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Antioxidant coating works well
Graphite electrodes are made from materials like petroleum coke and needle coke, combined with binders such as coal pitch or vacuum glue. These components go through processes like calcination, mixing, kneading, pressing, roasting, graphitization, and high-pressure machining. They function by discharging electric energy in the form of an electric arc inside an electric arc furnace, which heats and melts conductors. Depending on their working power index, they can be categorized as standard power, high power, or ultra-high power electrodes.
When used in the high-temperature oxidizing environments of electric arc furnaces or refining furnaces, graphite electrodes can sublime due to the intense heat of the arc. Additionally, the high-temperature oxidation reactions between the electrode and furnace gases, oxygen, and corrosive gases lead to the continuous consumption of the electrode. This can result in breakages or fractures. Side oxidation of the graphite electrode accounts for approximately 40-60% of its total consumption. This side oxidation causes a gradual reduction in the diameter of the electrode's arc, increasing the instability of the arc combustion and consequently raising the energy consumption per ton of steel produced. Furthermore, when the threaded portions of the electrode oxidize, the threads on the electrode joints become thinner, potentially causing accidents where the electrode breaks or its lower section detaches.
The primary role of a graphite electrode anti-oxidation coating is to isolate the electrode material from the oxidative corrosive environment. Key features include: 1) significantly reducing the oxygen diffusion coefficient; 2) having excellent self-healing properties against thermal expansion and contraction, effectively blocking cracks from the oxidation threshold (around 400°C) to the maximum service temperature. This helps prevent erosion and infiltration, while also reducing inclusions in the steel, ensuring purity in the molten steel; 3) forming a strong bond with the electrode matrix, offering resistance to thermal shock, fatigue, and matching thermal expansion. In steelmaking, the consumption of graphite electrodes makes up about 5-10% of the total steelmaking cost. The single consumption of graphite electrodes for steelmaking in China is roughly 1-5 kg per ton of steel, sometimes even higher, compared to the international average of 0.5 kg per ton of steel.
Research and development over many years, along with extensive on-site inspections, have led to the creation of a graphite electrode anti-oxidation coating by the paint development team at Beijing Zhisheng Weihua Chemical Co., Ltd. The ZS-1021 high-temperature sealing coating is primarily designed for high-temperature resistance, oxidation resistance, and corrosion resistance. Its core temperature is a crucial factor in its antioxidant properties and coating technology. The paint binder uses a unique Chinese Wei Sheng Zhi temperature solution, curing at room temperature and forming a polymer mesh structure adhesive composition at high temperatures. By selecting oxides that promote inert material sintering at high temperatures, the coating's air-tightness is enhanced. The ZS temperature-curable coating material remains stable at room temperature, offering excellent bonding ability with graphite electrodes and compatibility. At elevated temperatures, the binder penetrates and forms a unified structure with certain strength, resisting erosion and corrosion from oxygen gas. It also has a certain degree of penetration into the graphite substrate, enhancing adhesion and thermal shock resistance.
The material composition of the graphite electrode anti-oxidation coating follows these principles: 1) selecting materials with strong anti-oxidation capabilities and optimal overall performance; 2) choosing glass-phase materials that meet performance requirements as self-sealing materials to act as crack-sealing materials at high temperatures; 3) selecting materials with a higher affinity for oxygen than carbon-oxygen at steelmaking temperatures (1650-1750°C), prioritizing oxygen oxidation to protect the graphite electrode. The new phase formed after oxidation has a larger volume than the original phase, helping to block oxygen diffusion and form an oxidation barrier; 4) At working temperatures, large amounts of inclusions like AL2O3, SiO2, and Fe2O3 in the molten steel can be adsorbed and reacted with the coating, gradually incorporating various inclusions from the molten steel into the coating. Thus, the graphite electrode anti-oxidation coating exhibits anti-oxidation, sealing, and auxiliary electrode functions at different temperatures. The ZS-1021 high-temperature anti-oxidation sealing coating from Beijing Zhisheng Weihua uses the company's high-temperature special solution, capable of withstanding temperatures up to 1700°C. When applied to various graphite electrode products, it prevents high-temperature oxidation of the electrode. The coating is easy to apply, highly wear-resistant, fire-resistant, and offers high-temperature protection, significantly extending the electrode's service life. The Zhisheng Weihua graphite electrode anti-oxidation coating uses a nano-ceramic fish-scale-like structure, melting and sintering into a network phase state at high temperatures, providing excellent compactness. It forms a decarburization layer on the surface to prevent gas and material contact, achieving a hardness of 7-8H and excellent impact resistance. The ZS-1021 coating itself is acid and alkali resistant, without volatile substances at high or normal temperatures, making it environmentally friendly and non-reactive with quenching media. It effectively protects materials from chemical reactions at high temperatures and can prevent the high-temperature oxidation rate of materials by over 95%.
Coating the surface of graphite electrodes with this anti-oxidation protective coating creates a layer resistant to high temperatures and oxidation, reducing electrode consumption during steelmaking by 19-50% and extending the electrode's service life by 22-60%. This saves graphite electrode material and reduces electrode power consumption. The high-temperature oxidation coating developed by Zhisheng Weihua can effectively reduce electrode consumption, with a determined reduction rate of over 15%. In practical use, based on a consumption rate of 5.3 kg per ton of steel, there is a 13% reduction, thereby lowering steel production costs. This makes it a highly efficient energy-saving and valuable material.
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