30+ YEARS OF EXPERIENCE IN CARBON INDUSTRY

Electrode paste high consumption directly increases production costs and may affect furnace stability. The causes of electrode paste high consumption are complex, usually resulting from the combined effects of equipment, process operation, raw materials, and management. This article discusses the main causes, process operation and furnace condition factors:

1. Unstable furnace conditions, especially over-reduction
   When there is excessive reducing agent in the furnace or improper operation leading to excessively high furnace temperature, an "over-reduction" phenomenon occurs, generating substances such as silicon carbide (SiC). Silicon carbide has an extremely high formation temperature (approximately 1700-2400℃), which drastically increases the furnace temperature, especially the arc zone temperature, causing sublimation consumption on the electrode sides and ends. This is the primary cause of abnormal electrode paste consumption. The manifestation is that the electrode sintering rate cannot keep up with the consumption rate, the electrode becomes thinner and softer, and even "paste overflow" accidents occur, resulting in electrode paste high consumption.

2. Electrode Working End Too Short or Too Long
   If the electrode is too short, to maintain the necessary arc length, the electrode needs to be lowered, easily causing incompletely sintered electrode paste to enter the high-temperature zone. This easily leads to soft breakage or direct burning of a large amount of paste, resulting in electrode paste high consumption.
   If the electrode is too long, it penetrates too deeply into the material layer, increasing the contact area between its sides and the high-temperature furnace charge, exacerbating chemical erosion and oxidation on the sides, resulting in electrode paste high consumption.

3. Improper Current Load Control
   Excessively high current density causes a sharp increase in the electrode's own resistance heating, leading to accelerated electrode oxidation and sublimation consumption. Large current fluctuations affect the stability of the electrode sintering zone, reducing its strength and making it more prone to breakage and wear, resulting in electrode paste high consumption.

4. Unreasonable Operating Resistance
   Operating resistance is a core parameter of the submerged arc furnace. Too low resistance means high current, short arc, low thermal efficiency, and increased erosion of the electrode tip, resulting in high electrode paste consumption.
   Therefore, when electrode paste high consumption occurs, it is recommended to first analyze the furnace condition: check the furnace bore condition, product composition, and material surface permeability to determine if over-reduction exists. This is the most common and most impactful reason.