Reasons forgraphite electrodebreakage
If you are looking for more details, kindly visit Zhongsheng.
The reason for the fracture of the graphite electrode lies in the operation and control, but the quality of the electrode itself is also the decisive factor for the fracture of the electrode.
1. Reasons for the intrinsic quality of the electrode
1.1 Reasons for broken joints Joints play a key role in connecting electrodes in steelmaking, and the quality of joints is directly related to the use of electrodes in electric furnace steelmaking. The connection area formed by the graphite electrode and the joint is a part with large and complex electrical, thermal and mechanical loads, and it is also a common fracture part. According to relevant information, in electric furnace steelmaking, more than 80% of the electrode use accidents are caused by broken joints or loose and tripping. As far as the quality of the joint itself is concerned, the main reasons for breaking are as follows: the bulk density of the joint is low, the strength is generally low, and it is easy to break during use; The resistivity is too high, and the temperature of the joint part rises quickly when the power is turned on, which will cause the thermal stress of the joint part at the electrode connection to be large and the probability of breakage to increase; The flexural strength of the joint is not enough; The internal split joint is mixed into the finished joint to form a major hidden danger; The machining accuracy index of the joint and the electrode is not reasonably matched, and it is also prone to breakage.
1.2 Usually, the probability of electrode breakage is low. The main reasons for electrode breakage are as follows: the electrode screw hole has quality defects; the bulk density and strength of the electrode are not enough; the electrode and the joint index and machining accuracy do not match ; The deep crack at the end of the electrode is caused by the poor thermal shock resistance of the electrode; in addition, the electrode with internal transverse crack is mixed into the finished product and is not detected, and there is a great risk of breaking.
2. Preventive measures for graphite electrode breakage
2.1 Breaking prevention measures in smelting operation
2.1.1 The layout of the charge structure is reasonable: the layout of various scrap steels in the material basket and the conditions of adding them into the furnace should be reasonably configured to avoid the light and thin steel materials forming a ball at the top of the furnace and difficult to descend, and to avoid large pieces of scrap steel to break the electrode.
2.1.2 Carefully observe the distribution of unmelted charge during smelting, especially when it is close to melting. If a bridging structure has been formed, oxygen blowing or physical swinging or shaking should be used first to let the charge collapse under the condition of a power failure and the electrode has been raised to a high position, so as to prevent the collapsed material from breaking the electrode.
2.1.3 The strength of the electrode should be suitable for the process requirements. The connection electrode should use a nut of suitable strength, clean it up, and use a special holding device. Before replacing the electrode and lifting it, the lifting ring must be fastened to ensure that the lifting ring is in close contact with the electrode. To keep the interface clean, it is required to keep the end caps of the new electrodes until the lifting ring is installed.
2.1.4 The electrode holder should not hold the area between white line near to the electrode connections. The electrode connection must not be above the electrode holder. The electrode holder cannot be clamped on an open tip or a tip with a loop.
2.2 Preventive measures in the control process
2.2.1 After the high-voltage power transmission, it is necessary to observe whether the three phases of the no-load voltage of the secondary short network are balanced (determined by the insulation resistance of the three-phase short network to ground, and the unbalanced voltage should be within 10%).
2.2.2 Before the electrode is automatically lowered, make sure that there is no non-conductive object in the scrap layer directly under the electrode.
2.2.3 After the first phase electrode descends and touches the scrap, observe whether the secondary voltage of the phase electrode drops immediately.
2.2.4 When an arc occurs in a certain phase electrode, whether the secondary current display of the phase electrode can be seen (the pointer of the ammeter swings greatly).
2.2.5 Regularly check whether the braking force of the electrode hydraulic drive mechanism and the system delay coefficient change.
In terms of the intrinsic quality of the electrode, the key technical indicators of the electrode (joint) in the smelting process will eventually affect the electrode breakage. Many scholars have carried out detailed research on this. However, there is a certain one-sidedness in judging the quality of the electrode (joint) only by the physical and chemical indicators of the electrode (joint), and the matching of comprehensive factors such as the smelting process, furnace structure and smelting steel grade of our products and different customers should be fully considered.
3. Conclusion
3.1 Material collapse, resonance effect, irregular clamping operation, abnormal condition of the electrode regulator, the hydraulic drive mechanism of the electrode regulator, and improper control measures for the internal quality of the electrode can all cause the electric furnace electrode to break.
3.2 By taking corresponding technical and management measures for such factors as fabric structure, electrode clamping, secondary short-circuit no-load voltage, non-conductive objects, secondary current, braking force of electrode hydraulic drive mechanism and system delay coefficient, the electrode breakage phenomenon can be significantly improved.
3.3 There is a certain one-sidedness in judging the quality of electrodes (joints) based on the physical and chemical indicators of electrodes (joints). The compatibility of our products and the comprehensive factors of different customers' smelting process, furnace structure and smelting steel should be fully considered.
The Graphite Electrode Market accounted for USD 15.77 Billion in and is expected to reach USD 25.46 Billion by , growing at a CAGR of around 4.45% between and . The graphite electrode market exists to manufacture and apply graphite electrodes used in Electric Arc Furnace applications to produce steel. These electrically conducting electrodes serve as conduits to transmit power that allows the scrap metal and various materials to melt. The steel industry’s expansion and the establishment of EAF-based steel production together with rising automotive and construction requirements propel this market’s advancement. The market price of graphite electrodes depends on three main factors including raw material supply availability alongside technological development requirements and the general costs of energy. The market expands because producers demand electrodes that are of higher quality and demonstrate improved operational characteristics. The market operates under two main issues: supply chain interruptions and variable raw material cost fluctuations.
"The graphite electrode market is expected to see continued growth as demand for electric arc furnace steel production rises, driven by the construction and automotive sectors. However, raw material shortages, particularly in petroleum needle coke, pose a challenge for manufacturers. Innovations in electrode technology, such as improving conductivity and lifespan, will be key to addressing these supply challenges and driving market advancements."
"Although the graphite electrode market is expanding, the volatility in raw material prices and the increasing environmental regulations around steel production are influencing the market dynamics. The shift towards more energy-efficient and sustainable production methods, like green steel, will likely impact graphite electrode demand. Companies that focus on sourcing sustainable raw materials and improving production processes will remain competitive in this evolving market."
The steelmaking industry grows its graphite electrode demand because of expanding electric arc furnace (EAF) market usage. Manufacturers of steel require more powerful graphite electrodes because Electric Arc Furnace technology now controls the steel production market because of environmental advantages and rising steel scrap reuse. The electrodes act as essential elements by transmitting heat from high-temperature electric energy necessary for efficient steel melting processes.
Rising environmental restrictions and worldwide programs aimed at sustainable steelmaking have driven the world to speed up steel production transitions from blast furnaces to EAF steelmaking. The market requirement for graphite electrodes will rise because industries actively work to accomplish energy efficiency and emission reduction objectives. New steel manufacturers currently selecting EAF technology will boost the demand for graphite electrodes.
Lithium-ion battery adoption patterns have created a substantial rise in graphite usage because graphite constitutes essential anodes in battery cells. Modern trends in electric vehicles together with portable electronics and renewable energy storage systems create growing demand for high-performance batteries. Synthetic graphite production requires graphite electrodes to create the substance that forms anode components for lithium-ion batteries since the substance delivers both high conductivity and stability. The increasing need for graphite comes from government support of electric vehicle development as well as improved energy storage system technologies.
The company is the world’s best Graphite Electrode Scraps supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
Manufacturers of batteries now require high-purity graphite for producing efficient batteries with extended lifespans thus driving up synthetic and natural graphite manufacturing demand. Clean energy creation initiatives around the world will boost the graphite electrode market because lithium-ion batteries require this component as a fundamental element of their production process.
The production costs of graphite electrodes become challenging to maintain since raw material price fluctuations are very substantial. The market value of needle coke as well as other core materials keeps changing because of supply chain problems and energy expenses together with geopolitical factors. Worker expenses grow for manufacturers due to cost increases in raw materials thus resulting in end-user price increases for steelmaking and battery production sectors.
The cost instability in the market becomes worse because supply problems arise simultaneously with fluctuating market demands in related sectors such as petroleum refining and electric vehicle manufacturing. Alternative sourcing methods and efficiency improvements help firms reduce negative impacts but unpredictable prices still challenge their profitability levels. Research demand for graphite rises because governments support electric vehicle development while developing better energy storage system technologies.
Manufacturers are increasing their demand for ultra-high power (UHP) graphite electrodes because steel industry users opt for electric arc furnace technology. UHP graphite electrodes accomplish their purpose in steelmaking and metallurgical procedures by offering superior electrical conductivity together with high-temperature endurance and durable composition. High-performance electrodes are essential because industry leaders search for better steel production methods that require substantial energy consumption.
Stronger pollution controls together with worldwide efforts toward steel production emitting less pollution drive steel manufacturers away from blast furnaces toward Electric Arc Furnace (EAF) systems. Steel producers invest in advanced electrodes because UHP electrodes lead to increased output and reduced energy usage during production. Companies across the world that invest in EAF technology will drive steady market growth for UHP graphite electrodes.
Electric vehicle industry development has resulted in growing graphite use mainly because of its essential role in lithium-ion battery manufacturing. The importance of graphite as a battery anode exists because it supports stable energy storage capabilities through its excellent conductivity. Advanced battery technology development coupled with pollution control legislation and governmental EV promotions creates sustained rising markets for premium-grade graphite.
The expansion of battery factories and investments toward next-generation power storage technologies push forward the demand for graphite. The performance enhancement of batteries together with their operational lifespan and charging attributes depends on the combination of natural and synthetic graphite materials. The rising production of electric vehicles around the world will boost demand for graphite electrodes and their related materials which will enhance the development of the graphite market throughout the next decade.
Based on the product type, the Graphite Electrode Market is classified into Ultra High Power Graphite Electrodes, High Power Graphite Electrodes, and Regular Power Graphite Electrodes. The Graphite Electrode Market is dominated by Ultra High Power Graphite Electrodes. The high demand for this type exists because of its superior capabilities to conduct electricity along with thermal resistance and mechanical strength which makes it suitable for electric arc furnace operations in steel production. Industrial demand for excellent steel production and spreading electric arc furnace applications has resulted in substantial increases in ultra-high power graphite electrode usage. The market-leading position stems from their resistance to harsh conditions and energy efficiency capabilities which meet the requirements of businesses needing advanced materials.
Based on the raw material, the Graphite Electrode Market is classified into Petroleum Coke, Needle Coke, and Coal Tar Pitch. Needle Coke is the largest category in the Graphite Electrode Market. The production of high-performing graphite electrodes including ultra-high power and high power types requires needle coke because of its high purity good electrical conductivity and low thermal expansion behavior. The manufacturing industry currently demands needle coke because it serves as the primary component for electrodes that power electric arc furnaces for steel production. The graphite electrode market continuously selects needle coke because of its superior properties that enable excellent operational efficiency and extreme resistance conditions.
The North American graphite electrode market operates under strong steel industry demand primarily through electric arc furnaces employed in steel production. Manufacturing plants in the region together with existing steel production facilities create stable market conditions. Production costs and pricing may face change when petroleum needle coke raw material prices experience fluctuations. The area witnesses better innovation because of intensified environmental legislation together with new demands for eco-friendly manufacturing approaches. The rising market demand for steel because of electric vehicles and renewable power infrastructure development leads to enhanced requirements for high-quality graphite electrodes.
The graphite electrode market is experiencing its biggest and fastest expansion in Asia-Pacific because of the rapid industrialization trends and urbanization patterns throughout the area. The steel demand surge across construction, automotive, and infrastructure industries acts as the main force behind the expanding graphite electrode market consumption. The growing electric arc furnace steel industry in certain nations with extensive steel operations requires high-performance electrodes. The rising environmental awareness has led people to choose efficient and sustainable production methods. The market shapes itself through supply chain difficulties associated with raw material shortages within this area.
The competitive landscape in the graphite electrode industry requires major companies to boost manufacturing capacity and upgrade product quality as well as technology development to address rising market needs. GrafTech International together with Shaanxi Provincial Coal and Chemical Industry and HEG Limited control the market through their production of specialized steel manufacturing electrodes. The companies Imerys S.A. together with Tokai Carbon Co. Ltd. and Graphite India Limited invest research funds to improve electrode durability and operational efficiency as they work toward sustainable approaches.
The market demonstrates active engagement through Showa Denko K.K. and Zhejiang Material Industry Group along with Baoshun Graphite in terms of increasing their worldwide operations and supply chain expansion. Electric arc furnace steel production requires continuous innovation among companies due to increasing market demand while they must optimize their operations to suit evolving standards.
Graphite Electrode Market, Company Shares Analysis,
To explore in-depth analysis in this report - Request Sample Report
By Product Type
By Raw Material
By Application
By Distribution Channel
By End User
By Region
North America
Europe
Asia Pacific
Latin America
Middle East & Africa
List of Companies:
Are you interested in learning more about Graphite Block? Contact us today to secure an expert consultation!