When using electrode paste in submerged arc furnaces, soft breakages can disrupt operations and cause serious issues if not properly managed. These breaks occur when the electrode weakens or cracks, potentially leading to a loss of material and furnace inefficiency. In this article, we’ll explore three proven methods to address soft electrode breakage, ensuring your operations run smoothly without costly delays.
How to deal with soft breaks when they occur?
Once a soft break of the electrode is detected, the power should be immediately turned off. The handling should be done by the main operator, and excessive personnel should be avoided around the area. The electrode should be lowered quickly, deep into the furnace, to prevent the electrode paste from flowing out. Then, loosen the electrode to reconnect it with the broken part. Clear away the surrounding electrode paste, and resume power with a low load for baking. The soft-broken electrode phase should not be lifted, and the load can be gradually increased based on the baking progress. The baking process typically takes 6-8 hours.
If the broken section cannot be reconnected and the electrode paste has dried, making it non-flowable, release a certain amount of the electrode, with the quantity based on the electrode’s size. Proceed with low-load baking, following the previous method.
If the broken section cannot be reconnected and the electrode paste is still fluid, potentially leading to excessive outflow, or if the paste has flowed out nearly completely, a section of iron shell with a bottom (similar to the electrode head used when starting a new furnace) should be welded onto the electrode. Add new electrode paste, and bake using the same method as before, while paying special attention to the electrode’s air supply and the cooling water for the conductive clamp.
