The core equipment for producing graphitized petroleum coke is the continuous graphitization furnace. Its technological advantages and process characteristics have made it the mainstream choice in the industry, as detailed below:
I. The Core Position of Continuous Graphitization Furnaces
1. Process Principle
Continuous graphitization furnaces transform the carbon molecules in petroleum coke from a disordered arrangement into a hexagonal, uniformly arranged lattice structure through high-temperature (approximately 3000°C) and electrical treatment. This process endows petroleum coke with higher electrical conductivity and thermal stability, making it an excellent carbon additive and raw material for graphite electrodes.
2. Industry Comparison Advantages
- Traditional Acheson Furnace: It requires batch loading, heating, and cooling, resulting in high energy consumption and long cycle times (about 15-20 days). Additionally, it necessitates substantial amounts of insulating materials (such as coke) for filling, leading to high costs and low efficiency.
- Continuous Graphitization Furnace: It enables continuous feeding, graphitization, and discharging of raw materials, with a single furnace capable of producing 50-100 tons per day. Energy consumption is reduced by 30%-50%, and no filling material is required, minimizing waste generation.
II. Technological Characteristics of Continuous Graphitization Furnaces
1. High Efficiency and Energy Conservation
The furnace body employs a multi-layer insulation structure (e.g., carbon felt, graphite felt) to minimize heat loss, elevating thermal efficiency to over 80%. The resistance heating system provides precise temperature control, preventing local overheating or underheating and ensuring stable graphitization quality.
2. Automated Control
Equipped with a PLC control system, it continuously monitors parameters such as temperature, pressure, and current, automatically adjusting heating power and feeding speed. Remote monitoring capabilities support fault alerts and process optimization, reducing manual intervention.
3. Environmental Performance
The enclosed furnace design reduces dust and exhaust emissions, while integrated desulfurization and dust removal units meet environmental standards. A waste heat recovery system utilizes exhaust heat to preheat raw materials, further lowering energy consumption.
III. Core Equipment Components and Functions
1. Furnace Structure
- Heating Zone: Composed of graphite electrodes or resistance wires, it provides a high-temperature environment.
- Insulation Layer: Utilizes carbon felt or graphite felt to minimize heat loss.
- Feeding System: Screw conveyors or vibrating feeders ensure continuous and uniform raw material supply.
- Discharging System: Water-cooled or air-cooled devices rapidly cool graphitized products to prevent oxidation.
2. Auxiliary Equipment
- Crushing and Screening Machine: Breaks raw petroleum coke into 1-6mm particles to ensure uniform heating.
- Dust Removal System: Bag filters or electrostatic precipitators collect dust and purify exhaust gases.
- Control System: PLC or DCS systems enable fully automated operation throughout the process.
IV. Application Cases and Economic Benefits
1. Domestic Typical Projects
A company adopted a continuous graphitization furnace to produce graphitized petroleum coke carbon additives, achieving a daily output of 80 tons per furnace. Electricity consumption per ton dropped from 6000 kWh in traditional furnaces to 3500 kWh, saving over ten million yuan in annual electricity costs. The product’s fixed carbon content is ≥98.5%, and sulfur content is ≤0.05%, reaching international advanced standards and replacing imported products.
2. International Development Trends
Continuous graphitization technology is widely adopted in Europe and the United States, paired with intelligent control systems for unmanned production. Japanese companies have optimized furnace structures to control graphitization temperature uniformity within ±5°C, enhancing product consistency.
V. Selection Recommendations
1. Capacity Matching
Choose furnace size based on market demand: small furnaces (10-30 tons/day) are suitable for R&D or small-scale production, while large furnaces (over 50 tons/day) are ideal for industrial-scale production.
2. Technical Parameters
- Maximum Temperature: ≥3000°C (to ensure complete graphitization).
- Temperature Uniformity: ≤±10°C (to prevent local overburning or underburning).
- Energy Consumption: ≤3500 kWh/ton (below the industry average).
3. Supplier Selection
Prioritize manufacturers with proven track records and strong after-sales support, such as certain domestic heavy industry and machinery companies. Their equipment has passed ISO certification and has been exported to Southeast Asia and Europe.
Post time: Sep-02-2025