Manufacture

Production prebaked anodes

Production Cathode blocks

Production electrode paste

Production graphite electrodes

Production carbon electrodes

 

Production prebaked anodes

MIXING AND MOULDING

After crushing and sorting calcined petroleum coke is sent to the batch preheaters for premixing and heating to target temperature, then it goes to the batch blender, where it is mixed with coal tar pitch generating coke-pitch blend. The mass goes to the vibrating press and takes the shape of the anode block with the target dimensions.

 

   Production Cathode blocks        Production electrode paste    Production electrodes blocks        Production carbon electrodes           

BAKING

Moulded blanks are baked in the open hearth furnaces at the temperature in the furnace partitions not lower than 1250°C. During baking the anode blocks obtain the necessary physical and chemical properties due to carbonization of the pitch exposed to high temperature. The properties include: high mechanical resistance, electrical conductivity and chemical resistance.

MACHINING

Slots in anode blocks are made on a special bench with the use of diamond saws. The depth of cut can be adjusted by a wide range. The equipment cuts two slots simultaneously. The bench is able to machine up to 4000 tons of anode blocks per month.
 

PACKING AND SHIPPING

Baked anode blocks which satisfy the technical or the customer requirements are marked and handed over to the warehouse. Baked anodes are placed on wooden lodgment and are tightened with metal bands. Products are shipped by railway or motor transport.

RAW MATERIALS

Anthracite, petroleum coke and pitch are the main raw materials for the manufacturing of cathode blocks. The raw materials supplied to Novosibirsk Electrode Plant are stored indoors according to their grades and separately from other types of raw materials. All raw materials pass the entry tests against quality requirements.

Graphite as one of the most important components of cathode blocks is produced locally at the plant, which guarantees high quality of this material and stability of its parameters.

CALCINING

Pre-crushed anthracite is either gas calcined or electrically calcined depending on further product application. Gas calcination is performed in rotary baking furnaces. Electrically calcined anthracite is produced in electric calciners at temperature 1600-1800 C.

FORMING

BATCHING

According to the mix design, the selected fractions are dosed by weight from the graded bunkers into the cart hopper, and the collected charge portion is shot into mixers’ receiving hoppers.

Pitch batching is performed according to mixing formula by putting weight portions into a dosing tank and its subsequent discharge into mixers.

MIXING

Mixing of dry components with the binding pitch is performed in heated mixers.

Applied mixing technology allows to receive the homogeneity of the mix, which ensures the good structure of the block.

BILLET MOLDING

Molding of cathode blocks can be performed by both extrusion and vibropress methods depending on buyer’s request or product specification.


 

BAKING

Green cathodes are exposed to baking in multi-chamber gas-heated Riedhammer kilns at the temperature of 1250 C. Baking cycle is fully automatic and lasts 400-450 hours.

GRAPHITIZING

In order to produce cathode blocks in grade N-4 the billets are exposed to graphitization process.

Graphitization is conducted in Castner longitudinal graphitization furnaces. at temperature up to 3000 C.

MACHINING

Machining of cathode blocks is performed on the fully automatic line providing high accuracy in design and geometry. Maximum length of machinable units is 3700 mm.

QUALITY CONTROL

Each production stage ends up with strict quality monitoring whereas machining stage (final step of production) is followed up with 100% quality control of each cathode block. Every block is marked with its unique ID number.

PACKAGING

Cathode blocks at Novosibirsk Electrode Plant are securely packed for long distance multi-modal transportation.

Seaworthy packaging: each cathode block is wrapped in polyethylene film, stuffed into wooden crates, fastened with steel bands and placed onto wooden pallets.

By buyer’s request light packaging can be arranged.

CALCINATION

Process of anthracite gas or electrical calcination in a calciner

BATCHING

Batching of burden constituents (thermoanthracite, commercial graphite) in an automatic batching capsule

MIXING

Mixing of burden constituents (thermoanthracite, coal-tar pitch, commercial graphite) in a mixing machine

FORMING

Feed of ready burden to a forming drum to produce briquetted paste

MIXING AND EXTRUSION

Premium quality calcined coke is crushed, screened, and hot-blended with pitch in controlled proportions. The green mixture of coke and pitch is extruded through a forming press (1600 – 6300 mt) creating so-called green electrodes.

BAKING

Green electrodes are baked at temperature of up to 1000 C in specially designed, computer-controlled furnaces. It takes 3 – 4 weeks of baking to coke the pitch and remove volatiles from electrodes.

IMPREGNATING

Baked electrodes are impregnated with pitch in autoclaves to provide higher density, mechanical strength, and electrical conductivity. This process can be repeated several times for the production of connecting pins. Impregnated electrodes are rebaked at 750 C to carbonize the pitch and remove remaining volatiles. 

GRAPHITIZING

Electrode blanks are further graphitized in Castner or Acheson furnaces. Electrodes are heated to over 2700 – 3000 C. During the process of graphitization the amorphous structure of carbon is transformed into graphite.

MACHINING

During the last stage of production electrodes and connecting pins are machined to exact dimensions. Connecting pins and sockets are threaded to assure optimal electrode-pin joint.

QUALITY CONTROL

Each production stage ends up with quality monitoring whereas machining stage is followed with 100% quality control of each graphite electrode produced.

PACKAGING

Graphite electrodes with pre-set pins are packed in wooden crates, placed onto wooden pallets and fastened with steel bands. For seaworthy packaging polyethylene is used as a water protection and the ends are protected with wooden covers.

SHIPPING

Energoprom Group provides its customers with expertise in reliable and efficient supply of graphite electrodes. We deliver products around the World and deliver to your doors if necessary!

RAW MATERIALS

Anthracite, petroleum coke and pitch are the main raw materials for the manufacturing of carbon electrodes. The raw materials supplied to Novosibirsk Electrode Plant are stored indoors according to their grades and separately from other types of raw materials. All raw materials pass the entry tests against quality requirements.

Graphite — as one of the most important components of carbon electrodes is produced locally at the plant, which guarantees high quality of this material and stability of its parameters.

CALCINING

Pre-crushed anthracite is either gas calcined or electrically calcined depending on further product application. Gas calcination is performed in rotary baking furnaces. Electrically calcined anthracite is produced in electirc calciners at tempreture 1600–1800 C.

FORMING

BATCHING

According to the mix design, the selected fractions are dosed by weight from the graded bunkers into the cart hopper, and the collected charge portion is shot into mixers' receiving hoppers.

Pitch batching is performed according to mixing formula by putting weight portions into a dosing tank and its subsequent discharge into mixers.

 

MIXING

Mixing of dry components with the binding pitch is performed in heated mixers.

Applied mixing technology allows to receive the homogeneity of the mix, which ensures the good structure of the electrode.

 

BILLET MOLDING

The billets of carbon electrodes are pressed into molds, using vacuum degassing system. The billet molding occurs as a result of mixture compression caused by vibration (vibropressing) and under pressure.

BAKING

Green electrodes are exposed to baking in multi-chamber gas-heated furnaces at the temperature of 1250 С. Baking cycle is fully automatic and lasts 400-450 hours.

ULTRASONIC NONDESTRUCTIVE TESTING

Baked electrodes are checked with ultrasonic non-destructive method, specially developed by Energoprom R&D Center. This method allows to visualize the inner structure of the entire electrode body and identify all kinds of inner defects if any. From this stage only approved pieces go to further manufacturing process.

GRAPHITIZING

Baked electrodes of MGM grade are exposed to graphitization process. Graphitization is conducted in Acheson or LWG (Castner) graphitization furnaces. Graphitization accures at temperature up to 3000 C.

MACHINING

Machining of blank carbon electrodes is performed on the fully automatic line providing high accuracy in geometry.

QUALITY CONTROL

Each production stage ends up with strict quality monitoring whereas machining stage (final step of production) is followed up with 100% quality control of each carbon electrode. Every electrode is marked with its unique ID number.

PACKAGING

Carbon electrodes at Novosibirsk Electrode Plant are securely packed for long distance multi-modal transportation.

Seaworthy packaging: each carbon electrode is wrapped in polyethylene film, stuffed into wooden crates, fastened with steel bands, protected at both ends with plywood shields and placed onto wooden pallets,

By buyer's request light packaging can be arranged.