Electrode paste, also known as self-baking electrode, is widely used in Submerged Arc Furnaces due to its simplicity in production, short production cycle, and low cost. As the heart of the Submerged Arc Furnace, effectively managing and operating the three-phase electrodes is crucial for ensuring normal production, improving operation rates, increasing output, reducing consumption indicators, and minimizing electrode accidents, equipment malfunctions, and safety incidents.
Causes of Excessive Electrode Consumption:
- High ash content in electrode paste; strict overloading of the electric furnace.
- High secondary voltage, low current, high power factor, and large active power.
- Short electrode working length and furnace entry depth.
- High current firing electrode, high porosity, and poor strength.
- Use of low-quality lime with excessive burning or low carbon content, leading to poor product quality.
- Excessive addition of auxiliary lime, resulting in furnace bottom rise and shallow electrode entry.
If the sintering speed of the electrode is not considered, or if the electrode is released too quickly, causing the softened section of the electrode to be below the conductive element (copper tile), electrode flow or soft breakage accidents may occur.
Preventive Measures and Treatment Methods for Excessive Electrode Consumption:
- Adjust the ash content of the electrode paste to match the furnace type and process operation.
- Properly reduce power factor, active power, and secondary voltage while increasing secondary current to slow down electrode consumption and accelerate electrode sintering.
- Control the working length of the electrode and the depth of the furnace, and strictly monitor the quality of raw materials and products, avoiding the use of low-quality materials.
- Avoid excessive addition of auxiliary lime, which can cause furnace bottom rise and shallow electrode entry.
Many manufacturers calculate the consumption of electrode paste by dividing the amount of electrode paste added to the electrode cylinder by the output of calcium carbide. While this method is simple, it is not accurate. A more reasonable calculation method is to multiply the pressed volume of the electrode by the bulk density and then divide it by the output of the product. Assessing the consumption index of electrode paste by measuring the kilograms per 1000kW·h of electricity or per ton of calcium carbide, while considering all relevant factors, provides a more accurate assessment.
In conclusion, by implementing preventive measures and treatment methods for excessive electrode consumption, you can significantly enhance the performance and longevity of electrodes in electrode paste applications. From adjusting ash content to controlling furnace depth and improving raw material quality, every step counts in optimizing electrode consumption. Remember, a well-maintained electrode system leads to improved operation rates, reduced accidents, and increased output in Submerged Arc Furnaces. Take the necessary steps outlined in this article to achieve efficient electrode usage and unlock the full potential of your electrode paste production.
