser particles, such as ISEM-3. For electronic molds with high surface and precision requirements, materials with average particle size below 4 m are recommended to ensure the precision and surface finish of the molds to be processed. The smaller the average particle is, the smaller the loss will be and the greater the force between the ion groups will be.

Flexural strength

Flexural strength is a direct reflection of the strength of the material, indicating the tightness of the internal structure. The material with high strength has better discharge resistance. For the electrode with high precision, the material with better strength should be selected as far as possible.

Shore hardness

In the subconscious understanding of graphite, graphite is generally considered as a relatively soft material. However, the actual test data and application show that the hardness of graphite is higher than that of metal materials. In the special graphite industry, the general hardness test standard is the Shaw hardness test method, the test principle is different from the metal test principle. Due to the layered structure of graphite, it has a very superior cutting performance in the cutting process. The cutting force is only about 1/3 of the copper material, and the machined surface is easy to be treated.

Inherent resistivity

According to characteristic statistics, if the average particles are the same, the discharge rate with high resistivity will be slower than that with low resistivity. For materials with the same average particle size, the strength and hardness of materials with low resistivity will be correspondingly slightly lower than those with high resistivity. That is, the discharge speed, loss will be different. Therefore, it is very important to select materials according to the needs of practical application. Due to the particularity of powder metallurgy, each parameter of each batch of material has its representative value and has a certain range of fluctuation.

Process of Graphite Electrodes

Raw materials
Petroleum coke is the most important raw material, and it is formed in a wide range of structures, from highly anisotropic needle coke to nearly isotropic fluid coke. The highly anisotropic needle coke, due to its structure, is indispensable for the manufacture of high-performance electrodes used in electric arc furnaces, where a very high degree of electrical, mechanical and thermal load-bearing capacity is required. Petroleum coke is almost exclusively produced by the delayed coking process, which is a mild slow carbonising procedure of crude oil distillation residues.

Mixing and extrusion
The milled coke is mixed with coal tar pitch and some additives to form a uniform paste. This is brought into the extrusion cylinder. In a first step the air has to be removed by prepressing. Than the actual extrusion step follows where the mixture is extruded to form an electrode of the desired diameter and length. To enable the mixing and especially the extrusion process (see picture on the right) the mixture has to be viscous. This is achieved by keeping it at elevated temperature of approx. 120°C (depending on the pitch) during the whole green production process. This basic form with cylindrical shape is known as "green electrode".

Baking
Here the extruded rods are placed in cylindrical stainless steel canisters (saggers). To avoid the deformation of the electrodes during the heating process, the saggers are also filled with a protecting covering of sand. The saggers are loaded on railcar platforms (car bottoms) and rolled into natural gas - fired kilns.Here the electrodes are placed in a stone covert cavity in the bottom of the production hall. This cavity is part of a ring system of more than 10 chambers. The chambers are connected together with a hot air circulation system to save energy.

Impregnation
The baked electrodes are impregnated with a special pitch (liquid pitch at 200°C) to give them the higher density, mechanical strength, and electrical conductivity they will need to withstand the severe operating conditions inside the furnaces.

Re-baking
A second baking cycle, or "rebake," is required to carbonize the pitch impregnation and to drive off any remaining volatiles. Rebake temperature reach almost 750°C. In this phase the electrodes can reach density around 1,67 – 1,74 kg/dm3.

Graphitization
The final step in graphite manufacture is a conversion of baked carbon to graphite, called graphitizing. During the graphitizing process, the more or less pre-ordered carbon (turbostratic carbon) is converted into a three-dimensionally ordered graphite structure.

Machining
The graphite electrodes (after cooling) are machined to exact dimensions and tolerances. This stage may also include machining and fitting the ends (sockets) of the electrodes with a threaded graphite pin (nipple) joining system.

How to Maintain Graphite Electrodes

01/

Material Selection: The Foundation of Oxidation Resistance
Choosing high-quality graphite materials with excellent oxidation resistance is paramount. Look for keywords such as "high purity," "low impurity content," and "fine grain structure" when selecting graphite electrodes. These attributes ensure enhanced resistance to oxidation and prolonged electrode life.

02/

Surface Coatings: Shielding Against Oxidation
Applying protective coatings on graphite electrodes creates a physical barrier, preventing direct contact with oxygen and other reactive substances. Consider utilizing advanced coatings such as silicon carbide, resin-bonded graphite, or anti-oxidation coatings. These coatings act as a shield, reducing oxidation and promoting a longer electrode lifespan.

03/

Proper Handling and Storage: Preserving Integrity
Proper handling and storage practices are crucial in preventing premature oxidation. Ensure that graphite electrodes are stored in a controlled environment with controlled humidity levels. Avoid exposure to moisture, extreme temperatures, and corrosive substances. Implement strict protocols for transportation, avoiding any potential damage or contamination that could accelerate oxidation.

04/

Optimized Operating Parameters: Mitigating Oxidation Risks
Fine-tuning your operational parameters can significantly reduce oxidation risks. Maintain stable operating conditions such as electrode current density, power input, and process parameters. Avoid unnecessary power fluctuations, overloading, or sudden changes in voltage, which can generate excessive heat and accelerate electrode oxidation.

05/

Regular Maintenance and Inspection: Proactive Care
Implementing a proactive maintenance and inspection regime is essential for identifying early signs of oxidation and taking necessary preventive measures. Regularly monitor electrode performance, including surface condition, dimensions, and electrical resistance. Schedule periodic cleaning and reconditioning to remove surface impurities and extend electrode lifespan.

06/

Collaboration with Experts: Accessing Specialized Knowledge
Engage with experienced suppliers and industry experts who possess extensive knowledge of graphite electrodes. Seek their guidance on material selection, coating options, maintenance techniques, and best practices for preventing oxidation. Their expertise can help optimize your operations and minimize oxidation-related challenges.

Precautions for the use of Graphite Electrodes

Keep dry

Graphite materials need to maintain a good degree of dryness during use. Therefore, when using this type of electrode, you must first check whether the surface is dry. If there is moisture, it cannot be used, but a special dehumidification process is required to make the graphite It can be used again after it is dry.

How to clean up

General graphite electrode products don't seem to pay too much attention to cleaning, while graphite electrodes are different. It must be cleaned to avoid water and oil. Generally, compressed air is used for cleaning in the use environment, so that it can achieve Very good cleaning effect without polluting the electrode.

Hanging and placing

In the use of graphite electrodes, it is often necessary to hoist and assemble it, and when hoisting, pay attention to lifting the middle part of the electrode, and then turn its head down, and place it with a soft cushion. In this way, the entire electrode can be protected from vibration and damage, and the next installation can be carried out.

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FAQ

Q: Why Are Graphite Rods Used as Electrodes in Electrolysis?

A: Graphite rods are used as electrodes in electrolysis because graphite's structure enables it to be an excellent conductor. The high number of delocalized electrons allows electricity to pass through graphite rapidly. Graphite is also straight-forward to shape into a rod shape, cost-effective and a hard-wearing material.

Q: Are Graphite Electrodes Suitable for Electrolysis?

A: Yes! Graphite's excellent conductive properties, coupled with its high melting point (enabling it to be used appropriately in a wide range of different electrolysis reactions), low price and toughness means it's a good choice for an electrolysis electrode.

Q: What Happens to a Solution During Electrolysis When Graphite Electrodes Are Used?

A: Graphite enables positively charged ions (metals and hydrogen) to obtain electrons from the negatively charged electrode. Conversely, negatively charged ions lose electrons (oxidation).

Q: Why Are Graphite Electrodes Used In Electrolysis?

A: The main reason that graphite electrodes are used in electrolysis is that graphite is an excellent conductor. The structure of graphite is such that it has a large number of electrons floating freely between the different layers of atoms (graphite bonds are formed of only three out of the four electron shells of the carbon atom, leaving the fourth electron to move freely). These electrons act as a powerful conductor, enabling the electrolysis process to progress smoothly. In addition, graphite is economical, stable at high temperatures and hard-wearing. For all these reasons, graphite electrodes are frequently used in electrolysis.

Q: What should be paid attention to in the storage of graphite electrodes in steel works?

A: Electrodes and joints should be stored on clean cement floor to avoid electrode damage or sticking to soil; temporarily unused electrodes should not be removed from the packaging to prevent dust and debris from falling on the joint threads or on the electrical extreme surface and the thread in the electrode hole. The electrodes should be placed neatly in the warehouse. The two ends of the stack should be padded well to prevent slip stacking. The stacking height of the electrodes should not exceed two meters. Stored electrodes should be rain-proof and moisture-proof so as to avoid cracking and accelerating oxidation of electrodes during steelmaking. Keep electrode joint away from high temperature to prevent thrombolysis overflow.

Q: What are the main factors affecting the consumption of graphite electrodes in EAF steelmaking?

A: There are mainly:

The quantity and mode of charging.

Feeding time and power-off time.

Smelting cycle.

Exhaust gas discharge and dust removal system.

The quality of electrode adjustment.

Load regulation quality.

Oxygen blowing operation.

The quality of electrode connection.

Mass of electrode joint.

Machining accuracy of electrode joint hole and joint.

Q: How to avoid electrode breaking and tripping in steelmaking process?

A: In steelmaking process, the following measures can effectively avoid electrode breakage and release:

Correct electrode phase sequence, counterclockwise direction.

The scrap is evenly distributed in the furnace, and the large scrap is placed at the bottom of the furnace as far as possible.

Avoid the existence of non-conductive materials in scrap steel.

The electrode pillar is aligned with the furnace top hole, and the electrode pillar is parallel. The furnace top hole wall should be cleaned regularly to avoid the accumulation of residual steel slag and forcing the electrode off.

Keep the tilting system in good condition and keep the tilting stable.

The electrode gripper should avoid clamping at the electrode joint and the hole of the electrode joint. (7) Choose joints with high strength, high processing accuracy and high quality.

Q: What should we pay attention to when using graphite electrodes in steel works?

A: Whether using forklift truck or crane to transport electrodes, careful operation is required. In the process of electrodes hoisting, the damage of electrode ends and threads will cause serious problems for the use of electrodes, especially to protect the threads of threaded holes and joints. When lifting the electrode, it is necessary to have a cushion so as not to damage the end face of the electrode and the thread of the joint.

Q: How to connect the electrodes correctly?

A: When connecting, use compressed air to blow out the hole, the end face of the electrode and the joint, no dust and foreign matter can be embedded. The joint should be kept clean and flat. When the two electrodes are rotated to a certain extent (the gap is about 10 mm), the compressed air is used to blow once again, and then the electrodes are tightened and tightened with moment clamps. The moment should be appropriate. If there is a gap in the connection after tightening, the connection must be withdrawn and reconnected until there is no gap.

Q: On the Correct Holding Position of Electrode Holder

A: The electrode holder can not be clamped at the connection of the electrode and the thread hole of the electrode. It should be clamped between the white wires at both ends of the electrode. At the same time, before clamping the electrode, the electrode surface and the holder should be blown clean by compressed air so as to ensure good conduction of current and heat current between the electrode and the holder and prevent arcing. The gripper is damaged, thus prolonging the service life of the gripper.

Q: What measures can be taken to reduce the consumption of electrode oxidation in EAF steelmaking?

A: The main measures are:

Reducing the oxidation consumption around the electrode, strengthening the sealing of the furnace and reducing the air intrusion into the furnace; minimizing the exposure time of red-hot electrodes outside the furnace and standardizing the oxygen blowing operation.

For smelting furnaces, if conditions permit, spray cooling technology can effectively reduce the side oxidation consumption of electrodes.

Spraying antioxidants on the surface of electrodes in steel plants or using antioxidant impregnation technology before the electrodes leave the factory can improve the antioxidant performance of the electrodes.

Q: How does the phase sequence of electrodes affect the use of electrodes?

A: The discount and breakage of the positive and negative electrodes of the electrode phase sequence during the use of EAF steelmaking have a great influence. If the electrode phase sequence is clockwise, the electrodes will be loosened after a period of electrification, which will easily lead to the loosening of the electrodes or the fracture of the joints. The correct electrode phase sequence should be counterclockwise. In this way, the electrodes will be loosened after a period of electrification. Joints will become more and more tight in use.

Q: Why do phase electrodes need to be in parallel and aligned with the top hole of the furnace cover in EAF steelmaking?

A: In dealing with the electrode pillar and the top hole of the furnace cover, the friction between the electrode pillar and the furnace cover should be avoided. Otherwise, the friction between the electrode pillar and the furnace cover will cause the furnace cover to extrude the electrodes when it is lifted or lowered. For the AC furnace, the three-phase electrode pillar should be kept as parallel as possible.

Q: How to apply the moment when the electrode is switched?

A: Torque applied during electrode rotation should be appropriate, and operation should be continuous. Torque too small will cause joint thermal loosening. Torque too large will cause hole bracing of electrode joint. Special tool for electrode rotation should be used during rotation. Do not tighten or loosen too tightly. If the end contact is found to be cleared after tightening, it must be removed and cleaned before re-spinning.

Q: Why is a graphite hanger better than a metal hanger?

A: Although the metal hanger is durable and not easy to be damaged, the thermal expansion of the metal hanger is easy to crack the electrode hole after being heated in use. At the same time, the thread in the electrode hole is easy to be damaged when the metal hanger is connected, resulting in a large area scraping of the thread in the hole, which makes the electrode easy to trip off. Graphite hanger has the same thermal expansion as the electrode. The performance and hardness of the graphite hanger will not cause the above-mentioned bad use, but the graphite hanger has a short service life and is easy to be damaged. If serious damage is found, it should be replaced in time.

Q: How to select the correct electrode in EAF steelmaking?

A: The volume density of graphite electrode reflects the dense state of the electrode and is closely related to the manufacturing process of the electrode. The volume density of graphite electrodes of different specifications and varieties is regulated by the state. The products with low volume density show that the overall structure of the product has higher porosity, the oxidation speed of the product is faster at high temperature, and the consumption of electrodes is easy to increase. Generally speaking, the volume density of electrodes is better in the specified value when the steel mill chooses the electrodes, but the higher the volume density, the better, because some volume density is too high. Sometimes, due to the poor thermal shock resistance of electrodes, surface peeling, debris and cracks are prone to occur during steelmaking, which will affect steelmaking on the contrary.

Q: When using graphite electrodes, why should steel mills prevent multiple products from mixing?

A: Graphite electrodes used in steel mills are often supplied by many manufacturers. When many products are mixed in steelmaking, it will not only make it difficult for steel mills to make statistics on consumption of individual products, but also because of the different raw materials and manufacturing processes adopted by each manufacturer, the physical and chemical properties and processing tolerances of the electrodes and joints of each manufacturer are different. This is the case. Therefore, the matching tolerance produced in the mixed use can easily lead to the phenomenon of electrodes falling off and breaking. The correct way of use is to use the products of one manufacturer alone, and then continue the products of another manufacturer after the end. To reduce the number of electrodes replaced by different manufacturer, the electrodes of the same manufacturer should use the matching contacts with the manufacturer. Prevent mixing.

Q: What are the characteristics of needle coke?

A: Needle coke is a kind of high-quality carbon raw material, which is divided into coal and oil series. Its surface shows obvious stripe pattern. When broken, it is mostly long needle-shaped fragments. Fibrous structure can be observed under a microscope, so it is called needle coke. Needle coke is easily graphitized at high temperatures above 2000 degrees. Graphite electrodes made from needle coke have low resistivity, high bulk density and low coefficient of thermal expansion. They are the necessary raw materials for the production of ultra-high power electrodes and high power electrodes. The price of needle coke is much higher than that of ordinary coke, which is about 5-8 times higher at present.

Q: Will the vacuum system on the electric arc furnace affect the consumption of electrodes?

A: The fan used in the vacuum system produces a certain negative pressure when it works, which increases the air velocity around the red-hot electrodes in steelmaking, thus increasing the oxidation consumption of the electrodes. In steelmaking, a well-regulated vacuum system maintains a good working environment and stabilizes the consumption of the electrodes.

Q: How to avoid increasing electrode consumption in steelmaking?

A: To avoid the increase of electrode consumption in steelmaking, it is necessary to:

Maintain a good power supply state and supply electricity within the allowable current intensity range of the electrode according to the design requirements of the electric furnace.

Prevent the arcing point from immersing in the molten pool.

Prevent the increase of carbon by immersing the electrodes in molten steel.

If conditions permit, spray cooling technology is used for the electrodes.

Setting up the correct exhaust emission system.

To adopt the correct oxygen blowing system.

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