After the electric furnace is designed and installed, its geometric parameters and electrical parameters are determined. During the normal production process of the electric furnace, the physical and chemical indicators of the electrode paste are fixed, and the composition of the raw materials and the operating process are relatively stable. Under these premises, the baking and consumption speed of the electrode paste are also relatively balanced. At this time, the consumption and baking speed of the electrode are related to the load and power consumption of the electric furnace. How can we more accurately find the relationship between electrode consumption, sintering and the load and power consumption of the electric furnace, so as to consume how many electrodes, bake how many electrodes, press and release how many electrodes, and make the three-phase electrodes press and release evenly to reduce the occurrence of various electrode accidents? This requires scientific and accurate statistics from production practice, and the specific data such as the cumulative pressing and releasing amount, actual pressing and releasing amount, operating time, power consumption, average load, paste addition amount and output are statistically sorted and analyzed and calculated in the form of tables to find out the rules, guide production, and verify its accuracy again, and constantly revise it to guide production more accurately.
Several effective ways to reduce the consumption of electrode paste on electric furnaces
1 When counting statistics, the electrode barrel must be well scaled, the amount of electrode paste added must be accurately measured, and the statistical data must be accurate.
2 Cumulative pressure release volume = number of pressure releases × length of each pressure release; actual pressure release volume = difference between the handover scale and the handover scale; operating time = 24h-power outage time: average load = power consumption/operating time; subtotal pressure release volume = sum of actual pressure release volumes of three-phase electrodes; pressure release mass is calculated based on volume density; 10,000 kWh electrode pressure release length = subtotal pressure release volume/power consumption × 10000.
3 When the cumulative pressure release is greater than the actual pressure release, and the deviation is large, the electrode may be overburned, causing the electrode tube to curl. The protective screen should be opened immediately for inspection to avoid burning components or major water leakage accidents; when the cumulative pressure release is less than the actual pressure release, and the deviation is large, it means that the electrode has slipped. It may be that the paste column is too high, the clamping force of the clamping cylinder is insufficient, and the clamping force of the conductive clamp is insufficient. It is also necessary to shut down the power to check and eliminate the fault, otherwise the electrode may leak or break softly.
4 Statistical data must be counted and corrected for a long time to find the accurate electrode consumption to guide production. It can also be verified by reverse calculation of electrode paste unit consumption and electric energy unit consumption. The specific method is to count the monthly output and consumption, and calculate the mass of electrode paste consumed for every 10,000 kW•h of electricity consumed = electrode paste unit consumption/process electricity unit consumption × 10,000, and then convert it into electrode consumption length, and compare and correct it.
5Through data statistics, the electrode consumption length under various loads and power consumption can be calculated, and the power consumption, load and electrode consumption of the electric furnace can be organically combined to achieve the amount of electrode consumption and the amount of electrode pressure release, so that the electrode can be evenly pressed and roasted to prevent various electrode accidents.
6When the load of the electric furnace is unstable, the electrode can be pressed and released with reference to the power consumption.
To reduce electrode accidents, it is necessary to be familiar with the various factors that affect the sintering and consumption speed of the electrode, to accurately grasp the working length and furnace depth of the electrode, to scientifically operate and manage the three-phase electrode, so that the electrode roasting and consumption reach a relative balance, how many electrodes are sintered, how many electrodes are consumed, and how many electrodes are pressed and released. There are many reasons for electrode accidents, but they can be summarized into three aspects: operation reasons, equipment reasons and electrode paste quality problems. As the raw material of self-baking electrodes, electrode paste has a low probability of causing electrode accidents,
generally only accounting for 10% to 20%. Most electrode accidents are caused by not strictly following the process operation procedures, operating equipment with defects, and not being maintained and maintained for a long time. The speed of electrode sintering, the strength after sintering, the conductivity, and the consumption rate are closely related to the process operation. The height of the electrode paste column and the paste adding operation, as well as the insulation, clamping and conductive equipment failures of the equipment, the manufacturing accuracy and quality of the electrode tube, and the quality of the electrode tube docking may also cause electrode accidents.
Although the types, smelting varieties or operation methods of various ore-fired electric furnaces are different, the roasting principle of electrode paste in ore-fired electric furnaces is the same, and the causes and treatment methods of various electrode accidents are also similar. The cause analysis, preventive measures and treatment methods of various electrode accidents in ferroalloy electric furnaces (such as hard electrode break, electrode paste leakage, soft electrode break, electrode suspension, difficulty in electrode pressure release, electrode overburning, and excessive electrode consumption) can be referred to the relevant content of calcium carbide furnaces on the refractory material network for implementation.
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