Effects of TiO2/SiC/SiO2 coating on graphite electrode consumption in sublimation and oxidation states as determined by EAF simulation and experimental methods

• Published in: Surface & coatings technology 2021-08, Vol.420, p.127340, Article 127340
• Main Authors: Alian Moghadam, Hossein, Jabbari, Majid, Daneshmand, Saeed, Rasouli Jazi, Saeid, Khosravi, Arezoo
• Format: Article
• Language: English
• Subjects: Coated electrodes; Consumption; Electric arc furnace; Electric arc furnaces; Electrode coating; Electrode consumption; Electrodes; Experimental methods; Graphite; Laboratory tests; Oxidation; Production costs; Research methodology; Sherman Antitrust Act 1890-US; Silicon dioxide; Simulation; Steel production; Sublimation; Thickness; Titanium dioxide
• ISSN: 0257-8972; 1879-3347
• DOI: 10.1016/j.surfcoat.2021.127340

The graphite electrodes consumed in an arc furnace account for a major portion of steel production costs; hence, the costs associated with steel production may be reduced by reducing electrode consumption. Proper coating of electrodes is one solution, among the many others developed in the course of arc furnace evolution, that might reduce electrode consumption [1,2]. The present study uses the two simulation and experimental methods to analyze the effects of using a TiO2/SiC/SiO2 coating on graphite electrode consumption. Given the inherent complexity of the analytical methods used to determine oxidation-induced graphite electrode consumption, experiments and tests were performed in this study to gain a more accurate understanding of the oxidation-induced electrode consumption. Moreover, the highly efficient simulation method was used to gain a deeper insight into electrode consumption in the sublimation mode. Laboratory test results revealed that graphite electrode consumption due to oxidation might be optimized if the electrode is coated with two layers of the TiO2/SiC/SiO2 coating. It was also found from the simulation results that coating the electrode with TiO2/SiC/SiO2 layers of varying thickness would be effective in changing the conical height of the graphite electrode head. •Graphite electrode consumption might be optimized if the electrode is coated with two layers of the TiO2/SiC/SiO2 coating.•Change in the diameter of the coated electrode head was not significant when compared with that in the uncoated one.•Test results revealed that electrode consumption rate was more conspicuously affected by its longitudinal consumption.•The proposed coating had a greater effect on reducing electrode consumption due to oxidation than that due to sublimation.