To ensure the efficient operation of EAF furnaces, manufacturing graphite electrodes requires a high-tech industrial process. The electrodes used are very large and heavy, with diameters up to about 81cm.
Process begins by selecting high-quality materials. Petroleum coke and coal pitch are the most common. The raw materials then undergo a process called calcination, which involves heating the material to very high temperatures in the absence of oxygen to transform it into a carbon-rich precursor.
Once the precursor has been produced, it must be ground and screened in specific proportions to ensure that all of the carbon particles are evenly distributed. These processes help eliminate particles of a certain size that could interfere with graphite's properties.
The material, after milling and sizing it up to the desired size is blended in exact proportions in order to produce a mix that will be suitable for electrode production. The mixture is created by combining petroleum coke with coal tar pitch and recycled graphite. It is possible to pass the mix through a machine, which will then form the paste into the desired electrode.
The electrodes are then formed by heating this paste to extremely high temperatures under reducing atmospheres or an inert environment. Heat causes the nipples, slugs, and other components of the electrode to graphitize. They become dense graphitized particles. After a second baking process, the electrodes undergo a third step that reduces their porosity and improves their electrical conductivity.
It is not uncommon for electrodes to loose between 18-23% during the graphitization. This loss is a result of open porosity in the graphitized electrodes, and can be identified by testing for true density. True density refers to the total mass of the electrode excluding its volume.
Electrodes then go through mechanical strength testing in order to see if they can handle physical stresses. These tests can include impact and load bearing, bending, and flexing.
Once the electrodes have been properly inspected and tested, they are then ready to be shipped out for use. Ameri-Source helps our clients to select graphite electrodes that meet their needs and conform to industry-standards. Our customers will get more value out of the graphite they purchase. Ameri-Source can guarantee that graphite electrodes will meet the highest standards and last a very long time.
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