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<p>Graphite electrodes are a vital consumable in ladle furnace (LF) steelmaking significantly influencing operational costs through their role in electrical energy delivery, temperature control, and secondary refining. This study evaluates two industrial-scale process optimizations to reduce electrode consumption: slag chemistry modification and electrode tip spray cooling. Slag basicity was increased from ~ 1.22 to ~ 1.47 while reducing FeO below 1.5&#xa0;wt%, leading to a 9% decrease in viscosity at 1600&#xa0;°C which improved arc shielding and minimized oxidation at the electrode interface. Concurrently, fine mist spray cooling applied to electrode surfaces reduced average temperatures by ~ 11%, without causing thermal damage. Combining these approaches achieved a net reduction of ~ 10% in normalized electrode consumption. Additional benefits included extended refractory life and enhanced thermal stability. These findings demonstrate a practical, cost-effective methodology for improving electrode efficiency and reducing expenses in industrial LF steel refining operations.</p>

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Influence of Slag Composition Modification and Spray Cooling on Electrode Consumption in Ladle Furnace Steelmaking

  • 期刊论文

  • 发表日期：

    2026年6月23日

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  • Anand Ganvir,
  • Mukesh Raushan Kumar,
  • Vikash Kumar

摘要

Graphite electrodes are a vital consumable in ladle furnace (LF) steelmaking significantly influencing operational costs through their role in electrical energy delivery, temperature control, and secondary refining. This study evaluates two industrial-scale process optimizations to reduce electrode consumption: slag chemistry modification and electrode tip spray cooling. Slag basicity was increased from ~ 1.22 to ~ 1.47 while reducing FeO below 1.5 wt%, leading to a 9% decrease in viscosity at 1600 °C which improved arc shielding and minimized oxidation at the electrode interface. Concurrently, fine mist spray cooling applied to electrode surfaces reduced average temperatures by ~ 11%, without causing thermal damage. Combining these approaches achieved a net reduction of ~ 10% in normalized electrode consumption. Additional benefits included extended refractory life and enhanced thermal stability. These findings demonstrate a practical, cost-effective methodology for improving electrode efficiency and reducing expenses in industrial LF steel refining operations.