Preparation Technologies for Carbon Paste

Transcription

1 Preparatio Techologies for Carbo Paste CARBON

2 Tailor-made solutios effective ad tredsettig EIRICH is parter of the carbo idustry ad offers top preparatio techologies for the ecoomical preparatio of the followig core applicatios: Aode paste Electrode ad cathode paste Metallurgical Soederberg paste Graphite specialties The product lie icludes machiery ad systems as well as a full rage of services coverig everythig from cosultig to start-up. EIRICH has bee buildig machies ad complete plats for the carbo idustry for more tha 40 years ad a costatly growig umber of reowed maufacturers of carbo products all over the world uses EIRICH equipmet. The family-owed compay was established i Today, approx. 600 employees work at the compay s headquarters i Hardheim, Germay with i-house maufacturig facilities ad its ow plat egieerig office. Dealig with EIRICH i the carbo idustry provides: Experieced specialists Proprietary kow-how EIRICH test ceter for demostratio ad verificatio tests Laboratory ad pilot-scale equipmet for i-house tests Egieerig, maufacturig ad service by oe supplier All key machiery maufactured i EIRICH workshops A outstadig reputatio for reliability Worldwide presece ad after-sales service Worldwide success Up to ow, EIRICH has delivered more tha 200 machies to the carbo idustry worldwide Today, more tha 50 % of the world s paste productio for prebaked aodes are prepared i plats with EIRICH equipmet 2 Frot page pictures 2/5: SGL Group-The Carbo Compay

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4 Aode paste preparatio EIRICH Mixig Cascade (EMC ) Techology The fudametal fuctio of a aode paste plat is to heat up various coke fractios, to mix them with gree scrap ad pitch ad to feed the easily moldable mix to the press. Startig with trials i Switzerlad i 1993, a pilot plat i Norway ad the 15 t/h idustrial-scale productio uit i Cameroo, the iteratioal breakthrough was achieved i The EMC is operatioal for capacities from 20 t/h up to 60 t/h. The mai techical objectives are: Cosistet productio High level of desity Zero aode icidet i the potlie - o crackig by thermal shock - o dustig ad mushrooms Low reactivity Excellet pot performace The key elemet to achieve these objectives is a perfect mixig process Perfect homogeizatio of all igrediets Pitch peetratio to fill the coke pores Eve coatig of coke grais Mixig is more importat tha formig! Sufficiet mixig time, high mixig temperature ad sufficiet power iput are the most importat coditios to cope with the above metioed requiremets. Beefits of the EIRICH solutio Low capital expediture (CAPEX): savigs of at least % per lie Low operatioal expeditures (OPEX): savigs of at least 30 % Perfect adaptatio to low raw material qualities ad property fluctuatios Throughput rates of more tha 60 t/h i oe sigle lie Low variatio of retetio time durig mixig Optimum mixig ad coolig coditios for excellet paste quality Simple machie desig Vibrocompactig of aode paste up to 165 C without vacuum system EIRICH Mixig Cascade 35 t/h 4

5 dry aggregate heatig screw pitch EIRICH Mixig Cascade (EMC ) EIRICH hot mixer (1) EIRICH remixer-cooler (2) coolig water formig Process descriptio The preheated dry aggregate is fed together with the bider pitch (i liquid or solid form) ito the hot mixer (1), the first key elemet of the EMC. The itesive mixig effect replaces short-time pitch peetratio by meas of keadig forces with log-time pitch peetratio by careful itesive mixig. Due to the special costructio priciple, the retetio time i the machies is approx. twice as log as i a covetioal keader. The paste comig from the hot mixer is remixed ad cooled simultaeously i the remixer-cooler (2). The effective coolig is achieved by ijectio of water ito the aode paste ad subsequet immediate evaporatio. The discharge temperature is precisely cotrolled with a variatio of less tha +/- 3 C. Steam ad pitch fumes are led to the exhaust air treatmet ceter by meas of saturated air flowig through the machie. 5

6 Aode paste preparatio EIRICH Remixer-Cooler for retrofittig of existig plats Based o the log-term experiece i aode paste mixig, oly a plat with two differet mixig stages (hot mixig ad remixig-coolig) ca fulfill today s requiremets i a optimum way. Whereas ormal paste coolers are oly good to reduce the paste temperature, the EIRICH remixercooler with its special iclied machie desig realizes homogeizig ad coolig of the paste simultaeously. Paste quality improvemet by cotiuous remixig oly keadig keadig ad remixig Beefits of the EIRICH solutio Efficiet paste coolig The most efficiet paste coolig system Referece: Norsk Hydro Research, Porsgru - Norway Compariso of importat paste properties kg/dm³ 1,63 before after moderizatio 1,62 1,61 1,60 1,59 1,58 1,57 1,56 1, Baked apparet desity before/after istallatio of a remixer-cooler µ /m 55 before after moderizatio Specific electric resistace before/after istallatio of a remixer-cooler Free choice of fial temperature Maximum temperature variatio at paste discharge: +/- 3 C Better paste properties Low paste porosity = high paste homogeeity Higher gree ad baked desity Raised aode quality Lower aode resistivity Lower pitch cotet (typically % absolute) Less rejects System advatages Prove techology, umerous refereces worldwide Simple machie desig with low maiteace costs Easily adaptable to varyig operatig coditios ROI i less tha 3 years By courtesy of: Talum, Kidricevo - Sloveia 6

7 dry aggregate heatig screw pitch keader (1) coolig water EIRICH remixer-cooler (2) formig Process descriptio Paste prepared i a keader (1) is discharged cotiuously ito the dowstream istalled EIRICH remixer-cooler (2). The machie is equipped with weighig devices for mass flow cotrol ad a ifrared temperature measurig system. Due to the additioal mixig eergy iput ad retetio time, the fial paste is of costat high quality. Paste coolig is realized via evaporative coolig with ijected water. This is added depedet o the temperature of the paste which is measured via a ifrared temperature measurig system. The cooled paste is discharged cotiuously. 7

8 Electrode ad cathode paste preparatio EIRICH batchwise operated systems The EIRICH preparatio plat cocept comprises coke heatig, paste preparatio ad cotrol system. This system with oe EIRICH mixer may replace 8-12 covetioal batchwise operated machies. Thus, productivity icreases up to 200 % i the gree productio of graphite electrodes. The cotrol system moitors the mometary sequeces of all processes i the preparatio plat as well as the adjustmet of the required eergy amout at the electric resistace heater, the hadlig ad storig of all importat plat operatio data as well as the idicatio ad loggig of all faults. Compariso of paste quality Beefits of the EIRICH solutio Batch mixig with Sigma blade mixer Coke heatig Fully electric coke heatig equals the most elegat solutio o the market Rapid ad accurate adjustmet of the coke temperature No HTF heatig system required, i. e., o risk of fire, self-igitio, leakage, etc. Reduced eergy cosumptio Mixig Reductio i pitch cosumptio of 2-5 % Batch mixig with EIRICH mixer Simple machie desig Wear ad spare parts easily exchageable Isesitivity to varyig operatig coditios Plat desig Ivestmet ad maiteace costs up to 30 % lower High ad freely selectable temperature level of the preparatio process thaks to direct electric heatig ad evaporative coolig Compact tower system close to the press Fully automatic plat operatio Referece: NTNU Trodheim - Norway 8

9 dry aggregate gree scrap pitch EIRICH electric coke heater (1) EIRICH mixer-cooler (2) coolig water EIRICH table feeder (3) formig Process descriptio The coke fractios from either a specially desiged receivig hopper (i case of existig fractio weigh scales ad peumatic trasport) or alteratively from a cetral coke weigh scale are fed ito the EIRICH direct electric coke heater (1). Coke preheatig works simultaeously with the ogoig paste preparatio i the mixer-cooler (2). After the itroductio of a precalculated amout of electric eergy ito the coke, the system switches off automatically ad waits for the discharge request from the mixer-cooler. As soo as the preheated coke batch has bee discharged ito the empty mixer-cooler, a short dry mixig ad homogeizatio phase starts before liquid pitch is added by meas of a pitch weigh scale. Coke ad pitch are itesively mixed ad rapidly homogeized. For paste temperature measuremet, the mixer is equipped with a ifrared camera. Addig a precalculated amout of water starts the coolig process. The fiished paste is discharged batchwise from the mixer ito the dowstream table feeder (3). Based o the press requiremet, portios (by weight) of electrode paste are discharged from this table feeder ito the press. 9

10 Carbo ad graphite specialties EIRICH batchwise operated systems EIRICH supplies tailor-made mixers ad plats for a great variety of carbo ad graphite specialties such as isostatically molded ad extruded semifiished products, carbo fiber composites, carbo brushes, graphite heat exchagers, etc. The stadard operatig temperature is up to 250 C. Optioal iductio heatig is provided for fast ad highly efficiet dry aggregate preheatig. Beefits of the EIRICH solutio Dry aggregate heatig, mixig ad coolig (optioal) i oe sigle machie No HTF heatig system required, i. e., o risk of fire, self-igitio, leakage, etc. Eergy iput easily adjustable via tool speed ad mixig time Rapid homogeizatio Sigificatly reduced cycle time Simple machie desig, thus low maiteace costs Wear ad spare parts easily exchageable Pictures: Schuk Hoffma Carbo Techology AG 10

11 Thermographic picture of a iductio-heated mixig pa Mixer type RV16W 11

12 Machies ad systems The EIRICH desig provides optimum performace i both batchwise ad cotiuous operatio. The excellet processig efficiecy is guarateed by a rotatig mixig pa which trasports the material cotiually to the rotatig mixig tools rotatig mixig tools: rotatioal speed ad drive power are optimized for each applicatio a multi-purpose bottom/wall scraper which prevets cakig i the pa ad accelerates the discharge of the material The results are currets of material with high velocity differetials ad cotiually chagig positios. Mixig itesity ca be modified ad eergy iput ca be optimized by either co-curret or coutercurret operatig mode. Paste coolig by water evaporatio is available for both batch ad cotiuous mixers. Mode of operatio Batchwise operated machies With a discharge gate i the ceter of the mixig pa ad a swivelig wall ad bottom scraper for rapid discharge Cotiuously operated machies Istalled o load cells. The cotiuous mass flow through the machie is cotrolled by meas of a swivelig discharge mechaism which keeps the fillig level iside the machie costat. Sice the itroductio of liquid pitch, the hot mixig temperatures have bee raised to 175 C or eve higher to reduce pitch cosumptio. However, with the paste viscosity beig lower ow, covetioal solutios bear the risk of particle degradatio. Itesive mixers are well-kow for their high homogeizatio effect which is based o a strog horizotal ad vertical mass flow caused by the rotatig mixig pa together with oe or two rotor tools. Highlights of the EIRICH techology Process-wise Rapid homogeizatio Log residece time Variable eergy iput No dead zoes i the mixer High-performace coolig Outstadig paste quality Operatioal-wise Service-friedly desig Ultra-high reliability Wear parts of simple desig ad easy to replace No reweldig iside the machie Short dowtime for maiteace Good access ito the machie 12

13 Robust ad service-friedly tool Statioary multi-purpose tool as bottom/wall scraper Rotatig mixig pa Product flow with high velocity differetial Globally uique mixig priciple Mixer type RV28/RV33 13

14 Machie types Just the right size for all performace classes The EIRICH rage of mixers covers all user-specific requiremets with great efficiecy. I may cases, various applicatios ca be performed i successio, step by step, i oe ad the same mixer. All machiery for carbo paste preparatio is made for operatio temperatures up to 200 C higher temperatures o request. R&D equipmet For quality assurace ad/or research ad developmet applicatios, EIRICH offers laboratory mixers as well as complete laboratory systems for reliable scale-ups. The maximal stadard operatig temperature is 200 C. High-temperature desig for max. 300 C is available as well. RV02 RV12 14

15 RV28 Mixer types RV24 Capacity rages realized i existig plats Batch mixig: 60-4,200 kg/batch Cotiuous mixig: t/h 15

16 EIRICH Plat Egieerig Cosultig Our experts are available to aswer ay questio you may have about carbo paste preparatio. They liste to your ideas, istructios ad wishes, work with you to idetify the performace requiremets for your plaed istallatio ad develop useful alteratives. Basic ad detail egieerig All available iformatio ad the performace data defied joitly with the customer form the basis for a project-specific plat cocept. Project executio is very efficiet because the umber of iterfaces is kept to a miimum ad as we maitai a quality stadard that is recogized all over the world. Oly machies ad equipmet developed ad built by EIRICH itself ad products from qualified ad experieced parters are cosidered i the egieerig ad order hadlig stage. System modules Storig, coveyig, feedig Each proportio of the formula i defied quatity ad at the correct momet this is the simple but idispesable coditio for optimum utilizatio of the applied raw materials. EIRICH offers system compoets which have bee especially developed to meet the demads of the carbo idustry. The exact dimesioig is tailored to the local coditios. Meterig ad measurig To match the particular productio requiremets ad local coditios, EIRICH maily uses hopper scales, belt weighers or loss-i-weight feeders. All the compoets ca be coected to selfoptimizig process cotrol systems. All the crucial process parameters are scaed automatically. Process cotrol EIRICH develops ad builds its ow machie ad process cotrol systems ad istrumetatio. The rage covers ew istallatios as well as the moderizatio or expasio of existig machies ad preparatio systems. All compoets are exactly cofigured i accordace with the user s eeds. The results are tailor-made solutios coverig everythig from covetioal keyboard cotrol systems to special batch cotrollers i accordace with formula maagemet. Specific software fuctios of the cotrol system Assurace of product quality ad its reproducibility Moitorig ad cotrollig of maiteace itervals Assurace of plat availability Visualizatio of process sequeces ad operatig coditios Documetatio of all importat process parameters 16

17 weigh scales EIRICH electric coke heater EIRICH mixer-cooler colig water EIRICH table feeder press system By courtesy of: ERIE Press Systems 17

18 EIRICH LifeCycle Services Reparatur Repairs Origialteile Origialteile Origial parts Retal machies Mietmaschie EIRICH offers a comprehesive rage of after-sales services for the carbo idustry worldwide: from the iitial cosultatio to the plaig ad implemetatio of a preparatio solutio, reliable after-sales service ad the depedable delivery of origial spare parts. This icludes reliable customer service for EIRICH machiery ad systems throughout the whole life cycle. EIRICH LifeCycle Service begis right with the machie desig ad systems plaig stage. Istallatio ad commissioig A experieced service team is available for istallatio ad commissioig. Local parters assist us, ad the customer's persoel are istructed i the course of the work. Traiig Traiig for your operatig ad maiteace team is provided by expert istructors to esure that you get the most out of your ivestmet over the log term. It icludes istructios cocerig the system's operatio, safety regulatios, process optimizatio, maiteace itervals ad repair work. Teleservice Teleservice EIRICH LifeCycle Service Coditio Moitorig EIRICH LifeCycle Service Leistuge The compoets Die EIRICH- Bausteie für eie of spot-o puktgeaue service Service Basic services Basis-Leistuge Coditio Moitorig Maiteace Wartug Schulug Umbau/Moderisierug Customer traiig Coversio/Moderizatio Customer service EIRICH after-sales service is your guaratee of expertise, high availability ad comprehesive support. The portfolio icludes the worldwide supply of geuie EIRICH spare parts, rapid respose to productio stoppages ad fast machie / system repairs. Particularly beeficial optios are: Teleservice Remote diagosis via data lik. This is guarateeig fast, low-cost support whe problems occur. Coditio Moitorig Sesors mouted o key fuctioal elemets sed data i real time to a cetral aalysis system i order to detect compoet degradatio before a major fault occurs. This ca ehace machie availability ad reduce maiteace costs. Maiteace software packages The software ServiceExpert ECD provides simple access to egieerig drawigs, images ad photos to quickly idetify eve very small parts, icludig a shoppig basket fuctio. With the ServiceExpert ECS a tailored, comprehesive, state-of-the-art maiteace maagemet software solutio is available which helps to maximize machie availability. Machie Motage istallatio Maschie System istallatio Motage Alage Ibetriebahme Commissioig 18

19 Coditio Moitorig System 19

20 Idustrial Mixig ad Fie Gridig Techology Traditio ad iovatio sice 1863 EIRICH stads worldwide for a comprehesive rage of products ad services i the field of preparatio techology. Its particular focus is o mixig ad fie gridig techology, with kow-how developed over 150 years of close cooperatio with idustrial users, uiversities ad research istitutios. Pursuig a corporate philosophy of operatig iteratioally ad thereby esurig close proximity to every customer, the EIRICH Group has secured its place i all the key ecoomic regios of the world. The focus is o iovative techology for machiery ad systems egieerig desiged to offer solutios for high-stadard preparatio tasks from a sigle source. Applicatios ad process techology with ow test ceters, a high vertical rage of productio ad comprehesive after-sales service provide the ideal basis for the developmet of moder ad ecoomical processes for a multitude of idustries. Buildig materials Ceramics Glass Carbo paste Battery paste Frictio liigs Metallurgy Foudries Evirometal protectio The EIRICH Group worldwide: Maschiefabrik Gustav Eirich GmbH & Co KG Postfach Hardheim, Germay Phoe: Fax: eirich@eirich.de Iteret: Eirich Frace SAS Sait-Priest, Frace OOO Eirich Maschietechik Moscow, Russia OOO Eirich Maschietechik Depropetrovsk, Ukraie Eirich Machies, Ic. Guree, IL, USA Eirich Idustrial Ltda. Jadira S.P., Brazil Nippo Eirich Co., Ltd. Nagoya, Japa Eirich East Asia/Pacific Seoul, Republic of Korea Eirich Group Chia Ltd. Shaghai & Beijig, P.R. Chia Eirich Machiery Jiagyi Co., Ltd. Jiagyi, Jiagsu Provice, P.R. Chia Eirich Idia Pvt. Ltd. Mumbai, Idia H. Birkemayer (Pty.) Ltd. Isado, Republic of South Africa KM e 11/16 Prited i Germay. Subject to chages.