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Antioxidant coating works well
Graphite electrodes serve as essential components in electric arc furnaces, primarily used for generating intense heat through electrical arcs to melt conductive materials. These electrodes are crafted from materials like petroleum coke and needle coke, with coal pitch or binders ensuring their structural integrity. Depending on the application, they can be categorized into ordinary, high power, and ultra-high power types based on their capacity to handle varying levels of electrical output.
However, these electrodes face significant challenges in high-temperature environments typical of electric arc furnaces or refining setups. The extreme heat causes them to sublime, leading to continuous degradation due to oxidation reactions with furnace gases, oxygen, and other corrosive agents. Approximately 40-60% of this degradation occurs along the sides of the electrode, resulting in a gradual reduction of its diameter. This not only destabilizes the arc but also escalates the energy required per ton of steel produced. Furthermore, oxidation at the electrode’s threaded portions weakens joints, posing potential risks of breakage or detachment.
To mitigate these issues, anti-oxidation coatings have been developed to shield graphite electrodes from harsh oxidative conditions. These coatings aim to minimize oxygen diffusion while offering thermal stability and crack sealing capabilities. A notable example is the ZS-1021 high-temperature sealing coating by Beijing Zhisheng Weihua Chemical Co., Ltd., which boasts excellent resistance against high temperatures, oxidation, and corrosion. This coating integrates advanced technologies, including a unique Chinese Wei Sheng Zhi temperature solution that cures at room temperature yet forms robust adhesive structures at high temperatures. By enhancing the inert properties of the material and blocking oxygen ingress, this coating significantly improves the electrode's lifespan and operational efficiency.
The development of such coatings involves meticulous material selection, prioritizing those with superior anti-oxidation properties and self-sealing abilities at elevated temperatures. For instance, glass-phase materials are chosen for their ability to seal cracks autonomously within the operational temperature range. Additionally, materials with higher oxygen affinity than carbon are selected to protect the electrode by forming an oxidation barrier. At steelmaking temperatures (approximately 1650-1750°C), the coating also facilitates the absorption and reaction of steel inclusions like AL2O3, SiO2, and Fe2O3, further reinforcing its protective role.
Practical applications of ZS-1021 have demonstrated impressive results. By applying this coating, the electrode's consumption during steel production can be reduced by 19-50%, extending its service life by 22-60%. Notably, in real-world scenarios, implementing this coating on a baseline consumption rate of 5.3 kg per ton of steel resulted in a 13% reduction, translating to substantial cost savings in steel production. This makes the ZS-1021 coating a highly efficient and eco-friendly solution for modern industrial needs.
In conclusion, advancements in anti-oxidation coatings represent a breakthrough in optimizing graphite electrode performance. Their ability to withstand extreme conditions while minimizing wastage and energy expenditure underscores their importance in sustainable manufacturing practices. As industries continue to seek ways to enhance efficiency and reduce costs, innovations like the ZS-1021 coating will undoubtedly play a pivotal role in shaping future technological landscapes.
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