In the production process of graphite electrodes, energy consumption issues can be addressed through comprehensive measures, including optimizing process flows, enhancing energy utilization efficiency, strengthening equipment management, and adopting energy-saving technologies. The specific solutions are as follows:
I. Optimizing Raw Material Calcination and Baking Processes
Raw Material Pretreatment Optimization
During the calcination stage, controlling the temperature (1,250-1,350°C) and duration reduces residual volatiles, improves the thermal stability of raw materials, and lowers subsequent baking energy consumption. For instance, replacing traditional pot furnaces with rotary kilns or electric calcination furnaces can enhance thermal efficiency by 10%-15%.
In the baking process, secondary baking or multiple impregnations (e.g., three impregnations and four bakings) fill pores, reduce the porosity of finished products, and enhance bulk density and mechanical strength, thereby lowering unit product energy consumption.
Impregnation Process Improvement
In the impregnation stage, optimizing asphalt injection pressure (1.2-1.5 MPa) and temperature (180-200°C) improves impregnation weight gain rates (≥14% for the first impregnation and ≥9% for the second), reducing the number of repeated bakings and indirectly lowering energy consumption.
II. Upgrading Graphitization Treatment Technologies
High-Temperature Heat Treatment Optimization
During graphitization, replacing traditional Acheson furnaces with internal heat series-connected (LWG) furnaces shortens power-on time (9-15 hours for LWG furnaces vs. 50-80 hours for Acheson furnaces) and reduces electricity consumption by 30%-50%.
Precisely controlling graphitization temperature (2,300-3,000°C) avoids energy waste from overheating while ensuring the conversion of carbon structures into three-dimensionally ordered graphite crystals, enhancing electrical conductivity.
Waste Heat Recovery and Utilization
During the cooling phase of graphitization furnaces, waste heat is recovered for raw material preheating or hot water production, reducing auxiliary energy consumption. For example, one enterprise saved over 500,000 cubic meters of natural gas annually through a waste heat recovery system.
III. Strengthening Production Equipment and Energy Management
Equipment Energy Efficiency Enhancement
Selecting high-efficiency extruders, screw extruders, and other forming equipment reduces mechanical friction losses; adopting variable frequency drive technology to control motor speeds matches production loads and minimizes idle energy consumption.
Regular maintenance of key equipment, such as baking and graphitization furnaces, ensures airtightness and reduces heat loss. For instance, upgrading furnace insulation layers can lower single-furnace energy consumption by 8%-12%.
Energy Monitoring and Optimization
Deploying an Energy Management System (EMS) enables real-time monitoring of electricity, gas, and heat consumption across processes, optimizing production plans through data analysis. For example, dynamically adjusting baking furnace loading based on order demand avoids “over-sizing” scenarios.
Implementing peak-valley electricity pricing strategies schedules high-energy-consuming processes (e.g., graphitization) during off-peak periods to reduce electricity costs.
IV. Promoting Energy-Saving Technologies and Clean Energy
Low-Temperature Forming Technology Application
Replacing traditional high-pressure forming with low-temperature or isostatic pressing technologies reduces heating energy consumption. For example, one enterprise lowered energy consumption per ton of electrode forming by 20% through low-temperature forming processes.
Clean Energy Substitution
Gradually introducing natural gas and biomass fuels instead of coal in calcination and baking processes reduces carbon emissions and energy costs. Some enterprises have achieved over 60% natural gas usage, cutting annual CO₂ emissions by over 10,000 tons.
Waste Heat Power Generation and Green Electricity Procurement
Utilizing waste heat from graphitization furnaces for power generation meets partial production electricity demands; procuring green electricity (e.g., wind or solar power) reduces reliance on fossil fuels and enables low-carbon production.
V. Implementing Full-Process Energy-Saving Management
Production Plan Optimization
Consolidating similar processes (e.g., centralized impregnation and baking) reduces equipment start-stop cycles and lowers standby energy consumption. For example, one enterprise saved over 2 million kWh of electricity annually through production scheduling optimization.
Employee Energy-Saving Training
Regularly conducting energy-saving operation training enhances employee awareness. For instance, standardizing equipment start-up/shutdown procedures and optimizing material handling routes can cumulatively reduce energy consumption by 5%-8%.
Case References
- A Large Graphite Electrode Enterprise: By upgrading to LWG graphitization furnaces, deploying an EMS system, and substituting coal with natural gas, the enterprise reduced comprehensive energy consumption by 35%, decreased unit product carbon emissions by 40%, and saved over $7 million in annual costs.
- Industry Benchmark Practices: Some enterprises have achieved “near-zero carbon” production through waste heat recovery and green electricity procurement models, aligning with global carbon neutrality trends and enhancing market competitiveness.
Post time: Aug-11-2025