ZHENGSHAN TECHNOLOGY

During the production process of nickel iron ore furnaces, electrode soft breakage is a common fault that seriously affects the continuity and safety of production. This article will explore the main causes of electrode soft breakage and propose corresponding preventive measures to improve production efficiency and equipment reliability.
The main reason for electrode soft breakage
Poor quality of electrode paste:
High ash content: Excessive ash content in electrode paste can lead to a decrease in the conductivity and mechanical strength of the electrode, increasing the risk of electrode soft breakage.
The volatile matter content does not meet the standard: If the volatile matter content of the electrode paste is too high or too low, it will affect the sintering effect of the electrode and cause the electrode to break.
Unreasonable particle size distribution: The particle size distribution of the electrode paste is uneven, with poor fluidity, which can easily form voids and cracks, increasing the possibility of electrode soft fracture.
Improper electrode placement:
Excessive pressing speed: If the electrode pressing speed is too fast, it will cause insufficient compaction of the electrode paste, resulting in gaps and cracks inside the electrode, which can easily cause soft fracture.
Pressure release equipment malfunction: The electrode pressure release equipment malfunctions and cannot work properly, resulting in uneven electrode pressure release and increasing the risk of electrode soft breakage.
Electrode cooling system malfunction:
Insufficient cooling water flow: Insufficient electrode cooling water flow leads to high electrode temperature, accelerating the sintering and softening of electrode paste, ultimately causing electrode soft fracture.
Blockage of cooling system: Blockage of cooling system pipelines leads to a decrease in cooling effect, high electrode temperature, and increased risk of electrode soft breakage.
Improper operation:
Improper electrode adjustment: During the electrode adjustment process, the operator failed to detect the abnormal flow of electrode paste in a timely manner and did not take timely measures to adjust it.
Insufficient emergency response capability: Operators lack emergency response capabilities, and once an electrode soft break occurs, they cannot take effective measures quickly, leading to the escalation of the accident.
preventive measure
Strictly control the quality of electrode paste:
Regular testing: Regularly check the ash content, volatile matter content, and particle size distribution of the electrode paste to ensure that the quality of the electrode paste meets the requirements.
Choose high-quality suppliers: Choose high-quality electrode paste suppliers, establish long-term cooperative relationships, and ensure the stability and quality of electrode paste supply.
Optimize electrode pressure release process:
Reasonably control the pressing speed: Reasonably control the electrode pressing speed to ensure uniform compaction of the electrode paste and reduce the formation of gaps and cracks.
Regular equipment inspection: Regularly inspect the electrode pressing equipment to ensure its normal operation and avoid improper pressing caused by equipment failure.
Improve the electrode cooling system:
Regular inspection and maintenance: Regularly inspect and maintain the electrode cooling system to ensure that the cooling water flow and pressure meet the requirements.
Install temperature monitoring device: Install temperature monitoring device to monitor electrode temperature in real time, and promptly detect and handle abnormal electrode temperature situations.
Strengthen operator training:
Regular training: Regularly conduct operator training to improve their technical level and emergency response capabilities.
Develop operating procedures: Develop detailed electrode operating procedures, standardize operating procedures, and ensure that operators strictly follow the procedures for operation.
Establish a sound fault warning mechanism:
Installation of electrode monitoring system: Install an electrode monitoring system to monitor the electrode status in real-time, and promptly detect and handle electrode abnormalities.
Regular analysis and evaluation: Regularly analyze and evaluate the operation status of electrodes, take preventive measures in advance, and reduce the probability of faults occurring.