Application of Electrodes in Ferro Alloy Furnaces

Electrodes in ferro alloy furnaces primarily function to conduct current and convert electrical energy into heat. Electrodes are typically made of high-temperature resistant materials, such as electrode paste or carbon electrodes.

Electrode paste can operate stably in high-temperature environments, while carbon electrodes, due to their lower resistance, offer significant energy savings.

During ferroalloy smelting, current flows through the electrodes into the electric furnace, generating an electric arc. The heat generated by this arc is used to smelt the ferroalloy. The alternative use of carbon electrodes can also reduce pollutant emissions.

Application of Electrodes in Ferro Alloy Furnaces

In ferroalloy submerged arc furnace, the core function of the electrodes is to efficiently and stably introduce a large amount of electrical energy into the enclosed furnace chamber. The arc heat generated at the electrode tip and the resistance heat generated by the current passing through the furnace charge provide the necessary high temperatures (typically exceeding 1600℃ to 2000℃) for the entire smelting process, thereby completing the reduction of the ore, the melting of alloying elements, and the formation of liquid ferroalloys. Two main types of electrodes are used in submerged electric furnaces:

1. Self-baking electrodes

This is the most commonly used type of electrode in large, enclosed submerged arc furnaces.

Structure & Working Principle: 

It is not a pre-fired finished product, but rather a product that is "self-fired" on-site from a steel electrode shell (cylindrical) and an internal electrode paste (a mixture of anthracite, coke, pitch, and tar).

The electrode shell is continuously lengthened as it is consumed, and new electrode paste is added.

As the electrode passes through the conductive clamps on the meting furnace lid, the electrode paste is gradually fired into a solid carbon electrode by the heat within the furnace itself, and then enters the furnace to participate in the reaction.

Application Characteristics in SAF:

• Low Cost: Eliminates the high-energy-consuming external firing process, resulting in a manufacturing cost far lower than graphite electrodes.

• Large Size: Allows for the manufacture of very large diameter electrodes (up to 2 meters or more), suitable for ultra-high-power large submerged arc furnace, such as those used in smelting ferrosilicon, high-carbon ferromanganese, and high-carbon ferrochrome.

• Seamless Connection: It is a continuous whole, eliminating the risk of joint breakage.

2. Graphite Electrode

Typically used in ferro alloy furnaces with lower power or special process requirements.

Structure & Working Principle: 

High-purity, high-density finished electrodes are pre-manufactured in the factory through a series of complex processes (calcination, kneading, molding, baking, graphitization).

Electrodes are connected together via threaded connectors to form the required length.

Application Characteristics in SAF:

• Excellent Performance: Good conductivity (low resistivity), high energy efficiency; strong resistance to high temperatures, oxidation, and thermal shock.

• High Purity: Does not introduce additional impurities, suitable for smelting high-purity ferroalloy products.

• Easy Operation: No on-site baking required, relatively simple maintenance, cleaner environment.

When using electrodes in ferro alloy furnaces, the appropriate type should be selected based on the type and characteristics. For submerged arc furnace and other metal smelting furnace, please feel free to contact us with any questions or needs; we provide one-stop solutions and services.