In the EAF steelmaking process, an electric current passing through graphite electrodes creates an arc and heats it to high temperatures. This heat is then used to melt and smelt raw materials as well as to eliminate impurities. After smelting, the mix of raw materials is reduced to liquid ferrous iron, and then transformed into steel. Graphite electrodes are an essential industrial consumable and represent about 3 to 5 percent of the total cost of production of steel (GrafTech International Ltd. 2019).
Before they are able to be reused, graphite electrodes have to go through various processes to make sure they last for the expected duration. They include:
The electrode's particles can be reduced in size and uniform by grinding and crushing recycled graphite or petroleum coke. This allows them to be more compactly molded and decreases porosity of the finished product. Once your particles are milled it is possible to add a binder, such as coal petroleum pitch or tar pitch to aid in the process of molding electrodes. Binder is used to hold the carbon particles during the manufacturing process. This gives graphite electrodes a shape.
Next, you'll need to expose your graphite particles to an acidic process called calcination. This is the process that creates chemical bonds, which creates electrodes that are more dense and hard, increasing their electrical conductivity and their mechanical strength. This process also eliminates any soluble matter, which is essential to maintain a high level of purity in your finished electrodes.
Once the calcination process is complete, you can begin to add a performance-enhancement additive to your graphite electrodes. The additive is mixed with the petroleum coke or recycled graphite at the production of electrodes. It also improves the efficiency of electrical energy transfer while arcing. The electrodes last longer and you'll save money on energy.
Once the graphitization process has been completed, your electrodes will undergo an array of tests to verify that they meet the specifications they were designed to meet. The electrodes are then made to meet the proper measurements and surface finish to be used for your electric furnaces. The electrodes will then be safely attached to the nipples on the EAF steelmaking.
Graphite is a critical industrial material, particularly in the EAF steelmaking industry. It is the only substance which cannot be substituted in EAF steelmaking. It conducts electric current, and also provides high-temperature heating. The quality of the graphite directly impacts the speed at the raw materials you have can be converted into steel. A better product will not only increase your productivity but also improve your efficiency and reduce the time it takes to repair due to unplanned maintenance.
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