Energy saving and corrosion control by heat recycling in re-baking process of graphite electrode manufacturing

In the graphite electrode manufacturing industry, the re-baking process is energy-intensive and poses significant challenges due to heat loss and corrosion of equipment. The current work focuses on developing an innovative approach to enhance energy efficiency and control corrosion through heat recycling. The proposed method, heat recycling and corrosion control, involves capturing waste heat generated during the re-baking process and redirecting it to preheat the electrodes, thereby reducing overall energy consumption. Key parameters investigated include the temperature profile, heat transfer rate, and the rate of corrosion in the furnace components. This approach explores potential methods to enhance the energy efficiency of an operational oil-fired re-baking furnace. The findings indicate a notable 19.56% improvement in heat transfer rates based on data collection and analysis. Additionally, the combustion air volume increased by 25.49%, while the temperature rose by 66.67%. The study also identified opportunities for energy savings, with a reduction of 26.08% in power consumption and 40% in oil usage per hour. The study demonstrates that the HRCC method not only conserves energy but also mitigates corrosion-related damages, leading to lower operational costs. Future work will focus on optimizing the heat recovery system, scaling the method for industrial applications, and exploring the integration of advanced materials to further enhance corrosion resistance. The HRCC approach holds promise for widespread application in the graphite electrode manufacturing industry, contributing to sustainable production practices and reduced environmental impact.