Electrode Paste Consumption and Furnace Condition Control of Ferrosilicon Furnaces (72# / 75#)(2026 -FAQ-Graphite Electrode and Electrode Paste Supplier | Rongxing Group-Graphite Electrode and Electrode Paste Supplier

Abstract

Ferrosilicon (FeSi) is the most typical slag-free smelting grade; 72# (about 72% Si) and 75# (about 75% Si) are the mainstream grades in China. The core contradiction in electrode management for ferrosilicon furnaces is not "under-baking" but "baking too fast and oxidizing too severely".

Keywords|Ferrosilicon (FeSi)；slag-free smelting；electrode oxidation；oxidation resistance；electrode slipping；burden surface management；arc exposure；72# / 75# grades；electrode paste unit consumption；three-phase current balance

Last updated: 2026-10-30·Owner: Rongxing Group Technical Team

Content

1. How the process characteristics of ferrosilicon furnaces affect the electrode

Characteristic	Impact on the electrode	Response direction
Slag-free smelting	No slag layer covers the burden surface, so the upper part of the electrode is exposed to high-temperature furnace gas	Strengthen burden surface maintenance (a problem that arises in open furnaces) to isolate air ingress as far as possible
Deep electrode insertion	The working end is buried in the burden layer, so the tip temperature is high and consumption is concentrated	Maintain a reasonable insertion depth and avoid "arc exposure"
High furnace mouth temperature	The side of the electrode oxidizes quickly and its diameter gradually thins	Improve the furnace-platform operating conditions and keep the electrode properly submerged in the arc
Carbon does not take part in the main reaction	Chemical consumption is lower than in silicomanganese, but mechanical and oxidation consumption account for a higher share	Focus on improving strength and oxidation resistance rather than simply raising the sintering speed

2. Consumption level and influencing factors

The general industry benchmark is that producing 1 tonne of ferrosilicon containing 75% silicon consumes about 45 kg of electrode paste. Actual values, however, vary greatly with furnace capacity and operating level: the common domestic operating range is 25–45 kg/t, and a well-managed large furnace can approach 30 kg/t or even lower.

Influencing factor	Direction	Explanation
Ash content of electrode paste	Ash ↑ → unit consumption ↑	Ash takes part in slag formation and accelerates tip consumption
Oxidation resistance	Oxidation resistance ↑ → unit consumption ↓	Graphite fines and low porosity can slow side oxidation
Electrode insertion depth	Too shallow → unit consumption ↑	Arc exposure causes simultaneous high-temperature oxidation of the tip and the side
Burden surface management	Burden surface collapse → unit consumption ↑	The impact of a collapse causes block loss and breakage
Secondary current	Too high → unit consumption ↑	Higher current density means faster tip erosion

3. Furnace condition control

"Stability" comes first: ferrosilicon furnaces dislike frequent adjustments. The unbalance of the three-phase current should be controlled within 5%; the burden surface should be kept "flat, full and loose", avoiding "sparking" (local arc exposure) and large burden collapses.

Matching electrode slipping with sintering: the electrode consumption rate of ferrosilicon furnaces is moderate, so the "small amount, many times" slipping principle should be followed. Each slip should preferably not exceed 100–150 mm, and after slipping one should observe for 2 h before deciding on the next slip. The daily slipping amount can serve as an indirect monitoring indicator of unit consumption.

Differences between 72# and 75#

Grade	Silicon content	Smelting difficulty	Focus of electrode management
72#	About 72%	Relatively easy, with a slightly lower furnace temperature	Control oxidation and stabilize the burden surface
75#	About 75%	Higher furnace temperature and more severe electrode erosion	Strengthen oxidation resistance and strength; unit consumption is usually higher than that of 72#