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The general aim of this project was to reduce graphite electrode consumption at DC EAF plants. Camera-based systems allowing for monitoring of the state of the electrode after the melting of each scrap basket were installed in the steel plants of ArcelorMittal Esch-Belval and Differdange. Dedicated image analysis software and logging systems were developed to follow up the electrode wear. Three industrial measurement campaigns were carried out. Electrode consumption was calculated on a basket-by-basket basis and the accuracy of the measurement method was evaluated. Industrial results were studied in detail, splitting electrode consumption into three main mechanisms: continuous consumption, crack losses and stub-end losses. Statistical analyses were then carried out, and the main operating parameters influencing the different modes of consumption identified. An extended version of the BFI electrode consumption model was proposed and validated. Additional investigations (using X-ray scanning and metallographic analyses) were carried out on industrial electrode samples to study the generation and propagation of cracks in the electrode material. CSM carried out dedicated pilot-scale tests in order to evaluate the influence of several process parameters on electrode consumption and to study the behaviour of artificially cracked electrodes. Guidelines to reduce the electrode consumption in DC plants were proposed. Four such camera-based electrode-monitoring systems have now been installed in industrial EAF plants and more are envisaged. The system is used both online by furnace operators and offline by plant managers to negotiate with electrode suppliers and to support the development of new electrode solutions.

Additional information

Authors: BORLÉE J, CRM, Liège (BE);WAUTERS M, CRM, Liège (BE);MATHY C, CRM, Liège (BE);WEBER M, CRM, Liège (BE);PICCO M, ProfilARBED, Esch-sur-Alzette (LU);BAUMERT J-C, ProfilARBED, Esch-sur-Alzette (LU);KLEIMT B, VDEH-BFI, Düsseldorf (DE);DI SANTE L, CSM, Roma (IT);FRITTELLA P, CSM, Roma (IT)
Bibliographic Reference: EUR 23889 EN (2009), 139 pp. Euro: 20
Availability: (Catalogue Number: KI-NA-23889-EN-S)
ISBN: ISBN: 978-92-79-11982-8
Record Number: 200910491 / Last updated on: 2009-12-11
Original language: en
Available languages: en
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