What do I need to pay attention to when producing low power graphite electrodes?

Low power graphite electrodes are specifically designed for use in electric furnaces or electrolytic processes at lower current densities and lower operating temperatures. These electrodes need to have good electrical conductivity, mechanical strength, thermal shock resistance, and some corrosion resistance, and in order to reduce energy consumption and cost, they need to have an optimized structure to reduce unnecessary power loss. Below are some points and recommendations that can be considered when designing low power graphite electrodes:

1. Material selection and proportioning

High-quality graphite raw materials: choose high-purity, low-ash, fine-grained graphite raw materials as the base material, these materials have better conductivity and stability. Appropriate additives such as binders (e.g. bitumen), reinforcing agents (e.g. carbon fiber, silicide) and antioxidants are added to improve the mechanical strength, thermal shock resistance and oxidation resistance of the electrode.

2. Structural design

Optimization of cross-section shape: Low-power electrodes can adopt more economical circular or rectangular cross-section, but the best cross-section shape can also be determined through simulation analysis to reduce resistance and power loss. Optimization of internal structure: Multi-layer or composite structure design, using high-density graphite internally to ensure electrical conductivity, and low-density graphite externally to increase thermal stability and resistance to thermal shock.

Reduction of interfaces: Reduce the number of interfaces between electrode segments and adopt high-precision machining and high-quality welding technology to reduce interface resistance and failure rate.

3. Production process

Isostatic Pressure Molding: Adopt isostatic pressure molding technology to make graphite particles evenly distributed and improve the density and strength of the electrode.

Low-temperature roasting: Roasting at a lower temperature to retain a certain porosity and improve the electrode's resistance to thermal shock, while reducing energy consumption.

Impregnation treatment: By impregnating the bitumen several times and roasting it, the density and mechanical strength of the electrode are improved while its corrosion resistance is enhanced.

4. Surface treatment

Antioxidant Coating: A layer of antioxidant coating is applied to the surface of the electrode to prolong its service life at high temperatures.

Conductive Coating: Coating a layer of highly conductive coating on the contact surface of the electrode and the furnace chamber to reduce the contact resistance and improve the efficiency of electrical energy transmission.

5. Use and Maintenance

Regular inspection: Regularly inspect the electrode to find and deal with cracks, spalling and other problems in time to prevent the failure from expanding.

Reasonable operation: Maintain proper current density and temperature during operation to avoid overloading the electrode and prolong its service life.

Through the optimization of the above design and production process, high-quality graphite electrodes can be produced to meet the low power demand, improve production efficiency and reduce energy consumption and cost.