Comprehensive Analysis of Graphite Electrode Production Process

--Modern Energy-Efficient and Eco-Friendly Production System

I. Core Production Equipment & Process Highlights

Raw Material Forming Stage

High-Precision Press System:

4100-ton vertical-horizontal press (industry-leading, ensures ultra-high-power electrode density)

Press fleet: 3500-ton × 2, 2500-ton × 1, 1700-ton × 1 (covers all electrode specifications)

Technical Advantage: Vertical-horizontal pressing improves green body density uniformity by 30%, reducing baking cracks.

Baking Process

Multi-Specification Baking Furnace System:

36-chamber baking furnaces × 3 (main equipment, single-furnace capacity ≥200 tons/cycle)

Car-bottom furnaces × 10 (ideal for special graphite, temperature uniformity ±5°C)

Energy-Saving Design:

18-chamber ring baking furnace enables waste heat recycling, reducing energy consumption by 15%.

Impregnation & Secondary Baking

High-Pressure Impregnation System × 3:

Working pressure: 12 MPa, pitch penetration rate >95% (Tier 1 international standard)

Tunnel Kilns × 4:

Fully automated temperature control, secondary baking yield increased to 98%.

Graphitization Core Equipment

Internal Series Graphitization Furnaces × 2:

DC power supply, energy consumption <3200 kWh/ton (60% of traditional Acheson furnaces)

Acheson Furnace × 1:

Retained for special large-sized electrode production.

Precision Machining System

Fully Automated CNC Machining Lines:

Electrode machining lines × 4 (±0.05 mm accuracy, UHP-grade threading)

Nipple machining lines × 3 (surface roughness Ra ≤1.6 μm)

Pre-Assembly System:

German-imported automatic detection device, assembly gap control <0.02 mm.

II. Key Technological Breakthroughs

Energy-Saving Design

Baking flue gas waste heat power generation system (annual electricity savings: 8 million kWh)

Internal series graphitization furnace with LHC (low heat capacity) filler reduces cooling cycle by 40%.

Environmental Innovations

Closed asphalt melting system (VOCs emissions <20 mg/m³)

Tunnel kiln SCR denitrification (NOx emissions ≤100 mg/Nm³)

Intelligent Control

AI algorithm for press pressure-temperature linkage (forming qualification rate: 99.2%)

Graphitization furnace infrared temperature measurement + automatic power adjustment system

III. Industry Application Comparison

Process Stage	Traditional Process	Advantages of This System
Forming	Unidirectional pressing, uneven density	Vertical-horizontal pressing, density deviation <1.5%
Graphitization	Acheson furnace, 4500 kWh/ton	Internal series furnace reduces energy consumption by 40%
Machining Accuracy	Manual lathe, ±0.2 mm	CNC machining, geometric tolerance ≤0.1 mm

IV. Typical Production Data

Electrode Specifications: Full range from Φ75 mm to Φ750 mm

UHP Electrode Performance:

Resistivity ≤5.5 μΩ·m

Flexural strength ≥16 MPa

Delivery Cycle: ≤45 days from raw material to finished product (industry average: 60 days)

V. Future Upgrade Directions

Digital Twin System: 3D thermal field simulation for baking furnace optimization

Hydrogen-Based Graphitization: Pilot phase (target: zero carbon emissions)

Waste Electrode Recycling: Development of crushed material remelting technology