Composite environmental protection electrode, production mold, manufacturing method and application of such an electrode
By adopting the design of composite environmentally friendly electrodes, and using structures such as axial reinforcement strips, radial positioning rings and carbon fiber strips, the problems of energy consumption and environmental pollution during production and use of traditional electrodes are solved, achieving high conductivity, low failure rate and significant energy-saving effects.
Patent Information
- Application Number
- CN202211519583.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2022-11-30
- Publication Date
- 2025-06-17
- Estimated Expiration
- 2042-11-30
AI Technical Summary
Traditional carbon electrodes and graphite electrodes consume a lot of energy during production and emit a large amount of carbon dioxide. During use, volatile harmful gases are discharged unorganized, causing harm to the environment and human health. At the same time, there are harmful elements in the electrode itself, affecting product quality.
The composite environmentally friendly electrode is adopted, including a base body, a first electrode reinforcement body and a second electrode reinforcement body arranged in the base body. The conductivity and stability of the electrode are improved through structures such as an axial reinforcement strip, a radial positioning ring, and an axial reinforcement, and the performance of the electrode is entangled by a carbon fiber strip.
It improves the conductivity of the electrode, saves electricity by 4-6%, reduces the electrode failure rate by 60-80%, reduces the energy consumption in the manufacturing process, achieves 99% energy-saving effect, and improves product quality.
Smart Images
Figure CN115854723B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the field of metallurgical technology, and relates to electrodes for submerged arc furnaces and refining furnaces, and particularly relates to a composite environmental protection electrode, a production mold, a manufacturing method and an application of such an electrode. Background Art
[0002] Traditional refining furnaces use graphite electrodes, and submerged arc furnaces mainly use self-baking electrodes and carbon electrodes. The basic materials are mainly anthracite, calcined petroleum coke, pitch, coke fines, graphite powder, carbon powder and return materials as raw materials.
[0003] The manufacturing process of graphite electrodes is as follows: calcination of petroleum coke (needle coke) - crushing, screening and batching - adding pitch binder for kneading - forming - adding filler metallurgical coke particles for roasting - impregnation in impregnating agent pitch - roasting again - adding resistance material and moisture-proof material, graphitization - machining - finished product inspection and packaging.
[0004] The difference between the production process flows of carbon electrodes and graphite electrodes is that carbon electrodes do not undergo graphitization treatment.
[0005] Self-baking electrodes use electrode paste as raw materials and are baked and formed in the application site, i.e., inside the submerged arc furnace.
[0006] The biggest problems existing in the production processes of carbon electrodes and graphite electrodes are as follows:
[0007] 1. Using carbon materials as raw materials, a large amount of energy is consumed in the production process, and a large amount of carbon dioxide is discharged. Taking graphite electrodes as an example, 3.663 tons of carbon dioxide are discharged per ton of production;
[0008] 2. The transportation distance from the electrode production enterprise to the user is long, the logistics cost is high, energy is consumed, and the environment is affected;
[0009] 3. A large amount of volatile harmful gases (nitrogen, hydrogen, methane, hydrogen sulfide, carbon dioxide, etc.) are emitted without organization during use, which is harmful to the physical health of the workers on the working posts and seriously pollutes the environment at the same time;
[0010] 4. The electrode itself contains relatively high concentrations of harmful elements such as phosphorus and sulfur, which pollute the target products of the submerged arc furnace and affect the product quality;
[0011] 5. The self-baking electrodes commonly used by each production enterprise often have hard breaks and soft breaks during use, which are particularly harmful to the smooth operation of the furnace condition. According to the statistical data of the practical experience of the factory, if medium electrode accidents occur twice a month, the unit power consumption of the product will increase by 10 - 30%. Taking an enterprise with an annual output of 100,000 tons of ferromanganese silicon alloy as an example, the energy consumption will increase by 10,000 - 30,000 tons of standard coal in a year;
[0012] 6. High resistivity results in large power loss. The resistivity of carbon electrodes is usually (10 - 90)×10 -6 Ω·m, and the power loss on the electrodes usually reaches 5 - 10%. SUMMARY OF THE INVENTION
[0013] The object of the present invention is to address the problems existing in the above-mentioned prior art, and provide a composite environmental protection electrode, a production mold, a production method and an application of such an electrode, which can meet the usage requirements of ferromanganese-silicon alloy, ferromanganese, ferrochrome and red mud smelting in electric arc furnaces, play the role of replacing traditional graphite electrodes, self-baking electrodes and carbon electrodes, and can achieve the effects of reducing costs, improving product quality and saving energy and reducing emissions.
[0014] The technical solution for achieving the object of the present invention is as follows:
[0015] A composite environmental protection electrode includes a matrix and a first electrode reinforcing body and a second electrode reinforcing body arranged in the matrix;
[0016] The matrix is made of alloy material and is in the shape of a cylindrical tube; the material components of the matrix are the same as those of the alloy material produced by the smelting equipment using this composite environmental protection electrode;
[0017] The first electrode reinforcing body includes:
[0018] Axial reinforcing bars, the axial reinforcing bars are columnar in shape; multiple axial reinforcing bars are axially evenly distributed in the matrix, and the outer sides of the axial reinforcing bars are flush with the outer side of the matrix;
[0019] Radial positioning rings, the radial positioning rings are annular in shape, and a plurality of radial positioning rings are axially arranged in the matrix, and the planes of the radial positioning rings are perpendicular to the axis of the matrix; the radial positioning rings are in contact with and integrated with the axial reinforcing bars;
[0020] One end of the axial reinforcing bar is flush with one end face of the matrix, and a long slot hole for abutting against the axial reinforcing bar is provided at one end of the matrix; the other end of the axial reinforcing bar protrudes 50 - 100 mm from the other end face of the matrix; the function of the slot hole is to allow the axial reinforcing bar protruding from the end face of another electrode to be inserted into the slot hole, so that the axial reinforcing bars of the two electrodes are close together, and then the axial reinforcing bars of the two electrodes are welded firmly by electric welding to prevent the two electrodes from separating from each other during use;
[0021] The second electrode reinforcing body includes:
[0022] Axial reinforcing members, the axial reinforcing members are in the shape of a cylindrical tube; the axis of the axial reinforcing members is concentric with the matrix; the function of the central through hole of the cylindrical tube-shaped axial reinforcing member is to pass a cooling medium during use to cool the electrode;
[0023] Radial positioning bars, the radial positioning bars are cylindrical; the number of radial positioning bars in each layer is the same as the number of axial reinforcing bars, and the radial positioning bars in the same layer are radially arranged in the matrix; one end of each radial positioning bar in the same layer is integrated with the axial reinforcing member, and the other end of the radial positioning bar is integrated with the corresponding axial reinforcing bar; multiple layers of radially arranged radial positioning bars are axially arranged in the matrix;
[0024] One end of the axial reinforcing member protrudes from one end face of the matrix, and this end face is the end face where the axial reinforcing bar is flush with the matrix.
[0025] Further, it includes carbon fiber bars, and carbon fiber bars are wound on the surface of the axial reinforcing bars.
[0026] Carbon fiber bars are wound on the surface of the radial positioning ring.
[0027] Carbon fiber bars are wound on the surface of the radial positioning bars.
[0028] Carbon fiber bars are wound on the surface of the axial reinforcing member.
[0029] Further, external threads are provided on the outer side of the end of the axial reinforcing member protruding from the end face of the matrix; internal threads are provided on the inner side of the other end of the axial reinforcing member, and the types and nominal dimensions of the external threads and the internal threads are the same.
[0030] The production mold for preparing the above-mentioned composite environmental protection electrode includes a mold body, a bottom mold and an upper mold;
[0031] The mold body is in the shape of a hollow cylinder, with a cylindrical through-hole in the middle of the mold body. The diameter of the cylindrical through-hole is the same as the diameter of the matrix, the length of the mold body is the same as the length of the matrix, the weight of the mold body is 5-10 times the weight of the matrix, and the mold body is divided into two along the diameter direction;
[0032] The bottom mold is cylindrical, and its outer contour size is larger than the size of the cylindrical through-hole of the mold body. The thickness of the bottom mold is not less than 50 mm. Several blind holes for inserting axial reinforcing bars are opened in the thickness direction. The number of blind holes is the same as the number of axial reinforcing bars. The diameter of the blind holes is larger than the diameter of the axial reinforcing bars. The depth of the blind holes is equal to the length of the axial reinforcing bars minus the height of the mold body. A bottom mold boss is provided on the plane of the bottom mold with blind holes, and the size of the bottom mold boss is slightly smaller than the size of the cylindrical through-hole of the mold body;
[0033] The outer contour size of the upper mold matches the outer diameter of the mold body. A circular upper mold boss is provided on one face of the upper mold. The diameter of the upper mold boss is slightly smaller than the diameter of the cylindrical through-hole of the mold body. Fixing rods with the same number as the blind holes in the bottom mold are arranged on the circumference of the upper mold boss. The diameter of the fixing rods is larger than the diameter of the axial reinforcing bars; a through-hole is provided in the center of the upper mold, and the diameter of the through-hole in the upper mold is larger than the outer diameter of the axial reinforcing member and smaller than the diameter of the upper mold boss.
[0034] The manufacturing method of the above composite environmental protection electrode, including the above production mold, the manufacturing method includes the following steps:
[0035] S1. Prepare the first electrode reinforcing body:
[0036] S1-1. Prepare the axial reinforcing bar:
[0037] Cut circular metal bars with a diameter of 10-50 mm into metal bars with a length equal to the length of the base plus 50 mm - 200 mm, and the number is M, where M is an integer greater than 2;
[0038] S1-2. Prepare the radial positioning ring:
[0039] Bend a metal round bar into a ring on a circular mold to obtain the radial positioning ring, and the number is N, where N is an integer greater than 2;
[0040] S1-3. Weld the first electrode reinforcing body:
[0041] Place the bottom mold horizontally with the side having blind holes facing up, insert the axial reinforcing bars one by one into the blind holes of the bottom mold, then place 1 radial positioning ring horizontally on the upper surface of the bottom mold so that the radial positioning ring and the bottom mold are concentric, and then fix the axial reinforcing bar and the radial positioning ring into one body. By analogy, fix the remaining radial positioning rings to the axial reinforcing bar one by one, and the distance between adjacent radial positioning rings is 200 - 500 mm;
[0042] S2. Prepare the second electrode reinforcing body:
[0043] S2-1. Prepare the axial reinforcing member:
[0044] Take 1 circular metal tube with a diameter of 50 mm - 300 mm, cut it into a length equal to the sum of the length of the mold body and the length of the upper mold plus 100 - 200 mm, and fill refractory material in the tube;
[0045] S2-2. Prepare the radial positioning bar:
[0046] Cut a long metal bar into M metal bars as the radial positioning bars, and the length of the radial positioning bars is equal to the difference between the outer diameter of the radial positioning ring and the outer diameter of the axial reinforcing member divided by;
[0047] S2-3. Weld the second electrode reinforcing body and weld it to the first electrode reinforcing body as one body:
[0048] Vertically place the axial reinforcement member made in S2-1 at the center of the first electrode reinforcement body obtained in S1. The bottom end of the axial reinforcement member is flush with the plane of the bottom die boss of the bottom die, and the top end of the axial reinforcement member protrudes 100-200 mm above the upper plane of the upper die. Then, fix one end of a radial positioning bar integrally with the outer surface of the axial reinforcement member, and fix the other end of the radial positioning bar integrally with the axial reinforcement bar. Keep the radial positioning bar perpendicular to the axis. By analogy, connect the remaining radial positioning bars to the axial reinforcement member and the axial reinforcement bar. The adjacent radial positioning bars in the axial direction are spaced 200-500 mm apart.
[0049] S2-4, after S2-3 is completed, wind carbon fiber strips on the surfaces of the axial reinforcement bars, axial reinforcement members, radial positioning rings, and radial positioning bars.
[0050] S3, spray the cylindrical through-hole of the die body with a release agent twice.
[0051] S4, install the die body, vertically place the die body on the bottom die, ensure that the bottom die boss is completely inserted into the cylindrical through-hole of the die body, and then fix the bottom die and the die body together.
[0052] S5, install the upper die, install the side of the upper die with the upper die boss facing down on the upper plane of the die body, ensure that the upper die boss is completely inserted into the cylindrical through-hole of the die body, the fixing rod on the upper die boss abuts against the axial reinforcement bar, and then fix the upper die and the die body together.
[0053] S6, heat the entire production die to 200 °C and keep it warm for 2 h.
[0054] S7, inject the matrix alloy liquid into the model obtained in S6:
[0055] Slowly inject the matrix alloy liquid produced by the melting equipment using this composite environmental protection electrode into the inner cavity of the model obtained in S6 through the through-hole of the upper die. After filling, continuously supplement the alloy liquid as the temperature drops and the alloy liquid shrinks until the alloy liquid solidifies. The composition of the alloy liquid is the same as that of the alloy produced by the melting equipment using this electrode.
[0056] S8, demold 24 h after the completion of S7 process, and obtain the required composite environmental protection electrode after finishing and removing the refractory material in the inner cavity of the axial reinforcement member.
[0057] Further, it includes S9, machine an external thread on the outside of the end of the axial reinforcement member protruding from the matrix end face; machine an internal thread on the inside of the other end of the axial reinforcement member. The systems and nominal dimensions of the external thread and the internal thread are the same.
[0058] In S2-1, the components of the refractory material are composed of quartz sand: bentonite: water = 100: (3-10): (5-10) by weight ratio. After mixing the components evenly, it can be used.
[0059] In S3, the components of the mold release agent are composed of water: bentonite: dust removal powder: graphite powder: polyacrylamide = 100:(5 - 20):(1 - 30):(1 - 10):(1 - 15) by weight proportion. After mixing all components evenly, it can be used.
[0060] The application of the above-mentioned composite environmental protection electrode in submerged arc furnace, refining furnace, electroslag furnace or red mud smelting furnace.
[0061] Advantages or beneficial effects of the present invention:
[0062] The conductivity of this composite environmental protection electrode is 5 - 10 times higher than that of traditional carbon electrodes, and users can save 4 - 6% of electricity; using this composite environmental protection electrode can reduce the electrode failure rate by 60 - 80%;
[0063] The manufacturing process of this composite environmental protection electrode is short. Using the alloy liquid produced by the electric furnace itself, it is directly cast into electrode products, reducing dozens of processes and the long logistics transportation process in the manufacturing of traditional carbon electrodes; the energy consumption during the manufacturing process tends to zero, and it is 99% more energy-efficient than the manufacturing of traditional carbon electrodes. Brief description of the drawings
[0064] Figure 1 Schematic structural diagram of the composite environmental protection electrode for a 1000 kVA refining low-carbon ferromanganese electric furnace in Example 1;
[0065] Figure 2 For Figure 1 Schematic cross-sectional view in the direction of A - A in
[0066] Figure 3 For Figure 1 Schematic cross-sectional view in the direction of B - B in
[0067] Figure 4 For Figure 1 Schematic cross-sectional view in the direction of C - C in
[0068] Figure 5 Schematic cross-sectional structure diagram of the die body in the production mold of the example;
[0069] Figure 6 For Figure 5 Schematic cross-sectional structure view in the direction of A - A in
[0070] Figure 7 Schematic structure diagram of the bottom mold in the production mold of the example;
[0071] Figure 8 For Figure 7 Schematic cross-sectional structure diagram of
[0072] Figure 9 Schematic structure diagram of the upper mold in the production mold of the example;
[0073] Figure 10 is Figure 9 the schematic cross-sectional structure diagram of
[0074] Figure 11 the schematic structure diagram of the composite environmental protection electrode for a 12000 kVA electroslag furnace in Example 2;
[0075] Figure 12 is Figure 11 the schematic cross-sectional view in the A-A direction of
[0076] Figure 13 is Figure 11 the schematic cross-sectional view in the B-B direction of
[0077] Figure 14 is Figure 11 the schematic cross-sectional view in the C-C direction of
[0078] In the figure, 1. matrix, 2. axial reinforcement bar, 3. radial positioning ring, 4. slot hole, 5. carbon fiber bar, 6. die body, 7. cylindrical through hole, 8. bottom die, 9. blind hole, 10. bottom die boss, 11. upper die, 12. upper die boss, 13. upper die through hole, 14. fixing rod, 15. axial reinforcement member, 16. radial positioning bar, 17. external thread, 18. internal thread. Specific embodiments
[0079] The following further elaborates on the content of the present invention in conjunction with the embodiments and the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of them. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.
[0080] Example 1:
[0081] As Figures 1-4 shown, this embodiment provides a composite environmental protection electrode for a 1000 kVA refined low-carbon ferromanganese electric furnace and its production method.
[0082] A composite environmental protection electrode includes a matrix 1 and a first electrode reinforcement body and a second electrode reinforcement body arranged in the matrix 1;
[0083] The matrix 1 is made of alloy material, in the shape of a cylindrical tube, with a length of 2000 mm and a diameter of Ø200 mm; the weight percentage components of the matrix 1 are Mn 80 - 95%, Si 0.5 - 5%, C 0.1 - 0.7%, the balance being Fe and a small amount of impurity elements, and the material components of the matrix 1 are the same as those of the alloy material produced by the refining electric furnace using this electrode;
[0084] The first electrode reinforcement body includes
[0085] Axial reinforcement bars 2, the axial reinforcement bars 2 are made of metal; in a columnar shape; multiple axial reinforcement bars 2 are axially evenly distributed in the matrix 1, and the outer side of the axial reinforcement bars 2 is flush with the outer side of the matrix 1, and the number of axial reinforcement bars 2 is 8; the axial reinforcement bars 2 are made of 20 ＃ round steel with a diameter of Ø20mm, evenly distributed on a pitch circle of Ø180mm, and its length is 2050mm;
[0086] Radial positioning rings 3, the radial positioning rings 3 are made of metal, in a ring shape, multiple radial positioning rings 3 are arranged at intervals along the longitudinal axis of the matrix 1, and the plane of the radial positioning rings 3 remains perpendicular to the longitudinal axis of the matrix 1; the outer side of the radial positioning rings 3 is in contact with and integrated with the axial reinforcement bars 2; the number of radial positioning rings 3 is 8, made of 20 ＃ round steel with a diameter of Ø16mm;
[0087] One end of the axial reinforcement bar 2 is flush with one end face of the matrix 1, and 8 long slot holes 4 for abutting against the axial reinforcement bar 2 are provided at one end of the matrix 1; the other end of the axial reinforcement bar 2 protrudes 50mm from the other end face of the matrix 1;
[0088] The second electrode reinforcement body includes:
[0089] Axial reinforcement member 15, the axial reinforcement member 15 is made of metal, in a cylindrical tubular shape; the axis of the axial reinforcement member 15 is concentric with the matrix 1;
[0090] Radial positioning bars 16, the radial positioning bars 16 are made of metal, in a cylindrical shape; the number of radial positioning bars 16 in each layer is the same as the number of axial reinforcement bars 2, and the radial positioning bars 16 in the same layer are radially arranged in a radial pattern in the matrix 1; one end of each radial positioning bar 16 in the same layer is welded to the axial reinforcement member 15 as a whole, and the other end is welded to the corresponding axial reinforcement bar 2; 8 layers of radially arranged radial positioning bars 16 are axially equally spaced in the matrix 1;
[0091] One end of the axial reinforcement member 15 protrudes from one end face of the matrix 1, and this end face is the end face where the axial reinforcement bar 2 is flush with the matrix 1.
[0092] It includes carbon fiber strips 5, and the surfaces of the axial reinforcement bars 2, radial positioning rings 3 and axial reinforcement members 15 are wound with carbon fiber strips 5.
[0093] External threads are provided on the outer side of the end of the axial reinforcement member 15 protruding from the end face of the matrix 1; internal threads are provided on the inner side of the other end of the axial reinforcement member 15, and the systems and nominal dimensions of the external thread 17 and the internal thread 18 are the same. The function of setting the internal and external threads is to facilitate the tight connection of two electrodes through the threads and ensure the smooth conduction of current.
[0094] The production mold of the composite environmental protection electrode in this embodiment includes a mold body 6, a bottom mold 8 and an upper mold 11, which are cast from gray cast iron;
[0095] As Figure 5 Figure 6 As shown, the mold body 6 is in the shape of a hollow cylinder, with a cylindrical through hole 7 in the middle. The diameter of the cylindrical through hole 7 is the same as that of the base body 1, and the length of the mold body 6 is the same as that of the base body 1. The weight of the mold body 6 is 5 - 10 times that of the base body 1. The mold body 6 is divided into two along the diameter direction;
[0096] In this embodiment, the diameter of the cylindrical through hole 7 in the middle of the mold body 6 is Ø200mm, and the outer diameter of the mold body is Ø700mm;
[0097] As Figure 7 Figure 8 As shown, the bottom mold 8 is cylindrical, and its outer contour size is larger than the size of the cylindrical through hole 7 of the mold body. The thickness of the bottom mold 8 is not less than 50mm. There are 8 blind holes 9 in the thickness direction for inserting the axial reinforcing bars 2. The number of blind holes 9 is the same as that of the axial reinforcing bars 2. The diameter of the blind holes 9 is larger than that of the axial reinforcing bars 2. The depth of the blind holes 9 is equal to the result obtained by subtracting the height of the mold body 6 from the length of the axial reinforcing bars 2. There is a circular bottom mold boss 10 on the plane of the bottom mold 8 provided with the blind holes 9. The size of the bottom mold boss 10 is slightly smaller than the size of the cylindrical through hole 7 of the mold body;
[0098] In this embodiment, the outer diameter of the bottom mold 8 is Ø700mm, the thickness is 150mm, the diameter of the bottom mold boss 10 is Ø198mm, and there are 8 Ø22mm blind holes 9 evenly distributed on the Ø180mm pitch circle of the bottom mold boss 10. The depth of the blind holes 9 is 50mm;
[0099] As Figure 9 Figure 10 As shown, the outer contour size of the upper mold 11 matches the outer diameter of the mold body 6. There is a circular upper mold boss 12 on one surface of the upper mold 11. The diameter of the upper mold boss 12 is slightly smaller than the diameter of the cylindrical through hole 7 of the mold body. There are fixing rods 14 with the same number as the bottom mold blind holes 9 distributed on the circumference of the upper mold boss 12. The fixing rods 14 are square rods or circular rods. The contour size of the square rod or the diameter of the circular rod is larger than the diameter of the axial reinforcing bars 2. The fixing rods 14 are used to form the slot holes 4; there is an upper mold through hole 13 in the center of the upper mold 11;
[0100] In this embodiment, the outer diameter of the upper mold 11 is Ø700mm, the diameter of the upper mold boss 12 is Ø198mm, and there are 8 fixing rods 14 with a cross-section of 35×35mm evenly distributed on the Ø180mm pitch circle of the upper mold boss 12. Square high-temperature resistant metal rods are used. The diameter of the upper mold through hole 13 is Ø150mm, and the thickness of the upper mold is 150mm.
[0101] The manufacturing method of the composite environmental protection electrode, including the above production mold, the manufacturing method comprises the following steps:
[0102] Step 1), preparing the first electrode reinforcement:
[0103] Step 1-1), preparing the axial reinforcement bar 2:
[0104] Using 20 ＃ Round steel to make 8 axial reinforcement bars 2 with a diameter of Ø20mm and a length of 2050mm;
[0105] Step 1-2), making the radial positioning ring 3:
[0106] Making 8 radial positioning rings 3 with an outer diameter of Ø180mm bent from 20 ＃ Round steel;
[0107] Step 1-3), welding the first electrode reinforcement:
[0108] Horizontally place the bottom mold 8 on a thick plane, with the side of the bottom mold 8 having the blind hole 9 facing up. Insert the axial reinforcement bars 2 one by one into the blind holes 9 of the bottom mold 8, then horizontally place 1 radial positioning ring 3 on the upper surface of the bottom mold 8, making the radial positioning ring 3 and the bottom mold 8 concentric. Then, use an electrode to weld the axial reinforcement bars 2 and this radial positioning ring 3 together. By analogy, weld the remaining radial positioning rings to the axial reinforcement bars one by one, with a distance of 250mm between adjacent radial positioning rings.
[0109] Step 2), preparing the second electrode reinforcement:
[0110] Step 2-1), preparing the axial reinforcement member 15:
[0111] Cut 1 seamless steel pipe with a diameter of Ø80×20×2200mm, and fill refractory material in the pipe. The components of the refractory material are mixed by weight ratio of quartz sand: bentonite: water = 100: 3: 5. After stirring evenly, it can be used;
[0112] Step 2-2), preparing the radial positioning bar 16:
[0113] Cut 64 round steel metal bars with a diameter of Ø20×40mm as the radial positioning bars 16;
[0114] Step 2-3), welding the second electrode reinforcement and welding it to the first electrode reinforcement as a whole:
[0115] Vertically place the axial reinforcement member 15 obtained in step 2-1) at the center of the first electrode reinforcement body obtained in step 1). The bottom end of the axial reinforcement member 15 is flush with the plane of the bottom die boss 10 of the bottom die 8, and the top end of the axial reinforcement member 15 is 100-200 mm higher than the upper plane of the upper die 11. Then, weld one end of a radial positioning bar 16 obtained in step 2-2) to the outer surface of the axial reinforcement member 15, and weld the other end of the radial positioning bar 16 to the corresponding axial reinforcement bar 2, keeping the radial positioning bar 16 perpendicular to the axis. By analogy, weld all the remaining radial positioning bars. The adjacent radial positioning bars in the axial direction are 250 mm apart.
[0116] Step 2-4), after the end of step 2-3), wind carbon fiber strips 5 on the surfaces of the axial reinforcement bars 2, axial reinforcement member 15, radial positioning rings 3 and radial positioning bars 16.
[0117] Step 3), spray the cylindrical through hole 7 of the die body with a release agent twice. The release agent composition is composed of water: bentonite: dust removal powder: graphite powder: polyacrylamide = 100:5:1:5:3 by weight. After mixing, stir evenly and then it can be used.
[0118] Step 4), install the die body. Vertically place the die body 6 on the bottom die 8 to ensure that the bottom die boss 10 is completely inserted into the cylindrical through hole 7 of the die body, and then fix the bottom die 8 and the die body 6 together as a whole.
[0119] Step 5), install the upper die. Install the upper die 11 with the side having the upper die boss 12 facing down on the upper plane of the die body 6 to ensure that the upper die boss 12 is completely inserted into the cylindrical through hole 7 of the die body. The fixing rod 14 on the upper die boss 12 abuts against the axial reinforcement bar 2, and then fix the upper die 11 and the die body 6 together.
[0120] Step 6), heat the whole production die to 200 °C and keep it warm for 2 h.
[0121] Step 7), inject the matrix alloy liquid into the model obtained in step 6):
[0122] Slowly inject the matrix alloy liquid produced by the refining electric furnace into the inner cavity of the model obtained in step 6) through the upper die through hole 13. When injecting the alloy liquid, prevent the liquid from directly flushing the axial reinforcement member 15. After filling, continuously supplement the alloy liquid as the alloy liquid shrinks until the alloy liquid solidifies. The composition of the alloy liquid is the same as that of the alloy produced by the refining electric furnace using this electrode. For example, the weight percentage composition of the alloy liquid is 80% manganese, 1% silicon, 17% iron, 1.5% carbon, and the balance is impurities.
[0123] Step 8), demold 24 h after the end of the process in step 7), finish machining, and remove the refractory material in the inner cavity of the axial reinforcement member 15.
[0124] Step 9), at one end of the axial reinforcement 15 protruding from the end face of the base body 1, an external thread 17 is machined by a lathe; at the other end of the axial reinforcement 15, an internal thread 18 is machined by a lathe, and the specifications and nominal dimensions of the external thread 17 and the internal thread 18 are the same.
[0125] Example 2:
[0126] As Figures 11-14 shown, this embodiment provides a composite environmental protection electrode for a 12000 kVA refining furnace and its production method.
[0127] A composite environmental protection electrode includes a base body 1 and a first electrode reinforcement and a second electrode reinforcement arranged in the base body 1;
[0128] The base body 1 is made of alloy material and is in the shape of a cylindrical tube; the length of the base body 1 is 2000 mm and the diameter is Ø500 mm; the material components of the base body 1 are the same as those of the ferromanganese alloy produced by this refining furnace, and the weight percentage components of the base body 1 are Fe 80 - 88%; Mn 10 - 15%, C 2 - 4%;
[0129] The first electrode reinforcement includes:
[0130] Axial reinforcement bars 2, the axial reinforcement bars 2 are made of metal material; they are in the shape of columns; the outer sides of the axial reinforcement bars 2 are flush with the outer side of the base body 1; there are 16 axial reinforcement bars 2 in total, which are buried in the entire electrode base body 1, and the axial reinforcement bars 2 are evenly distributed on the outer circumference of the base body 1. The material of the axial reinforcement bars 2 is 10 ＃ round steel with a diameter of Ø30 mm, and the length of the axial reinforcement bars 2 is 2100 mm;
[0131] Radial positioning rings 3, the radial positioning rings 3 are made of metal material and are in the shape of rings. 8 radial positioning rings 3 are arranged axially in the base body 1, and the planes of the radial positioning rings 3 are perpendicular to the axis of the base body 1; the outer sides of the radial positioning rings 3 are in contact with and integrated with the axial reinforcement bars 2;
[0132] One end of the axial reinforcement bar 2 is flush with one end face of the base body 1, and a long slot hole 4 for abutting against the axial reinforcement bar 2 is provided at one end of the base body 1; the other end of the axial reinforcement bar 2 protrudes 100 mm from the other end face of the base body 1;
[0133] The second electrode reinforcement includes:
[0134] Axial reinforcement member 15, the axial reinforcement member 15 is made of metal material; it is in the shape of a cylindrical tube, and the number is 1; the axial reinforcement member 15 is arranged at the center of the base body 1 and is coaxial with the base body 1;
[0135] The radial positioning bars 16 are made of metal and are columnar. Each layer of radial positioning bars 16 is arranged in a radially radiating pattern within the base body 1, and there are 8 radiation layers in total within the base body 1. One end of each radial positioning bar 16 in the same layer is welded integrally with the axial reinforcing member 15, and the other end of the radial positioning bar 16 is welded integrally with the corresponding axial reinforcing bar 2. The 8 layers of radially radiating radial positioning bars 16 are arranged at equal axial intervals within the base body 1.
[0136] One end of the axial reinforcing member 15 protrudes from one end face of the base body 1, and this end face is the end face where the axial reinforcing bar 2 is flush with the base body 1.
[0137] It includes carbon fiber strips 5, and the surfaces of the axial reinforcing bars 2, radial positioning rings 3, axial reinforcing members 15, and radial positioning bars 16 are wound with carbon fiber strips 5.
[0138] The production mold of the composite environmental protection electrode in this embodiment includes a mold body 6, a bottom mold 8, and an upper mold 11, which are cast from gray cast iron.
[0139] As Figure 5 Figure 6 shown, the mold body 6 is in the shape of a hollow cylinder. There is a cylindrical through-hole 7 in the middle of the mold body 6. The diameter of the cylindrical through-hole 7 is the same as the diameter of the base body 1, and the length of the mold body 6 is the same as the length of the base body 1. The weight of the mold body 6 is 5 - 10 times the weight of the base body 1. The mold body 6 is divided into two along the diameter direction.
[0140] In this embodiment, the diameter of the cylindrical through-hole 7 in the middle of the mold body 6 is Ø500mm, and the outer diameter of the mold body 6 is Ø1100mm.
[0141] As Figure 7 Figure 8 shown, the bottom mold 8 is cylindrical, and its outer contour dimensions are larger than the dimensions of the cylindrical through-hole 7 of the mold body 6. The thickness of the bottom mold 8 is not less than 50mm. There are 16 blind holes 9 for inserting the axial reinforcing bars 2 in the thickness direction. The diameter of the blind holes 9 is larger than the diameter of the axial reinforcing bars 2. The depth of the blind holes 9 is equal to the result obtained by subtracting the height of the mold body 6 from the length of the axial reinforcing bars 2. There is a bottom mold boss 10 on the plane of the bottom mold provided with the blind holes 9, and the dimensions of the bottom mold boss 10 are slightly smaller than the dimensions of the cylindrical through-hole 7 of the mold body 6.
[0142] In this embodiment, the outer diameter of the bottom mold 8 is Ø1100mm, the thickness is 100mm, the diameter of the bottom mold boss 10 is Ø498mm, and there are 16 Ø32mm blind holes 9 evenly distributed on the Ø470mm pitch circle of the bottom mold boss 10, and the depth of the blind holes 9 is 50mm.
[0143] As Figure 9 Figure 10As shown, the outer contour dimension of the upper die 11 matches the outer diameter of the die body 6. A circular upper die boss 12 is provided on one surface of the upper die 11. The diameter of the upper die boss 12 is slightly smaller than the diameter of the cylindrical through hole 7 of the die body. Fixed rods 14 equal in number to the blind holes 9 of the bottom die are arranged on the circumference of the upper die boss 12. The fixed rods 14 are square or round rods. The contour dimension of the square rod or the diameter of the round rod is larger than the diameter of the axial reinforcing bar 2. An upper die through hole 13 is provided at the center of the upper die 11.
[0144] In this embodiment, the outer diameter of the upper die 11 is Ø1100mm, the diameter of the upper die boss 12 is Ø498mm, and 16 square high-temperature resistant metal fixed rods 14 with a cross-section of 35×35mm are evenly distributed on the pitch circle of the upper die boss Ø470mm. The diameter of the upper die through hole 13 is Ø70mm.
[0145] The manufacturing method of the composite environmental protection electrode in this embodiment includes the following steps:
[0146] Step a), preparing the first electrode reinforcing body:
[0147] Step a-1), manufacturing the axial reinforcing bar 2:
[0148] Manufacture 16 axial reinforcing bars 2 with Ø30 round steel, and the length of each is 2050mm;
[0149] Step a-2), manufacturing the radial positioning ring 3:
[0150] Manufacture 8 radial positioning rings 3 with an outer diameter of Ø440mm bent from Ø20 round steel. ＃ The radial positioning ring 3 is bent from round steel with a diameter of Ø20.
[0151] Step a-3), welding the first electrode reinforcing body:
[0152] Horizontally place the bottom die 8 on a thick plane, with the side of the bottom die 8 having the blind hole 9 facing up. Insert the axial reinforcing bars 2 one by one into the blind holes 9 of the bottom die 8. Then horizontally place 1 radial positioning ring 3 on the upper surface of the bottom die 8, making the radial positioning ring 3 and the bottom die 8 concentric. Then use an electrode to weld the axial reinforcing bar 2 and this radial positioning ring 3 together. And so on, weld the remaining radial positioning rings 3 to the axial reinforcing bars 2 one by one. The distance between adjacent radial positioning rings is 250mm.
[0153] Step b), preparing the second electrode reinforcing body:
[0154] Step b-1), preparing the axial reinforcing member 15:
[0155] Cut 1 seamless steel pipe with a size of Ø200×20×2200mm, and fill refractory material in the inner cavity of the seamless steel pipe. The components of the refractory material are mixed in a weight ratio of quartz sand: bentonite: water = 100:5:7. After stirring evenly, it can be used.
[0156] Step b-2), manufacturing the radial positioning bars 16:
[0157] Cut 128 Ø20×120 mm round steel bars as the radial positioning bars 16;
[0158] Step b-3), welding the second electrode reinforcement and welding it into one body with the first electrode reinforcement:
[0159] Vertically place the axial reinforcement 15 obtained in step a) at the center of the first electrode reinforcement obtained in step b-1). The bottom end of the axial reinforcement 15 is flush with the plane of the bottom die boss 10 of the bottom die 8, and the top end of the axial reinforcement 15 is 100 - 200 mm higher than the upper plane of the upper die 11. Then weld one end of a radial positioning bar 16 obtained in step b-2) to the outer surface of the axial reinforcement 15, and weld the other end of the radial positioning bar 16 to the corresponding axial reinforcement bar 2, keeping the radial positioning bar 16 perpendicular to the axis. By analogy, weld all the remaining radial positioning bars. The adjacent radial positioning bars in the axial direction are 250 mm apart;
[0160] Step b-4), after step b-3), wind carbon fiber strips 5 on the surfaces of the axial reinforcement bars 2, axial reinforcement 15, radial positioning rings 3 and radial positioning bars 16;
[0161] Step c), spray the cylindrical through hole 7 of the die body with a release agent twice. The release agent composition is composed of water: bentonite: dust removal powder: graphite powder: polyacrylamide = 100:5:5:10:5 by weight. After mixing, stir evenly and then it can be used;
[0162] Step d), install the die body, vertically place the die body 6 on the bottom die 8, ensure that the bottom die boss 10 is completely sleeved in the cylindrical through hole 7 of the die body, and then fix the bottom die 8 and the die body 6 together as one body;
[0163] Step e), install the upper die. Install the side of the upper die 11 with the upper die boss 12 facing down on the upper plane of the die body 6, ensure that the upper die boss 12 is completely sleeved in the cylindrical through hole 7 of the die body, the fixing rod 14 on the upper die boss 12 is close to the axial reinforcement bar 2, and then fix the upper die 11 and the die body 6 together;
[0164] Step f), heat the whole production die to 200 °C and keep it warm for 3 h;
[0165] Step g), inject the matrix alloy liquid into the model obtained in step f);
[0166] Slowly pour the matrix alloy liquid produced by the refining furnace into the inner cavity of the mold obtained in step f) through the upper mold through-hole 13. When pouring the alloy liquid, prevent the liquid from directly flushing the axial reinforcement 15. Continuously supplement the alloy liquid as the alloy liquid shrinks until the alloy liquid solidifies; the components of the alloy liquid are the same as those of the alloy produced by the refining furnace using this electrode. For example, the weight percentage components of the alloy liquid are Fe 85%; Mn 12%, C 2%, and the balance is impurities;
[0167] Step h), demold 24 hours after the completion of the process in step g), finish, and remove the refractory material in the inner cavity of the axial reinforcement 15;
[0168] Step i), on one end of the axial reinforcement 15 protruding from the end face of the matrix 1, machine an external thread 17 through a lathe; on the other end of the axial reinforcement 15, machine an internal thread 18 through a lathe. The systems and nominal dimensions of the external thread 17 and the internal thread 18 are the same.
[0169] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The protection scope of the present invention is defined by the appended claims and their equivalents.
Claims
1. A composite environmental protection electrode, characterized in that, It includes a matrix and a first electrode reinforcing body and a second electrode reinforcing body arranged in the matrix; The matrix is made of alloy material and is in the shape of a cylindrical tube; the material components of the matrix are the same as those of the alloy material produced by the smelting equipment using this composite environmental protection electrode; The first electrode reinforcing body includes: Axial reinforcing bars, the axial reinforcing bars are in the shape of columns; a plurality of axial reinforcing bars are axially distributed in the matrix, and the outer sides of the axial reinforcing bars are flush with the outer side of the matrix; Radial positioning rings, the radial positioning rings are in the shape of rings, and a plurality of radial positioning rings are axially arranged in the matrix, and the plane of the radial positioning rings is perpendicular to the axis of the matrix; the radial positioning rings are in contact with and integrated with the axial reinforcing bars; One end of the axial reinforcing bar is flush with one end face of the matrix, and a long slot hole for abutting against the axial reinforcing bar is provided at one end of the matrix; the other end of the axial reinforcing bar protrudes from the other end face of the matrix; The second electrode reinforcing body includes: Axial reinforcing members, the axial reinforcing members are in the shape of cylindrical tubes; the axis of the axial reinforcing members is concentric with that of the matrix; Radial positioning bars, the radial positioning bars are in the shape of cylinders; the number of radial positioning bars in each layer is the same as the number of axial reinforcing bars, and the radial positioning bars in the same layer are radially arranged in the matrix in a radial manner; at one end of each radial positioning bar in the same layer is integrated with the axial reinforcing member, and the other end of the radial positioning bar is integrated with the corresponding axial reinforcing bar; multiple layers of radially arranged radial positioning bars are axially arranged in the matrix; One end of the axial reinforcing member protrudes from one end face of the matrix, and this end face is the end face where the axial reinforcing bar is flush with the matrix.
2. The composite environmental protection electrode according to claim 1, characterized in that, It includes carbon fiber strips, and carbon fiber strips are wound on the surface of the axial reinforcing bars.
3. The composite environmental protection electrode according to claim 1, characterized in that, It includes carbon fiber strips, and carbon fiber strips are wound on the surface of the radial positioning rings.
4. The composite environmental protection electrode according to claim 1, characterized in that, It includes carbon fiber strips, and carbon fiber strips are wound on the surface of the axial reinforcing members.
5. The composite environmental protection electrode according to claim 1, characterized in that, It includes carbon fiber strips, and carbon fiber strips are wound on the surface of the radial positioning bars.
6. The composite environmental protection electrode according to claim 1, characterized in that, External threads are provided on the outer side of the end of the axial reinforcing member protruding from the matrix end face; internal threads are provided on the inner side of the other end of the axial reinforcing member, and the types and nominal dimensions of the external threads and the internal threads are the same.
7. A production mold for manufacturing the composite environmental protection electrode according to any one of claims 1-6, characterized in that, It includes a die body, a bottom die and an upper die; The die body is in the shape of a hollow cylinder, with a cylindrical through hole in the middle of the die body. The diameter of the cylindrical through hole is the same as the diameter of the matrix, and the length of the die body is the same as the length of the matrix. The weight of the die body is 5-10 times that of the matrix, and the die body is divided into two along the diameter direction; The bottom die is in the shape of a cylinder, and its outer contour dimensions are larger than the dimensions of the cylindrical through hole of the die body. The thickness of the bottom die is not less than 50 mm. Several blind holes for inserting the axial reinforcing bars are opened in the thickness direction. The number of blind holes is the same as the number of axial reinforcing bars. The diameter of the blind holes is larger than the diameter of the axial reinforcing bars. The depth of the blind holes is equal to the length of the axial reinforcing bars minus the height of the die body. A bottom die boss is provided on the plane of the bottom die with blind holes, and the dimensions of the bottom die boss are slightly smaller than the dimensions of the cylindrical through hole of the die body; The size of the outer contour of the upper die matches the outer diameter of the die body. A circular upper die boss is provided on one surface of the upper die. The diameter of the upper die boss is slightly smaller than the diameter of the cylindrical through hole of the die body. Fixing rods equal in number to the blind holes of the bottom die are arranged on the circumference of the upper die boss. The diameter of the fixing rods is larger than the diameter of the axial reinforcing bars. A through hole of the upper die is provided at the center of the upper die. The diameter of the through hole of the upper die is larger than the outer diameter of the axial reinforcing member and smaller than the diameter of the upper die boss.
8. A manufacturing method of the composite environmental protection electrode according to any one of claims 1-6, characterized in that, Including the production mold according to claim 7, the manufacturing method includes the following steps: S1. Prepare the first electrode reinforcing body: S1-1. Prepare the axial reinforcing bars: Cut circular metal bars with a diameter of 10-50 mm into metal bars with a length equal to the length of the substrate plus 50 mm - 200 mm, with the number being M bars, where M is an integer greater than 2. S1-2. Prepare the radial positioning rings: Bend a metal round bar into a ring on a circular mold to obtain the radial positioning rings, with the number being N rings, where N is an integer greater than 2. S1-3. Weld the first electrode reinforcing body: Place the bottom die horizontally with the side having blind holes facing up. Insert the axial reinforcing bars one by one into the blind holes of the bottom die. Then place 1 radial positioning ring horizontally on the upper surface of the bottom die, making the radial positioning ring and the bottom die concentric. Then fix the axial reinforcing bars and the radial positioning ring into one body. By analogy, fix the remaining radial positioning rings to the axial reinforcing bars one by one. The distance between adjacent radial positioning rings is 200 - 500 mm. S2. Prepare the second electrode reinforcing body: S2-1. Prepare the axial reinforcing member: Take 1 circular metal tube with a diameter of 50 mm - 300 mm, cut it into a length equal to the sum of the lengths of the die body and the upper die plus 100 - 200 mm, and fill refractory material inside the tube. S2-2. Prepare the radial positioning bars: Cut a long metal bar into M metal bars as the radial positioning bars. The length of the radial positioning bars is equal to the difference between the outer diameter of the radial positioning ring and the outer diameter of the axial reinforcing member divided by 2. S2-3. Weld the second electrode reinforcing body and weld it to the first electrode reinforcing body as one body: Vertically place the axial reinforcing member prepared in S2-1 at the center of the first electrode reinforcing body prepared in S1. The bottom end of the axial reinforcing member is flush with the plane of the bottom die boss of the bottom die, and the top end of the axial reinforcing member is 100 - 200 mm higher than the upper plane of the upper die. Then fix one end of a radial positioning bar to the outer surface of the axial reinforcing member as one body, and the other end of the radial positioning bar to the axial reinforcing bar as one body, keeping the radial positioning bar perpendicular to the axis. By analogy, connect the remaining radial positioning bars to the axial reinforcing member and the axial reinforcing bars. The adjacent radial positioning bars in the axial direction are 200 - 500 mm apart. S2-4. After S2-3 is completed, wind carbon fiber strips on the surfaces of the axial reinforcing bars, axial reinforcing member, radial positioning rings, and radial positioning bars. S3. Spray the cylindrical through hole of the die body with a release agent twice. S4. Install the die body, vertically place the die body on the bottom die, ensure that the bottom die boss is completely inserted into the cylindrical through hole of the die body, and then fix the bottom die and the die body together as one body. S5. Install the upper die. Install the side of the upper die with the upper die boss facing down onto the upper plane of the die body, ensuring that the upper die boss is fully inserted into the cylindrical through-hole of the die body. The fixing rod on the upper die boss abuts against the axial reinforcing strip, and then fix the upper die and the die body together. S6. Heat the production die as a whole to 200 °C and keep it warm for 2 h. S7. Inject the matrix alloy liquid into the model obtained in S6: Slowly inject the matrix alloy liquid produced by the melting equipment using this composite environmental protection electrode into the inner cavity of the model obtained in S6 through the through-hole of the upper die. After filling, continuously supplement the alloy liquid as the temperature drops and the alloy liquid shrinks until the alloy liquid solidifies; the composition of the alloy liquid is the same as that of the alloy produced by the melting equipment using this electrode. S8. Demold 24 h after the completion of the S7 process, and after finishing and removing the refractory material in the inner cavity of the axial reinforcing member, the required composite environmental protection electrode is obtained.
9. The manufacturing method of the composite environmental protection electrode according to claim 8, characterized in that, It includes S9. Machine an external thread on the outside of one end of the axial reinforcing member protruding from the end face of the matrix; machine an internal thread on the inside of the other end of the axial reinforcing member. The types and nominal dimensions of the external thread and the internal thread are the same.
10. The application of the composite environmental protection electrode according to any one of claims 1-6 in a submerged arc furnace, a refining furnace, an electroslag furnace or a red mud smelting furnace.
Citation Information
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