The invention relates to a graphite electrode with an electrical connecting element as well as to a furnace for graphitizing carbon-containing materials by means of such graphite electrodes.
In the conversion of amorphous carbon to polycrystalline graphite, furnaces are being used for graphitizing the carbon-containing materials. During graphitization, a conversion of amorphous carbon to polycrystalline graphite takes place by heating to approximately 3,000° C. under the exclusion of air. Heating the carbon-containing material is carried out by means of electrical current, with the current being supplied via movable graphite electrodes that protrude into the furnace at the end faces at the furnace head and are pressed onto the ends of the carbon-containing material. This is done by means of hydraulic presses disposed at the end faces, which press the graphite electrodes against the carbon-containing material in order to establish an electrical contact.
With regard to the introduction of the large current loads required for graphitization, there is the problem of the providing contact between the graphite electrodes and the power supply. Known designs of such large-surface contacts on graphite electrodes include, for example, laterally screwed-on metal contacts. The space required for screwing results in a large proportion of unused graphite that does not contribute to the contact geometry. This causes large recurring costs for the replacement of electrodes and utilizes only about 10% of the contact surface for the actual current transmission because of the large difference in resistance of the contact materials. Expressed simply, most of the current merely flows along the shortest way from the metal contacts via the graphite electrode to the carbon-containing material, and for a large part, the contact material is not used for the actual current transmission. Apart from the safety precautions required, there is also a considerable amount of time involved for manually screwing on the contacts. Automatic screwing is not customary because that would be a considerable construction effort with additional space requirements. In order to avoid these drawbacks, large-surface contacts pressed onto the end faces are common. Screwing them on is in this case not possible because the threaded rod cannot be passed through the graphite electrode, as in the contacts screwed on laterally. Thus, the contacts on the end faces must be pressed on. The process hydraulic system, which is present in any case, can be used for this purpose. However, the contact force is much too small for the contact pressure required, because of the proportional relationship between the requirement for current and force. Pressure cannot be increased arbitrarily, because the material located in the furnace would otherwise be destroyed. However, if the contact pressure is too low, there are relatively few stable electrical contact points, due to flatness tolerances and roughness. These few contact points must then transmit a particularly large amount of current, and local overheating occurs, so that these tips melt off, with other tips taking over the current and also melting off. By and by, such contact pairings degrade increasingly because, apart from oxidation of the surfaces, the contact force also lets up, among other things. This phenomenon is referred to as “micro hot spots”. In the case of unilateral or multilateral introduction of current, there is generally a very non-uniform current distribution. If current is collected only at a small surface area, due to unevenness, for example, the contact materials are heated very strongly at this location. In the case of graphite as a contact partner, the electrical resistance then decreases at that location, and an even stronger current flows which leads to an even stronger heating. Consequently, a large hot spot forms which can lead to the partial destruction of the material contacts concerned.
It is therefore the object of the invention to provide an improved graphite electrode with an electrical connecting element.
This object is achieved by a graphite electrode having the features of the main claim. Advantageous embodiments are the subject matter of the dependent claims.
According to the invention, it was found that the above-mentioned drawbacks are eliminated by establishing an electrical connection between the graphite electrode and the connecting element by means of wedge-shaped contacting elements. The contact pressure between the contact element and the wedge-shaped surface on the graphite electrode required for electrical conductivity of the interface can be influenced by means of the wedge angle and the contact surface. In contrast, the ratio of the contact pressure to the contact force in the case of the above-described large-surface contact can only be influenced by means of the surface area. Therefore, the contact pressure can be increased without an increased contact force, e.g. by mechanical presses, being required.
In an advantageous embodiment, it is provided that the contact elements are resiliently mounted in the connecting element, individually or in groups, preferably of 2-3 contacting elements. Thus, settlements or changes in position of the graphite electrode or of the connecting element caused by manufacturing tolerances or thermally induced expansion can be compensated. Moreover, each contacting element can have a certain clearance about all axes which enables the compensation of greater angular or positional tolerances. This is important in particular in the case where the wedge-shaped surfaces into which the contacting elements are inserted are directly carved out of the graphite of the graphite electrode. In the process, greater angular and positional tolerances and greater deviations occur due to thermal expansion. If, in contrast, the electrical connecting element were rigidly provided with a plurality of contacting elements, these angular and positional tolerances would prevent an equally optimal contact of all contacting elements. The result would be an non-uniform current distribution in, and introduction of current into, the graphite electrode. Even though the invention can also be realized with lamellar contacting elements, the contacting element is preferably formed by a single or several massive wedges or partial wedges. Massive contacting elements, e.g. of copper, can transmit more current than the otherwise customary contact lamellas, and can also tolerate a higher contact pressure. They do not deform as easily as lamellas or spring lamellas, and facilitate a better surface contact. Partial wedges can be resiliently connected and form a wedge which is spring-elastic in itself. The partial wedges can be connected, for example, by springs that extend perpendicularly to the direction of the wedge. These springs consist, for example, of spiral springs or springy material. The partial wedges can also be carved out of a massive wedge so that only a web of the wedge material remains in the center of the wedge.
Preferably, the wedge-shaped surfaces or counter-surfaces form a wedge angle. Experiments have shown a wedge angle of 5 to 45° to be particularly advantageous. In that case, a sufficiently high contact pressure arises between the surfaces in relation to the contact force. Due to the wedge-shaped design according to the invention, the contact force transmitted by the spring is deflected laterally onto the wedge-shaped surfaces and amplified according to the parallelogram of forces. The forces introduced into the graphite electrode at the end faces therefore remain comparatively small and a sufficient contact pressure is generated nevertheless.
Preferably, a flexible electrical conductor is directly connected to every single contacting element. This is necessary for compensating the spring travel and the clearance of the contacting elements and for the movement of the electrode. This can include stacked metal foils or metal mesh or cables which are each connected with one of the contacting elements or one of the groups of contacting elements.
Preferably, all contacting elements are arranged so as to point in the same direction. This makes easy insertion of all contacting elements into the wedge surfaces possible. In this case, the contacting element do not necessarily have to be parallel to each other.
If the wedge-shaped surfaces are preferably disposed on the end face of the graphite electrode, it becomes possible to use the hydraulic presses disposed at the end faces, which are present anyway and which press the graphite electrodes against the carbon-containing material in order to establish an electrical contact, also for pressing the connecting element against the wedge-shaped surfaces, which are located at the end faces, of the graphite electrode at the same time. Because of the wedge-shaped design, the hydraulic pressure, which in view of the carbon-containing material cannot be increased arbitrarily, is now completely sufficient for establishing a connection sufficiently capable of carrying current between the connecting element and the graphite electrode.
Due to the comparatively high electrical resistance of graphite in relation to copper, the current tends to take the shortest path through the graphite electrode, which is most often cuboid. In order to take this into account, the wedge-shaped surfaces are preferably disposed on the end faces of the graphite electrode in such a way that the result is a comparable electrical current in operation for all contacting elements, takingi into account the above-mentioned specific resistance of graphite. This is the case if all currents conducted through the different contacting elements are within a range of +/−20%. This mostly results in a centrosymmetrical or mirror-symmetrical arrangement, e.g. along parallel lines or arc-shaped or circular.
Preferably, the wedge-shaped surfaces are directly disposed in the graphite electrode or the end face of the graphite electrode, e.g. by milling. The contacting element, which most often consists of copper, is thus brought into direct engagement with the wedge-shaped surfaces of graphite. The work-intensive attachment of a contact plate of, e.g., copper with the corresponding wedge-shaped surfaces can be dispensed with. Therefore, an unnecessary additional material interface is avoided.
Nevertheless, it also falls under the invention if a contact plate that is firmly connected with the surface of the graphite electrode is provided, which comprises the wedge-shaped surfaces according to the invention. Such a plate can consists, for example, of copper. Attachment to the end face of the graphite electrode is carried out, for example, by screwing with conventional threaded screws and cross thread bolts which are inserted into the graphite electrode through cross bores and are used for a uniform distribution of threaded bores over the end face of the graphite electrode. The plate can be pulled against the surface on the end face of the graphite electrode with a large force due this kind of fastening. However, the pressure is not passed on to the carbon-containing material to be graphitized in the furnace.
Preferably, the graphite electrode is formed of several parts, with several
Preferably, laterally disposed means acting in opposite directions with regard to force are provided for holding together the individual electrodes, whose direction of force is offset by approx. 90° relative to the separation joint and to the axial direction of movement of the contacting elements.
Preferably, the means for holding the individual electrodes together are such that they become effective while or after the connecting element is pressed against the graphite electrode.
Preferably, all individual electrodes have the same geometry.
Preferably, the wedge angle is selected such that a self-locking action arises, that is, that the wedge cannot slip out from its V-shaped groove due to the opposing frictional forces.
The invention will be described and explained in a non-limiting and exemplary manner with reference to figures.
Each of the contacting elements 11 is individually resiliently mounted in the connecting element 1. During contacting, the spring travel is at least 1 mm. In this case, the minimum spring length is at least ten times of the resulting spring travel, in order to achieve an almost uniform spring force over the required spring travel. Thus, the result for each contacting element is an almost equal contact pressure with the surfaces 21 of the wedge-shaped groove, irrespective of possible displacement of the various wedge-shaped grooves 21,
Separated by vertical slots 114, individual contact surfaces 12 are created which, mutually supported by a ball 20, can move relative to one another in all degrees of freedom.
A surface contact always has a statistically randomly occurring number of contact points between the surfaces which depend on the evenness and the roughness of the surfaces. The more contact points there are, the better the electrical contact and the heat transfer between the components of different potentials which can form, for example, a detachable circuit element.
Because of its spring-like character, the present construction permits, both in the direction of pressure as well as with regard to the mobility of the individual surfaces 12 relative to one another, a formation of contact points that is, statistically seen, “2×(N+1)” times more frequent than in a comparable, single-part, unslotted component, with “N” being the number of vertical slots 114.
If a simple flat contact between the pressure plate 40 and the counter-element 2 is compared, given the same surface ratios and the same pressure force, then the contact force FN is increased by about the factor 2 to 6 in the case of individual wedge angles of 30° to approx. 10°. The statistical probability of the number of contact points rises almost proportionally with an increasing contact force, so that a factor of 1.8 to 5 can be assumed. Compared with the flat large-surface contact, the solution shown, which comprises individual wedges slotted several times, thus offers a contacting which is better by a factor 100 to 300.
In the exemplary embodiments, the invention was described with reference to wedge-shaped contacting elements and wedge-shaped counter-elements. Conversely, the contacting element can also be formed as a wedge-shaped groove, of course, and the corresponding counter-element in the graphite electrode as a wedge. Preferably, the shape of the wedge is symmetrical. The invention was described within the context of graphitization, also merely by way of example. The contacting according to the invention of a graphite electrode to a metallic conductor can also be used in the same way in graphite electrodes for melting metals, e.g. from ores, steel from pig iron or scrap metal, nickel from nickel ores or in reduction processes, e.g. in aluminum production.
The separate individual electrodes 2a-2d, during the necessary processing of the lateral surfaces so as to obtain the required nominal dimensions, can receive in a simple manner the one or several chamfered wedge-shaped surfaces 21, which can later, during assembly, form the wedge groove or V-shaped contact surfaces for electrical contacting. This multi-part configuration of the graphite electrode can be used regardless of the design of the connecting element 1 in
The connecting element 1 carries a plurality of wedge-like contacting elements 11 and substantially corresponds to the above-mentioned exemplary embodiments. The contacting elements 11 can also be configured as was already described above, and are resiliently connected with the connecting element 1, which is indicated by the springs. Due to the multi-part configuration of the graphite electrode 2, the two-part configuration of the contacting element can possibly dispensed with, because the individual parts 2a-2d can absorb settlements if necessary. The contacting elements 11 can therefore be rigid and/or massive and thus be easier to produce.
The electrical terminals on the resiliently mounted contacting elements 11 and the workpieces of raw coal intended for graphitization are not shown.
Because the separation joints are subjected to tensile loads by the contacting elements during contacting and would form an opening gap, lateral means 51, 1a acting in opposite directions for holding together, e.g. in the form of hold-down devices, are provided, whose direction of force is offset by approx. 90° relative to the separation joint and to the axial direction of movement of the contacting elements 11.
These means can be static, e.g. a vise. Preferably, however, dynamic means are proposed that become effective while or after the connecting element 1 is pressed against the graphite electrode. The latter case has the following advantage: in order to build up a large contact pressure between the wedge surfaces 21 and the surfaces of the contacting elements 11 abutting them, the contacting elements can at first be pushed with a comparably small contact force in the axial direction between the wedge surfaces 21. At that point in time, the contact pressure is still small and not optimal for conducting current. It is only then that the means for holding together 51, 1a become effective. Because of the flat wedge shape of the contacting elements 11, they press the wedge surfaces 21 against the surface of the contacting elements 11. The intended high contact pressure builds up, without the large axial contact forces known from the prior art. The individual electrodes 2a-2d that lie next to one another can be pressed together sufficiently by the means for holding together, because of the separation joint. Depending on the design, a single-part graphite electrode can also be pressed together sufficiently.
Moreover,
A different or alternative measure for achieving independence of the contact pressure from the axial contact force is achieved if the wedge angle is selected such that a self-locking action arises, that is, that the wedge cannot slip out from its V-shaped groove due to the opposing frictional forces. Therefore, the axial contact force can even cease to apply or become negative without the contact pressure abating to a relevant extent. In the exemplary embodiment from
Number | Date | Country | Kind |
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10 2009 000 242.1 | Jan 2009 | DE | national |
10 2009 000 755.5 | Feb 2009 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP10/50478 | 1/15/2010 | WO | 00 | 7/11/2011 |