140 Electric Furnaco Proceedings, 1971

The Mechanics of Consumption of

Graphite Electrodes in Electric Steel
Furnaces

thermal stresses resulting from this situation are eccen-

In the economics of electric steelmaking, two cost tric, and the rate of sidewall oxidation is strongly af-
items can be determined with ease and accuracy: the fected by temperature.)
specific energy consumption (kw-hr per ton) from meter Further down, about a foot (250 mm) above the arc
readings and specific electrode consumption (Ibs of elec- tip, the current begins to concentrate toward the hot
trode per ton of steel produced) from number (or spot of the arc, which is roughly Y4" to Yz" in diameter
weight) of electrodes consumed relative to steel pro- (as schematically shown in Figure 3). The temperature
duced over a given period of time. of this coin-size area is 3600"-4000°C (6500"-
I As we shall see later, it is important to realize that 7200°F), and the rest of the surrounding graphite body
is at 2000°-23000C (3600"-4200"F). The major por-
these items depend on many other process variables;
although it is desirable to keep their values low, the tion of linear incremental consumption of the graphite
minimum overall cost of producing a ton of electric electrode takes place in this arc spot. A detailed analysis
steel is not necessarily reached when kw-hr/ton or lbs of the physics of the furnace arc with respect to elec-
electrode/ton are at a minimum rate. trode consumption is beyond the scope of this paper. For
practical purposes, it is sufficient to identify the effects
of the arc on electrode consumption as "vaporization".
Electrode consumption can be classified in two main
categories, as illustrated in Figure 1.
ELECTRODE CONSUMPTION
At the tip of the electrode column, the rapidly travel- I
ing arc spot, and the slag and metal, remove graphite in !
an incremental fashion without abruptly shortening the
length of the column. Similarly, oxidation of the side-
wall causes progressive tapering of the electrode. Arc INCREMENTAL CONSUMPTION SUDDEN SHORTENING
OF ELECTRODE C O L U M N
OF ELECTRODE C O L U M N !
tip, or linear (vertical), consumption occurs mostly when
the furnace is under power, whereas electrode sidewall
consumption in the horizontal direction occurs at all
ELECTRODE
times when the electrode is hot. This combination con- SIDEWALL
stitutes technological electrode consumption and is con- I
trollable to some degree by furnace practice.
In contrast to this gradual type of consumption oc- ARC A C l I O N
T H E R M ~ SHOCK
L
curring on the surface of the electrode, electrode column OXIDATION JOINT MAKEUP
SLAG EROSION HANDLING
length can change abruptly and drastically by breakage,
stubbage, and splitting. The causes for this type of con-
sumption can be found mainly in the areas of furnace
practice, type of scrap, regulator malfunctions, incorrect Fig. 1--Categories of electrode consumption.
electrical phase sequence, and electrode handling and
joint making. Human error, of course, plays a very im-
portant role. The underlying principles of both types of
consumption will be discussed in this paper.
ELECTRODE CONSUMPTION A T THE TIP O F
THE E L E C T R O D E
In order to understand the mechanism of consumption
at the arc tip, we must study the flow pattern of electric
current in the column. The distribution of the current
over the cross section is nonuniform due to a variety of
electromagnetic effects (skin effect, proximity effect),
and by the temperature-dependent resistivity and ther-
mal conductivity at various locations throughout the
column and its joints.
Figure 2 shows the current densities measured on the
surface of 24" diameter electrodes near the roof port-
holes of a typical large ultrahigh powered furnace. The 1 - 1, L12Ll,
crowding of the current toward the axis of the furnace 3

is obvious and leads to a substantial raise of the elec- Electrode Di~rneler

24" = 610 rnrn
trode temperature in these areas. (Needless to say, the C&4 hose Sequence

W. E. SCHWABE is Associate Director of Research and Engineering,

Union Carbide Corp., Carbon Products Div., Parma Technical Center,
Parma, Ohio. Fig. 2-Current densities measured on surface of 24" diameter elec-
trodes near roof portholes.

Fig. 3-Equipotentiol and current flow lines in an electrode tip sec-
tion. Original diameter of e l e c t r o d e 2 4 " (610mm). Tip diameter-
17" (430mm). Diameter of arc spot-O.5" (12mm). Current-70,000
amp rms.
From observations of small arcs and test work conducted
in experimental arc furnaces, as well as large produc-
tion units, it may be concluded that the rate of linear
consumption increases when operating currents and/or
power is increased. As increased power and current
levels usually result in higher productivity of the fur-
nace, electrode consumption in lbs/ton of product some-
times remains unchanged.
In addition to electrode consumption by arc effects,
analyses of high speed arc motion pictures have shown
that graphite particles are removed from the arc spot
and its vicinity. As schematically shown in Figure 4,
thermal expansion of the arc spot yields radial and axial
forces, f. and f., which may pry graphite particles loose.
The electric current flowing through the arc tip and the
hot spot into the arc column generates forces of its own.
The pinch effect force, f,, opposes the radial extension
force, f,. Furthermore, a force, f,, in the axial direction
DIRECTION OF FORCES
CAUSED BY EXPANSION
fa AXIAL
DIRECTION OF FORCES 3 + fp P'x{LFECT
CAUSED BY FLOW OF
CURRENT
f FORCE I N CONDUCTORS
HAVING A VARIABLE
CROSS SECTION
Fig. &Direction of forces existing in an arc spot on the tip of an
electrode.
Interrelation of Materials and Equipment 141
Fundamentals of Tip Consumption of a n Electrode
Al = Primary Zone of Arcing
A2 = Secondary Zones of Arcing
E = Zone af Erosion
Fig. 5-Schematic presentation of consumption of an electrode a t the
arc tip.
opposing the expansion force, fa, is present because of
the streamlined shape of the current flow lines through
the lower part of the electrode. To what extent a can-
cellation of these opposing forces of different origin may
take place is not known.
In addition, erosion of the electrode end face by metal
and slag also adds to linear consumption. Finally, oxida-
tion of the electrode end face contributes in a minor
way.
As a result of arc flare forces in furnaces with elec-
trodes arranged in an equilateral triangle, electrodes are
consumed in a pattern illustrated in Figure 5. Three
zones of consumption on the end face can be dis-
tinguished, however their borderlines may overlap con-
siderably.
Long arcs and/or strong flare cause the arc tip to
bevel at angles of 20"-30°, whereas the "heel" of short
arcs is distinctly eroded by slag and metal, resulting in
more or less horizontal arc tips (see Figure 6). Short
high current arcs tend to form a slightly concave tip
(see Figure 6c).
C O N S U M P T I O N O F THE E L E C T R O D E S I D E W A L L
In contrast with "linear" consumption, sidewall con-
sumption of the electrode column acts more or less in
the horizontal direction. It causes the column to taper
Long Arc Medium Arc Short Arc
Fig. &Electrode tip configurations for three different arc- lengths.
142 Electric Furnace Proceedings, 1971

and affects mostly the portions of the columns which are AGR AGX
below the furnace roof.
The most important factor of sidewall consumption is
oxidation. The oxygen content of the furnace atmo-
sphere during a heat undergoes great changes. An oxy-
gen content in the furnace atmosphere equivalent to that
existing in air is seldom reached unless excess oxygen
from oxygen lancing flows over the electrode surface
or, in cases in which the furnace is equipped with a fume
extraction system, excessive amounts of air are drawn
into the furnace.
Of minor, although not negligible, importance is con-
densation of metal and slag vapors on the electrode, a
phenomenon which causes droplets to form in the middle
section of the electrode. The droplets, by way of gravity,
then run downwards toward the tip, from where they
fall back into the bath. On their way down, they pick up
small amounts of graphite. During flat bath operation
with short arcs, the outer edge of the electrode tip is
continuously rounded off as a result of abrasion from
contact with slag and metal. This effect is pronounced
when continuously fed prereduced materials (metal-
lized pellets) are used.
Although the oxidation rate of electrode graphite de-
pends, to some extent, on the grade of the graphite, it Temperature
depends strongly on the surface temperature of the
Fig. 8-Oxidation rates of grade AGR and grade AGX electrodes in
electrode, velocity, and the turbulence of the passing
air vs. surface temperature (wind tunnel).
gas and its oxygen content.
Effect of Temperature and Velocity 00 Surrounding
IOft/sec = 3 . 0 5 m/sec
Atmosphere on Oxidation 5 fl/rec = 1 . 5 3 m/sec
Experiments to compare the effect of temperature Air Velocities

and velocity of typical furnace atmospheres have been

conducted under controlled conditions in wind tunnels
at different temperatures and velocity values. Figure 7
presents the results from a test series in which air is
used, indicating that increasing air velocity, and the
surface temperature of the graphite markedly increase
the rate of oxidation. Surface temperatures of the
graphite electrode under 600°C (-1100°F) are, for
practical purposes, noncritical, since appreciable oxida-
tion does not occur. The oxidation rates illustrated in
Figure 7 are higher than those experienced in normal
electric furnace practice, because the oxygen content of
-
the furnace atmosphere is considerably lower than that
which prevails in the wind tunnel.
- Temperature
-

Test results covering Grade AGR and Grade AGX
electrodes are shown in Figures 8 and 9. The lower rate
of oxidation of Grade AGX, particularly in range of
1100"-1600°F (600"-90O0C),is quite obvious.
Aside from these influences, sidewall consumption is
in direct proportion to time of exposure and, therefore,
- during furnace operation on the section of the electrode
600 700 800 Su) lCn, 1100 laX, 13Ul
Temperature, O C
Fig. 7-Rate of oxidation of electrode graphite vs, temperature in
wind tunnel.
Fig. 9-Oxidation of graphite in wind tunnel-air ratios of oxidation
rates AGX/AGR vs. temperature for different air velocities.
increases with the time of residence of a particular sur-
face unit in the furnace system, counting from the first
exposure to oxidation in the upper part of the column
to the time when this portion arrives at the edge of the
end face before final consumption in the arc zone. Large
residence times can lead to pronounced penciling of the
electrodes, a condition which is sometimes erroneously
interpreted as that which results from insufficient re-
sistance against oxidation of the electrode involved. On
the other hand, a short residence time of the electrode in
the furnace due to high linear consumption results in
less electrode taper.
The oxidation rate around the periphery of the elec-
trode column is not equal at all points. Effects of draft
through open doors, glands, and/or fume control sys-
tems may generate flow patterns in the furnace atmos-
phere, enhancing oxidation in certain areas on the elec-
trode surface. This condition results in eccentric de-
formation of the electrode columns. In some furnaces,
the surface portions lying within the electrode triangle
oxidize somewhat more than the rest of the surface.
Mutual heat radiation from these portions raises the
surface temperature in these sections of the columns
and causes higher rates of oxidation. This eccentric
temperature pattern of the electrodes is often indicated
columns between holder and roofline where the border
lines between visible red and black of the electrode sur-
face show a downward slope from the inside of the elec-
trode triangle to the outside.
 Interrelation of Materials and Equipment 143

During the process of oxidation, which takes place C O N S U M P T I O N (eo). Kg/ Ton M e t r ~ c
not only on the sidewall but also on the arc end face of IO
-
1 2
I
3
I
4
5
, - , 9 10
the electrode, heat is released due to combustion. The
theoretical value for the heat is approximately 3.4 kw-
hr/lb (7.5 kw-hr/kg) of graphite.
Based on these figures, one may speculate that the
combustion heat amounts to 10-20 kw-hr per ton of
steel. Whether or not this energy can be classified as
useful to the melting process is unknown; however, the
heat of combustion does perform a useful purpose when
the hot electrode columns are withdrawn from the fur-
nace during recharging. The heat of combustion counter-
acts to some extent the cooling of the surface caused by
radiation and thereby reduces tangential stress near the
surface of the electrode during this state of thermal
shock.
COMBINATION O F LINEAR CONSUMPTION A T ARC END
A N D OXIDATION O F SIDEWALL
Linear consumption at the arc tip and oxidation on
the sidewall occur, for practical purposes, simultane- CONSUMPTION (eo). Ibs/ ton
ously if one considers furnace operation over longer Fig. 11-Linear consumption per column of 24" diameter AGX
periods, for example, days, weeks, or months. The geom- electrodes as function of consumption rate (Ib/ton) and furnace
etry of the electrode column permits interesting conclu- productivity (ton/h).
sions as to the relative significance of both contributing
factors, as shown in Figure 10. II
In most furnace operations, one finds that sidewall h = 0 . IBIO"
( 25%)
oxidation comprises approximately 50% of the "net 10
Hourly Rote
consumption" (or consumption excluding breakage,
stubbage, etc.) .
- 9
h =0.1455"
(0%)
. of(Reduction
Oxidation
of
Electrode Rodiur)
Linear rate of consumption per phase, defined in inch f h =0.1091"
or centimeter per operating hour, can be readily cal- j 8 ( - 25%)
culated from operating data. One example is graphically
shown in Figure 11.
For given electrical operating conditions, the rate of -
2
'x 7

linear consumption is a function of area of the electrode .--5 6

tip. Generally, it increases as the tip area decreases. &

5
Linear electrode consumption, then, depends on the 0
following factors: U
b 4
c h =O
1. the height of the electrode column exposed to side-
wall oxidation, usually from roofline to arc tip; 3

2. the rate of oxidation, given by furnace conditions 2

(draft, air flow) and grade of graphite; and 0
3. residence time of electrode column between roof- Height (H-inches) of Tapered Section of Column
line and arc tip.
Fig. 12-Linear consumption vs.. electrode height for 24" diameter
One example of the results of mathematical analysis electrodes a t various sidewall oxidation rates, h.
of these conditions is shown in Figure 12. Here, linear
consumption is plotted against height of the tapered of rate of linear consumption being inversely propor-
column for various rates of oxidation. The point, P, on tional to the electrode tip area. Also shown are the re-
the solid line in the center is based on observation. (In sults referring to oxidation rates 25% higher and lower.
this case, the electrodes were red hot almost up to the The following conclusions can be drawn:
holder, covering a column height of 173" in a 22' diam-
eter furnace.) The curves were calculated on the basis 1. When the rate of sidewall oxidation increases, for
example, by 25 percent over the existing value, linear
consumption increases from 7.2"/hr to 8"/hr or approxi-
N e t Consumption, C = Ti si
Tip Consumption, Ti.
Sidewol l Consumption, Si
=C .
I
(d/D)2
mately 11%;
2. Lowering oxidation rate by 25% lowers linear con-
= c[I-(~/D)~] sumption to 6.35"/hr or by approximately 12%; and
of Tapered Electrodes 3. Reducing the height of the tapered portion of the
column by 25%, or 43", would also reduce electrode
consumption by 12%. (This fact illustrates the signi-
ficance of the height of a furnace; a tall furnace is auto-
matically penalized with higher electrode consumption.)
OTHER FACTORS OF CONSUMPTION
Electrode breakage high in the column is the major
contributing factor in this category. The principal cause
for such breakage is falling scrap resulting in cantilever
action often fracturing the electrode joint closest to the
clamp (top joint). The direction of this impact force is
generally aimed from a point outside of the electrode
triangle more or less toward the center of the furnace.
. 1 . 2 .3 .4 .5 .6 .8 .9 1.0 It is interesting to note that the three electrode columns
.707 are also affected by electrodynamic forces in the oppo-
--- d/D site direction, forces which tend to separate the columns
in the same direction as arc flare (see Figure 5). These
Fig. 10-Percent net consumption of sidewall and tip as function of forces increase with the square of the current amperage
taper ratio, d/D. and decrease with the distance between the electrodes.
144 Electric Furnace Proceedings, 1971

Table 1. 17' Diameter Furnace, 20" Diameter Electrodes, 66 Tons Hot Metal Per Heat
- -

Average Electrode Relative Values

Current Productivity Consumption Produc- Electrode Pr
Power
Level
Meltdown
ka
Tap-Tap
h:min
tous/hr
Elapsed
Ibs/tou
Liquid
tivity
Pr
Consumption
Er
-
Er

Low
High
UHP

handed threads require counterclockwise phase rota-

Table II. K-Values tion) of the furnace.
Excessive thermal shock, developing when a column
24' Diameter ( 30................ 50) . 104 is raised out of the furnace chamber, may establish
20' Diameter ( ..
50................ 90) 10-9 tangential stress on the surface and, under extreme
16' Diameter (130................170) 10-3
conditions, even split an entire electrode section length-
wise.
When, during meltdown of heavy scrap, the arc re-
In a large furnace in which a current of 50-80 ka is mains stationary, e.g., on the outer edge of the tip,
used, these forces can amount to several thousand severe temperature gradients can develop generating
pounds. so-called V-cracks which may propagate to the nearest
The presence of forces of this magnitude demands joint. Depending on the depth of the crack, the stub
good electrode practice with respect to handling and may split open and drop off.
joint making, as well as nonnal functioning of the regu- Whatever the reasons for a sudden shortening of an
lator mechanism, and absence of excessive mechanical electrode may be, if it affects a well-tapered column, the
movements of the arms. arc finds an 'enlarged area represented by the fractured
Stub losses may be caused by a variety of conditions, surface. Many hours of furnace operation are then re-
such as loose joints (which may be due to improper quired to reestablish the normal column taper typical
joining practice) and/or wrong phase rotation (right for this furnace.
ELECTRODE C O N S U M P T I O N A N D FACTORS O F
FURNACE OPERATION
c - Effect of Tap-to-Tap Time
Electrode Consumption vs.
Top-Top Time - 7.:$ 2-E
*
Electrode consumption a t the arc tip, caused mainly
20" D i o . AGR Em by arc action and erosion by slag and melt, occurs dur-
43 Ko Meltdown ing power-on periods. In contrast, sidewall oxidation
Single slog -
-
3 occurs practically at all times, both during power-on
regr.- 3.9 lb/ton/hr g-
6 .- and power-off periods, as long as the electrodes are hot.
-
&
a Furthermore, during these periods, such effects as
E, spalling and thermal shock exposure may occur. Ob-
- 562 viously, when furnace operations are slow, specific elec-
trode consumption must be high.
u
w
2 The effect of furnace productivity (or tap-to-tap
l l , , ,
W
, , , , , , , If time) upon electrode consumption is shown in Figure
13, where the results of a 17-ft diameter furnace (65 t )
2.4 2 5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 producing single slag heats are shown. Shortening the
Top/Top Time , hrs.
Fig. 13-Electrode consumption vs. tap-to-tap time.
Electrode Diameter
Electrode Diameter 9 A 24" = 600 rnm

1 2 3 4 5 6 7 8 9101112
, .. h
Heat Time (Tap-Tap),
. ,
Heat Time (Tap-Tap), h
Fig. 14-Specific electrode consumption vs. heat time, single slag
and double slag operation combined. Fig. 1 j S p e c i f i c electrode consumption vs. heat time.
 Interrelation of Materials and Equipment 145

Kg/Ton Ib/ton
Short Metric Chorged Charged
ton, Tons Metric Short
3 hr.
4 hr. 30min.3 h r .

t 20" AGR
Single Slag
,2hr.30min. Tap/
Top
-7

,2hr.20rnin.
I Roductivitv 1517f /4 / 2 hr.
Time

-5

- 2

MD Current
--.-....-...~-..-..---.-----.-------------
Arc 40 45 45 45 50 55 55 58
Current (kAj '50 '55 '58 '58 '62
Fig. I b T w e n t y - i n c h diameter electrode consumption (Ibs/short ton)
as function of meltdown current, J, for various tap-to-tap times, T.
--- 4.80 4.78 4.9 5.24 5.62 5.42 6.00 6.40 s";b'i:
2.40 2.36 2.46 2.62 2.81 2.71 3.00 3.20 & ;: I

tap-to-tap time by one hour reduced electrode con-

sumption by 3.9 lb/ton. Figures 14 and 15 show the re-
sults of computer studies covering numerous furnaces
in which 20" diameter and 24" diameter electrodes were
employed and where single and double slag heats were
produced. Here one hour tap-to-tap increment changes
electrode consumption by 1, respectively, 1.3 lb/ton.
Effect of Current Levels Used During Meltdown
Frequently, tap-to-tap times are shortened by in-
creasing furnace power and operating currents. An in-
teresting example is shown in Figure 16, which shows
the history of a 17-ft furnace in which 20" diameter
electrodes were employed before and after conversion
to ultrahigh power.
Principally, when higher operating currents are used,
the rate of "burn-off" during power application in-
creases; however, scrap is melted faster and production
rate is increased. This result is also demonstrated in
Table I and Figure 17.
This 19-ft, 77-ton UHP furnace, equipped with a 65-
mva transformer and 20" diameter electrodes, was op-
erated at various meltdown current levels ranging from
40 to 62 ka. Electrode consumption and productivity
Fig. 17-Electrode consumption and productivity of a 19-ft diame+er
UHP furnace-tapping weight 77 tons, transformer rating 45/65
mva.
been established at larger and smaller furnaces.
Statistically, electrode consumption, C, can be ex-
pressed as
where C = Electrode consumption (lb/ton) ,
K = Numerical factor, related to operating char-
acteristics, ,
J = Current during meltdown (ka), and
T = Tap-to-tap time ( h ) .
Typical K-value ranges are listed in Table 11.
A variety of statistical relationships have been de-
veloped to correlate electrode consumption with op-
erating factors. Although useful as guides, their weak-
ness is that, in many cases, no precise information co,n-
cerning magnitude of the operating current is available.
CONCLUSIONS I

increase with current; however, if one relates both vari-
ables to each other, one finds that an increase of elec-
trode consumption from 10.2 lb/ton at 40 ka to 11.2 lb/
ton at 50/55 ka or 10% is accompanied by a productivity
increase from 27.5 t/hr to 34 t/hr or 23.5%. The ratio
P./E, is also 1.12.
Similar relationships between furnace productivity,
current levels, and electrode consumption have also
The mechanics of electrode consumption in an elec-
tric arc furnace are quite complex. Some factors are
well understood, while others require still more in-
depth study. The objective, of course, is to keep elec-
trode consumption as low as possible. This benefits the
steelmaker in terms of low cost per ton of product, and
the electrode manufacturer by enhancing the competi-
tive position of the arc furnace in the steel industry.

DISCUSSION
by J. S. Davis and P. Schroth

ELECTRODE BREAKAGE PATTERNS AS A
FUNCTION OF ELECTRODE/NIPPLE
STRENGTH RELATIONSHIP
INTRODUCTION
Total electrode consumption results from longitudinal
and transverse loss as well as breakage. The wear rates
in the longitudinal and transverse directions are gen-
J. 5. DAVIS and P. SCHROTH are affiliated with Research and Tech-
nology, Armco Steel Corp., Middletown, Ohio.
erally referred to as net consumption. When loss due
to breakage is added to the net consumption the total
is designated as gross consumption. Net consumption is
responsible for roughly 70 to 90% of gross consumption.
Breakage accounts for the remaining 10 to 30%.
In spite of the fact that net consumption constitutes
the largest part of electrode wear and electrode ma-
terial cost, at this point in time very little can be done
to significantly reduce net consumption short of dras-
tically altering the electric arc furnace process. To re-
duce costs, emphasis must be placed on those causes
responsible for electrode breakage. Although breakage
represents primarily a material cost, it also will show
146 Electric Furnace Proceedings, 1971
up as cost related to non-productive furnace time and
interrupted smooth operations.
ECONOMICS O F BREAKAGE L O S S E S
It is obvious that reduced graphite electrode break-
age will lower gross electrode consumption. But, still
just as important, to increase the salvageability of elec-
trodes will also decrease gross electrode consumption.
Figure 1 defines the socket area and indicates the three
important planes of reference, namely (1) top of socket,
(2) center of pin, and ( 3 ) bottom of socket. Figure 2
illustrates the types of breaks most frequently experi-
enced. Important here is that when either a top or bot-
tom of socket break occurs a portion of the electrode is
destroyed.
From the standpoint of salvageability of broken elec-
trodes, the pin break and top of socket break offer the
greatest potential. When a nipple break is experienced,
the portion of the nipple remaining in the fallen section
is merely removed. The salvaged electrode can at least
be reused as a starter section. If the fallen piece con-
tains two electrode sections, it can be disassembled and
the upper section can be used again as a regular addi-
tion to the furnace. A top of socket break offers the
same salvage potential as the center of pin break be-
cause only the collar of the uppermost section need be
Top of Socket
Socket Area Center of Pin
Bottom of Socket
Fig. 1-Electrode column.
T o p of S o c k e t Center of Pin Bottom of Socket
Fig. 2-Types of electrode breaks.
removed and discarded. Therefore, of the three most
frequently experienced types of breaks, two are less
costly. However, an electrode joining system can be de-
signed only in two ways: (1) the nipple is weak rela-
tive to the electrode so a high percentage of center of
pin breaks ensue or (2) the nipple is strong relative
to the electrode so there is a predominance of collar
breaks. If there is a tendency for collar breaks to occur,
only chance will decide if there will be a top or bottom
of socket break. Since the bottom of socket break offers
the least potential for salvage, the electrode joining
system must be designed in such a manner that the
nipple is weaker than the electrode. Only such a design
will preclude the frequent occurrence of bottom of
socket breaks and insure the highest salvage rate.
OPTIMUM JOINT SYSTEM DESIGN
The proper relationship between electrode strength,
nipple strength and nipple size can help to determine
(1) the breakage rate, and (2) the breakage pattern.
(1). The breakage rate is the total number of breaks
experienced as a percentage of the total number of elec-
trodes added.
(2). The breakage pattern is the number of collar
breaks and nipple breaks as a percentage of the total
number of breaks experienced.
It must be made clear that the joining system design
considerations regarding the relative strength of elec-
trodes and nipples are intended to alter breakage pat-
terns without increasing breakage rates. Only if the
breakage rate remains unchanged or is decreased will
changes in the breakage pattern favorably affect the
economics of the process.
In order to develop this approach further, calculations
of the optimum assemblage have been conducted. It is
understood that other variables might also affect break-
age rates and patterns. In spite of all these factors, ex-
perience has shown that the maximum load bearing
ability of a joint does control overall breakage pattern
and breakage rate.
ELECTRODE A N D N I P P L E LOAD B E A R I N G A B I L I T Y
To calculate the load bearing ability of a n electrode
joint, based on the flexural strength of graphite, the
cross-sectional area of the nipple at its maximum di-
ameter is first calculated. The area is multiplied by the
flexural strength to yield the maximum load that can be
sustained. Table I shows the calculated strengths of
nipples from 9 % " ~ through 1 2 % " ~ with flexural
strengths ranging between 1950 and 3000 psi.
Next, the strength of the electrode at the plane cor-
responding to the normal top or bottom of socket break
is calculated. The calculation accounts for the taper of
the socket. The cross-sectional area of the socket break-
age plane is affected by both the nipple diameter and
the overall length of the nipple. In any event, decreasing
the area of the socket breakage plane lowers the maxi-
mum strength of the electrode. Tables I1 and I11 illus-
trate the maximum load that an electrode can sustain
at the socket plane for 2 0 " ~and 2 4 " ~electrodes for
different nipple diameters and electrode flexural
strengths. The dimensions of the most frequently used
commercially available standard nipples are noted in
Table I.
Table I. Nipple Load ~ e a ' r i nAbility
~
Maximum Load Bearing Abillty (Ih)
Area at with Nominal Flexural Strengths of:
Maximum
Nipple Diameter 1950 2200 2750 3000
Size (in.) (in.2) Psi psi psi PSI
 Interrelation of Materials and Equipment 147

FLEX. STR. FLEX. STR.

Table 11.' Electrode Load Bearing Ability 20"+ Electrodes APPLIED P.S.1. P. S.I.

Maximum Load Bearlng 600,000

Electrode Ablllty (lb) wlth Nomlnal
Cross- Area at Area of Flexural Strengths of:
Nlpple Sectional Bottom of Breakage
Size Area Socket Plane 800 1000 1200
(In.) (Ln.2) (111.2) (111.2) PSI PSI PSI

Table Ill. Electrode Load Bearing Ability 24"@ Electrode

Elec- Maximum Load Bearlng Abillty

trode Area at Area of (Ib) wlth Nomlnal Flexural
Cross- Bottom Break- Strengths of:
Sectional of ase
Nlpple Area Socket Plane 800 1000 1300 1600
Size (In.?) (in.2) (In?) psl psi psl psl

NIPPLE DIAMETER (IN.)

Plotting of the numerical values from Tables I
through 111 result in Figures 3 and 4. The solid lines Fig. &Load bearing relationship between electrodes and nipples-
indicate the maximum load bearing ability of the elec- 24-inch diameter electrodes.
trodes. The dotted lines show the strengths of nipples.
The graphs denote the maximum load that can be sus- O/oNIPPLE BREAKS
tained by an electrode joint area once the following
items are determined: (1) nipple diameter, (2) nipple
flexural strength, (3) electrode diameter, and (4) elec-
trode flexural strength. For a given set of diameters
and flexural strengths the graphs also predict whether
loo 0
the nipple or electrode will fail under the maximum
load.
Domestically, there are two grades of electrodes avail-
able to the steel industry, namely high density or pre-
mium electrodes and low density or regular electrodes.
The premium electrodes generally have higher strength
than the regular electrodes. Typically, premium elec-
trodes will have flexural strengths of about 1300-1600
psi (91-112 kg/cm" whereas regular electrodes show
flexural strengths of about 800-1000 psi (56-70 kg/cm2).
It is frequently stated that the stronger the electrode,
the better. This axiom is at best misleading. The follow-
ing example will serve to prove that a stronger elec-
trode alone is not what is needed in many cases. In the
case of a 24"+ premium electrode with a 1600 psi (112
kg/cm2) flexural strength and a n 11-%"+ nipple with a

APPLIED
LOAD FLEX. STR. FLEX. STR. I I I
(POUNDS) P s I. P. S.I.
0.5 1 .O 1.5 2.0 2.5
ELECTRODE /NIPPLE LOAD BEARING ASILITY RATIO
Fig. ftElectrode/nipple load bearing ability vs % nipple breaks.

flexural strength of 3000 psi (210 kg/cm2) the maximum

load bearing ability of the nipple is 330,000 pounds
(150,000 kg) and that of the electrode 615,000 pounds
(280,000 kg). Obviously, when a load of greater than
330,000 pounds (150,000 kg) is applied to the electrode
column the nipple will fracture. Even if the electrode
were twice as strong, the break would not have been
prevented. In an electrode socket area the "weakest
link" will be the most likely to fracture under load. If
the illustration is changed to use a nipple of 13'hW+
with a 3000 psi flexural strength, the maximum load
that could be sustained would be about 430,000 pounds
(195,000 kg). The probability of a break occurring would
be lessened considerably. Still, a stronger electrode
alone would not lower the frequency of breaks.
The foregoing example illustrates that the weakest
NIPPLE DIAMETER (IN.) link will cause failure and that breakage rates as well
Fig. 3-Load bearing relationships-20-inch diameter electrodes. as patterns can be altered. In current electrode/nipple
148 Electric Furnace Proceedings, 1971

both the breakage rates and patterns for each melt shop.
Table IV. Breakage Rates and Patterns of Armco Melt Shops In the shops utilizing 24"@ premium density electrodes
(September 1971) the average nipple strengths are about 3000 psi (210 kg/
cm') ; the average electrode strength about 1600 psi (112
Breakage Pattern (I) kg/cm2). Houston No. 2 also uses 24"@ regular electrodes
with nipple strengths of 3000 psi (210 kg/cm2) and elec-
% Break- Top of Center Bottom
age Rate Socket of Pin of Socket Other trode strengths of about 1000 psi (70 kg/cm2). In shops
utilizing 20"@ regular electrodes average nipple
strengths run 2200 psi (155 kg/cm2) ; the average elec-
ZI"$-Premium
Shop A trode strengths about 1000 psi (70 kg/cm2).
Shoo B The shops utilizing 24"@ electrodes use 113/4"@ nip-
ples; the shops using 20"@ electrodes use lO3/4"@ nip-
ples. With nipple and electrode diameters and their
r~hop B 6.9 23.6 51.2 23.6 1.5 flexural strengths known, the load bearing abilities can
Shop C 7.2 24.2 38.5 24.5 12.8 be calculated. A ratio of the electrode to nipple load
Shop D 8.6 22.0 40.0 19.4 18.8 bearing ability is determined. For Armco Melt Shops
using 24"@ premium electrodes the ratio is 1.89. The
shop using 24"@ regular electrodes has a ratio of 1.18.
joint designs a difference exists between the maximum Shops using 20"@ regulars have a ratio of 1.30. Figure
load carrying ability of the electrode and the nipple. 5 is a plot of the electrode/nipple load bearing ability
The magnitude of the difference is what gives rise to a ratio vs. the % nipple breaks as shown in Table IV. The
particular breakage pattern. linear regression of the ratio on the % nipple breaks
has an explained variance of 61.9%.
BREAKAGE PATTERN In summary, the electrode/nipple load bearing ability
At the various Armco shops, electrode breakage has ratio can reasonably predict the breakage pattern for an
been monitored for several years. Table IV illustrates electric furnace operation.