The electric arc is used by steelmakers to melt scrap metal into molten iron. The process requires extreme heat to break down and melt the scrap, so the electrodes are able to control the temperature inside the steel melting zone. So, the process of making steel is made more efficient. This also helps steelmakers reduce costs. The electrodes must also resist oxidation and thermal stress. Choosing high-quality electrodes, improving raw material sorting, and optimizing electric arc furnace operations can help reduce oxidation, thermal stress, and wear on the electrodes, thus increasing their lifespan.
The electrodes lose carbon monoxide and carbon dioxide by two different processes during smelting. The carbon layer formed on the electrode's surface helps protect against oxygen attack, but anything that damages or disrupts this coating causes accelerated oxidation losses. Smelting itself consumes electrodes as carbon dioxide, slag and waste products are produced.
In order to reduce oxidation on the graphite side, which is closest to the arc, its conductivity should be very low and its porosity should be extremely low. Also, a large area of black should cover less than 5 percent of its diameter. In addition, it is important that the electrode be composed of highly dense and pure materials. Besides, the electrode should have a large bulk density and good thermal conductivity, a small thermal expansion coefficient, and sufficient mechanical strength to prevent a crack at the joint part.
For a stable rotation, a good electrode should have the right geometry and mounting. This connection must be solid and not loose. There should also be no dirt, dust or any other contaminants in the joint. Otherwise, the resistance will increase, the electric power consumption will rise, and it may even rupture.
Graphite electrodes are an expensive raw material used in steelmaking. They must therefore be used efficiently to avoid damage and loss. The electrode consumption is affected by several factors, such as the waste gases generated during the smelting, the peeling and oxidation of the electrode surface, followed by cracking and direct losses caused by damaged electrodes.
A typical steel mill consumes one electrode (and requires the addition of another) once every 8 to 10 hours of operation. In a typical steel mill, the rate at which electrodes are consumed and added depends on furnace productivity and efficiency. By choosing better-quality electrodes and improving the quality of your scrap metal, you can reduce consumption by a significant amount. This will reduce the amount of energy used, as well as emissions. This can improve steel quality. High-quality premium electrodes can be used to reduce the amount of waste required. A variety of modern technologies, such as furnace door oxygen lances, oil oxygenation clusters, or EBT clusters, can reduce emissions while improving the steel's metallurgical properties.
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