Hebei Heyuan New Material Technology Co., Ltd - Graphite Electrode Direct Plant
If you want to learn more, please visit our website Super High Power Graphite Electrode.
Advantage
(1) The increasing complexity of mold geometries and the diversification of product applications have led to increasingly higher requirements for discharge accuracy of spark machines. The advantages of graphite electrodes are easier processing, high discharge machining removal rate, and low graphite loss. Therefore, some customers of Qunji EDM machines have abandoned copper electrodes and switched to graphite electrodes. In addition, some electrodes with special shapes cannot be made of copper, but graphite is easier to shape, and copper electrodes are heavier and are not suitable for processing large electrodes. These factors have caused some Qunji spark machine customers to use graphite electrodes.
(2) Graphite electrodes are easier to process and the processing speed is significantly faster than copper electrodes. For example, the milling process is used to process graphite, which is 2 to 3 times faster than other metal processing and does not require additional manual processing, while copper electrodes require manual grinding. Similarly, if a high-speed graphite machining center is used to manufacture electrodes, the speed will be faster, the efficiency will be higher, and there will be no dust problem. During these machining processes, choosing tools and graphite with appropriate hardness can reduce tool wear and copper electrode breakage. If we specifically compare the milling time of graphite electrodes and copper electrodes, graphite electrodes are 67% faster than copper electrodes. In general discharge machining, machining with graphite electrodes is 58% faster than copper electrodes. In this way, processing time is significantly reduced, and manufacturing costs are also reduced.
(3) The design of graphite electrodes is different from traditional copper electrodes. Many mold factories usually have different allowances for roughing and finishing of copper electrodes, while graphite electrodes use almost the same allowance, which reduces the number of CAD/CAM and machine processing. For this reason alone, It is enough to improve the accuracy of the mold cavity to a great extent.
Hebei Heyuan New Material Technology Co., Ltd - Graphite Electrode Direct Plant
Production characteristics
(1) The production cycle is less and less than previous years. Currently our daily output is 40tons/day.
(2) Energy consumption is less than before. The production of 1 ton of ordinary power graphite electrodes requires about 6000kW·h of electric energy, thousands of cubic meters of coal or natural gas, and about 1 ton of metallurgical coke particles and metallurgical coke powder.
(3) Although the product is simple, every step of the production process is very strict. The production process includes raw material calcination, crushing and grinding, batching, kneading, molding, roasting, impregnation, graphitization and mechanical processing. Its production requires a lot of special machinery and equipment and kilns with special structures. The construction investment is large and the investment recovery period is long.
(4) A certain amount of dust and harmful gases are generated during the production process, and now we take environmental protection measures to reduce dust and eliminate harmful gases through ventilation.
(5) Although the carbonaceous raw materials required for production, such as petroleum coke and coal pitch, are by-products of production and processing by oil refining companies and coal chemical companies. But the quality and stability of the raw materials are still can fully guarantee, especially in the production of high-power and ultra-high-power graphite electrodes.
Hebei Heyuan New Material Technology Co., Ltd - Graphite Electrode Direct Plant
Detailed Application
(1) Used in electric arc steelmaking furnace
Electric furnace steelmaking is a large user of graphite electrodes. my country's electric furnace steel production accounts for about 18% of crude steel production, and graphite electrodes used in steelmaking account for 70% to 80% of the total graphite electrode consumption. Electric furnace steelmaking uses graphite electrodes to introduce current into the furnace, and uses the high-temperature heat source generated by the arc between the electrode end and the charge to smelt.
(2) Used in ore thermal electric furnace
The submerged thermal electric furnace is mainly used to produce industrial silicon and yellow phosphorus. Its characteristic is that the lower part of the conductive electrode is buried in the charge, forming an electric arc in the material layer, and using the heat energy emitted by the resistance of the charge itself to heat the charge, which requires a current High-density ore thermal electric furnaces require graphite electrodes. For example, approximately 100kg of graphite electrodes are consumed for every 1t of silicon produced, and approximately 40kg of graphite electrodes are consumed for every 1t of yellow phosphorus produced.
(3) Used in resistance furnace
Graphitization furnaces that produce graphite products, furnaces that melt glass, and electric furnaces that produce silicon carbide are all resistance furnaces. The materials in the furnace are both heating resistors and heated objects. Usually, conductive graphite electrodes are embedded in the end of the resistance furnace. In the bottom burner wall, the graphite electrode used here is consumed discontinuously.
(4) Used to prepare special-shaped graphite products
The blanks of graphite electrodes are also used to be processed into various special-shaped graphite products such as crucibles, molds, boats and heating elements. For example, in the quartz glass industry, for every 1t of electrofusion tube produced, 10t of graphite electrode blanks are needed; for every 1t of quartz bricks produced, 100kg of graphite electrode blanks are consumed.
We are a Direct Graphite Electrode Factory
❤Contact: Anna Xu (Sales Manager)
❤Mob/Whatsapp+86 18630194260 (Wechat: +86 13068776121)
Graphite electrode is nothing more than a sharp graphite rod, taken from a pile, subject to a support conductor of the current, copper tube, and at a reasonable distance a plastic handle, PVC tube. The handle should be far enough away so that it does not reach so much heat to soften it. Anyway it is clear that PVC is the worst plastic that can be used for this but it was there.
This is a sheet metal welder for almost any metal. It does not require input of material and practically does not admit it unless they are very thin rods. It is not about electric arc welding. What melts the metal is the graphite tip that shortly turns to bright white. What is heated by the current is graphite, not metal, Graphite electrode because the first one has a much greater resistance and dissipates most of the power. It is important that the graphite tip is sharp for two reasons:
The finer the point of contact between the material and the tip more resistance to current and more temperature reach. If it is too thick, heat is transmitted easily from the tip to the soldering iron and a large part of it dissipates without reaching the necessary temperature. The soldering iron only works if it concentrates most of the power at the point to be soldered. Everything has to be thought for that.
The truth is that to have been done in 10 minutes, nothing else came up with the idea, it was pretty good. The way to hold the Graphite electrode was the idea of a friend and is interesting for its simplicity. It involves making two cuts on the edge of the tube longitudinally dividing it into 4 more or less equal parts. Two of them are eliminated and the tube is left with two tabs. Each one is tightened with pliers to give it a round shape and it adapts to the bar and then approaches each other. You are looking for a large brass nut that snaps into place and, without the rod; you turn the nut with force, making a thread in the copper. Then open, put the bar and do the same again and is perfectly subject. This system allows changing the bar quickly, adjusting its position, and providing a good electrical contact.
Graphite electrode is mainly used in electric arc furnace. They are presently the only products available that have the high levels of electrical conductivity and the capability of sustaining the extremely high levels of heat generated in EAF. Graphite electrodes are also used to refine steel in ladle furnaces and in other smelting processes. Graphite electrodes are divided into 4 Types: RP Graphite electrodes, HP Graphite electrodes, SHP Graphite electrodes, UHP Graphite electrodes.
Diameter and length for all grades:
Diameter mm
Length mm
Nominal Diameter
Actual Diameter
Nominal Length
Allowance
mm
inch
Max
Min
mm
Standard
Short
200
8
205
200
1800
± 100
-275
250
10
256
251
1800
300
12
307
302
1800/2000
350
14
357
352
1800/2000
400
16
409
403
1800/2000
450
18
460
454
2100/2400
500
20
511
505
2100/2400
550
22
562
556
2100/2400
600
24
613
607
2400/2700
650
26
663
657
2400/2700
700
28
714
708
2500/2700
Machining Dimension of Electrode and Nipple：
Applicable
Dia.
mm
IEC code
Nipple
Socket
Large Dia.
mm
Length
mm
Small Dia.
mm
Socket Depth
mm
UHP
SHP
HP
RP
250
155T3N
155.57
220.00
147.14
116.00
300
177T3N
177.16
270.90
168.73
141.50
350
215T3N
215.90
Are you interested in learning more about graphite electrode price? Contact us today to secure an expert consultation!
304.80
207.47
158.40
400
215T3N
215.90
304.80
207.47
158.40
400
241T3N
241.30
338.70
232.87
175.30
450
241T3N
241.30
338.70
232.87
175.30
450
273T3N
273.05
355.60
264.62
183.80
500
273T3N
273.05
355.60
264.62
183.80
500
298T3N
298.45
372.60
290.02
192.20
550
298T3N
298.45
372.60
290.02
192.20
UHP
SHP
HP
RP
200
122T4N
122.24
177.80
115.92
94.90
250
152T4N
152.40
190.50
146.08
101.30
300
177T4N
177.80
215.90
171.48
114.00
350
203T4N
203.20
254.00
196.88
133.00
400
222T4N
222.25
304.80
215.93
158.40
400
222T4L
222.25
355.60
215.93
183.80
450
241T4N
241.30
304.80
234.98
158.40
450
241T4L
241.30
355.60
234.98
183.80
500
269T4N
269.88
355.60
263.56
183.80
500
269T4L
269.88
457.20
263.56
234.60
550
298T4N
298.45
355.60
292.13
183.80
550
298T4L
298.45
457.20
292.13
234.60
600
317T4N
317.50
355.60
311.18
183.80
600
317T4L
317.50
457.20
311.18
234.60
650
355T4N
355.60
457.20
349.28
234.60
650
355T4L
355.60
558.8
349.28
285.40
700
374T4N
374.65
457.20
368.33
234.60
700
374T4L
374.65
558.80
368.33
285.40
Graphite electrodes uses
Graphite electrodes are used primarily in electric arc furnace steel manufacturing. Graphite electrodes can provide high levels of electrical conductivity and capability of sustaining the extremely high levels of generated heat. Graphite electrodes are also used in the refinement of steel and similar smelting processes.
1. The electrode holder should be held in the place beyond the security line of the top electrode; otherwise the electrode would be easily broken. The contact surface between the holder and the electrode should be cleaned up regularly to maintain a good contacting. The cooling jacket of the holder shall be avoided from water leakage.
2. Identify the reasons if there is gap in the electrode junction, do not use the muntil the gap is eliminated.
3. If there is falling off of nipple bolt when connecting electrodes, it is necessary to complete the nipple bolt.
4. The application of electrode should avoid of tilting operation, particularly, the group of connected electrodes should not be put horizontally so as to prevent from breaking.
5. When charging materials to the furnace, the bulk materials should be charged to the place of the furnace bottom, so as to minimize the impact of the large furnace materials on the electrodes.
6. The large pieces of insulation materials should be avoided of stacking on the bottom of the electrodes when smelting, so as to prevent from affecting the electrode use, or even broken.
7. Avoid of collapsing the furnace lid when rising or dropping the electrodes, which may result in electrode damage.
8. It is necessary to prevent the steel slag from splashing to the threads of the electrodes or nipple stored in the smelting site, which my damage the precision of the threads.
Hebei Heyuan New Material Technology Co., Ltd - Graphite Electrode Direct Plant
Advantage
(1) The increasing complexity of mold geometries and the diversification of product applications have led to increasingly higher requirements for discharge accuracy of spark machines. The advantages of graphite electrodesgraphite electrodes are easier processing, high discharge machining removal rate, and low graphite loss. Therefore, some customers of Qunji EDM machines have abandoned copper electrodes and switched to graphite electrodes. In addition, some electrodes with special shapes cannot be made of copper, but graphite is easier to shape, and copper electrodes are heavier and are not suitable for processing large electrodes. These factors have caused some Qunji spark machine customers to use graphite electrodes.
(2) Graphite electrodes are easier to process and the processing speed is significantly faster than copper electrodes. For example, the milling process is used to process graphite, which is 2 to 3 times faster than other metal processing and does not require additional manual processing, while copper electrodes require manual grinding. Similarly, if a high-speed graphite machining center is used to manufacture electrodes, the speed will be faster, the efficiency will be higher, and there will be no dust problem. During these machining processes, choosing tools and graphite with appropriate hardness can reduce tool wear and copper electrode breakage. If we specifically compare the milling time of graphite electrodes and copper electrodes, graphite electrodes are 67% faster than copper electrodes. In general discharge machining, machining with graphite electrodes is 58% faster than copper electrodes. In this way, processing time is significantly reduced, and manufacturing costs are also reduced.
(3) The design of graphite electrodes is different from traditional copper electrodes. Many mold factories usually have different allowances for roughing and finishing of copper electrodes, while graphite electrodes use almost the same allowance, which reduces the number of CAD/CAM and machine processing. For this reason alone, It is enough to improve the accuracy of the mold cavity to a great extent.
Hebei Heyuan New Material Technology Co., Ltd - Graphite Electrode Direct Plant
Production characteristics
(1) The production cycle is less and less than previous years. Currently our daily output is 40tons/day.
(2) Energy consumption is less than before. The production of 1 ton of ordinary power graphite electrodes requires about 6000kW·h of electric energy, thousands of cubic meters of coal or natural gas, and about 1 ton of metallurgical coke particles and metallurgical coke powder.
(3) Although the product is simple, every step of the production process is very strict. The production process includes raw material calcination, crushing and grinding, batching, kneading, molding, roasting, impregnation, graphitization and mechanical processing. Its production requires a lot of special machinery and equipment and kilns with special structures. The construction investment is large and the investment recovery period is long.
(4) A certain amount of dust and harmful gases are generated during the production process, and now we take environmental protection measures to reduce dust and eliminate harmful gases through ventilation.
(5) Although the carbonaceous raw materials required for production, such as petroleum coke and coal pitch, are by-products of production and processing by oil refining companies and coal chemical companies. But the quality and stability of the raw materials are still can fully guarantee, especially in the production of high-power and ultra-high-power graphite electrodes.
Hebei Heyuan New Material Technology Co., Ltd - Graphite Electrode Direct Plant
Detailed Application
(1) Used in electric arc steelmaking furnace
Electric furnace steelmaking is a large user of graphite electrodes. my country's electric furnace steel production accounts for about 18% of crude steel production, and graphite electrodes used in steelmaking account for 70% to 80% of the total graphite electrode consumption. Electric furnace steelmaking uses graphite electrodes to introduce current into the furnace, and uses the high-temperature heat source generated by the arc between the electrode end and the charge to smelt.
(2) Used in ore thermal electric furnace
The submerged thermal electric furnace is mainly used to produce industrial silicon and yellow phosphorus. Its characteristic is that the lower part of the conductive electrode is buried in the charge, forming an electric arc in the material layer, and using the heat energy emitted by the resistance of the charge itself to heat the charge, which requires a current High-density ore thermal electric furnaces require graphite electrodes. For example, approximately 100kg of graphite electrodes are consumed for every 1t of silicon produced, and approximately 40kg of graphite electrodes are consumed for every 1t of yellow phosphorus produced.
(3) Used in resistance furnace
Graphitization furnaces that produce graphite products, furnaces that melt glass, and electric furnaces that produce silicon carbide are all resistance furnaces. The materials in the furnace are both heating resistors and heated objects. Usually, conductive graphite electrodes are embedded in the end of the resistance furnace. In the bottom burner wall, the graphite electrode used here is consumed discontinuously.
(4) Used to prepare special-shaped graphite products
The blanks of graphite electrodes are also used to be processed into various special-shaped graphite products such as crucibles, molds, boats and heating elements. For example, in the quartz glass industry, for every 1t of electrofusion tube produced, 10t of graphite electrode blanks are needed; for every 1t of quartz bricks produced, 100kg of graphite electrode blanks are consumed.
We are a Direct Graphite Electrode Factory
❤Contact: Anna Xu (Sales Manager)
❤Mob/Whatsapp+86 18630194260 (Wechat: +86 13068776121)
Graphite electrode is nothing more than a sharp graphite rod, taken from a pile, subject to a support conductor of the current, copper tube, and at a reasonable distance a plastic handle, PVC tube. The handle should be far enough away so that it does not reach so much heat to soften it. Anyway it is clear that PVC is the worst plastic that can be used for this but it was there.
This is a sheet metal welder for almost any metal. It does not require input of material and practically does not admit it unless they are very thin rods. It is not about electric arc welding. What melts the metal is the graphite tip that shortly turns to bright white. What is heated by the current is graphite, not metal, Graphite electrode because the first one has a much greater resistance and dissipates most of the power. It is important that the graphite tip is sharp for two reasons:
The finer the point of contact between the material and the tip more resistance to current and more temperature reach. If it is too thick, heat is transmitted easily from the tip to the soldering iron and a large part of it dissipates without reaching the necessary temperature. The soldering iron only works if it concentrates most of the power at the point to be soldered. Everything has to be thought for that.
The truth is that to have been done in 10 minutes, nothing else came up with the idea, it was pretty good. The way to hold the Graphite electrode was the idea of a friend and is interesting for its simplicity. It involves making two cuts on the edge of the tube longitudinally dividing it into 4 more or less equal parts. Two of them are eliminated and the tube is left with two tabs. Each one is tightened with pliers to give it a round shape and it adapts to the bar and then approaches each other. You are looking for a large brass nut that snaps into place and, without the rod; you turn the nut with force, making a thread in the copper. Then open, put the bar and do the same again and is perfectly subject. This system allows changing the bar quickly, adjusting its position, and providing a good electrical contact.
Graphite electrode is mainly used in electric arc furnace. They are presently the only products available that have the high levels of electrical conductivity and the capability of sustaining the extremely high levels of heat generated in EAF. Graphite electrodes are also used to refine steel in ladle furnaces and in other smelting processes. Graphite electrodes are divided into 4 Types: RP Graphite electrodes, HP Graphite electrodes, SHP Graphite electrodes, UHP Graphite electrodes.
Diameter and length for all grades:
Diameter mm
Length mm
Nominal Diameter
Actual Diameter
Nominal Length
Allowance
mm
inch
Max
Min
mm
Standard
Short
200
8
205
200
1800
± 100
-275
250
10
256
251
1800
300
12
307
302
1800/2000
350
14
357
352
1800/2000
400
16
409
403
1800/2000
450
18
460
454
2100/2400
500
20
511
505
2100/2400
550
22
562
556
2100/2400
600
24
613
607
2400/2700
650
26
663
657
2400/2700
700
28
714
708
2500/2700
Machining Dimension of Electrode and Nipple：
Applicable
Dia.
mm
IEC code
Nipple
Socket
Large Dia.
mm
Length
mm
Small Dia.
mm
Socket Depth
mm
UHP
SHP
HP
RP
250
155T3N
155.57
220.00
147.14
116.00
300
177T3N
177.16
270.90
168.73
141.50
350
215T3N
215.90
304.80
207.47
158.40
400
215T3N
215.90
304.80
207.47
158.40
400
241T3N
241.30
338.70
232.87
175.30
450
241T3N
241.30
338.70
232.87
175.30
450
273T3N
273.05
355.60
264.62
183.80
500
273T3N
273.05
355.60
264.62
183.80
500
298T3N
298.45
372.60
290.02
192.20
550
298T3N
298.45
372.60
290.02
192.20
UHP
SHP
HP
RP
200
122T4N
122.24
177.80
115.92
94.90
250
152T4N
152.40
190.50
146.08
101.30
300
177T4N
177.80
215.90
171.48
114.00
350
203T4N
203.20
254.00
196.88
133.00
400
222T4N
222.25
304.80
215.93
158.40
400
222T4L
222.25
355.60
215.93
183.80
450
241T4N
241.30
304.80
234.98
158.40
450
241T4L
241.30
355.60
234.98
183.80
500
269T4N
269.88
355.60
263.56
183.80
500
269T4L
269.88
457.20
263.56
234.60
550
298T4N
298.45
355.60
292.13
183.80
550
298T4L
298.45
457.20
292.13
234.60
600
317T4N
317.50
355.60
311.18
183.80
600
317T4L
317.50
457.20
311.18
234.60
650
355T4N
355.60
457.20
349.28
234.60
650
355T4L
355.60
558.8
349.28
285.40
700
374T4N
374.65
457.20
368.33
234.60
700
374T4L
374.65
558.80
368.33
285.40
Graphite electrodes uses
Graphite electrodes are used primarily in electric arc furnace steel manufacturing. Graphite electrodes can provide high levels of electrical conductivity and capability of sustaining the extremely high levels of generated heat. Graphite electrodes are also used in the refinement of steel and similar smelting processes.
1. The electrode holder should be held in the place beyond the security line of the top electrode; otherwise the electrode would be easily broken. The contact surface between the holder and the electrode should be cleaned up regularly to maintain a good contacting. The cooling jacket of the holder shall be avoided from water leakage.
2. Identify the reasons if there is gap in the electrode junction, do not use the muntil the gap is eliminated.
3. If there is falling off of nipple bolt when connecting electrodes, it is necessary to complete the nipple bolt.
4. The application of electrode should avoid of tilting operation, particularly, the group of connected electrodes should not be put horizontally so as to prevent from breaking.
5. When charging materials to the furnace, the bulk materials should be charged to the place of the furnace bottom, so as to minimize the impact of the large furnace materials on the electrodes.
6. The large pieces of insulation materials should be avoided of stacking on the bottom of the electrodes when smelting, so as to prevent from affecting the electrode use, or even broken.
7. Avoid of collapsing the furnace lid when rising or dropping the electrodes, which may result in electrode damage.
8. It is necessary to prevent the steel slag from splashing to the threads of the electrodes or nipple stored in the smelting site, which my damage the precision of the threads.