High Purity Graphite Electrode Process

Takahashi said the integration plan with SGL Carbon provides an opportunity for its staff and SDK to learn from each other. Combining the core competencies of the two companies - particularly the cost efficiency of the former and the product quality expertise of the latter - helps to deliver "a product with the best value for use: a combination of quality and price," he said. He emphasized the importance of consistent UHP electrode performance.

Monitoring each plant's key performance indicators and comparing them to those of the group's sister projects helps to benchmark their relative positions. For example, he points out that the number of people needed to produce a ton of UHP graphite electrodes can vary from two to 20. Energy and labor costs are also being monitored and compared.

The basic quality parameters of the produced electrodes are low thermal expansion coefficient, high flexural strength and low electrical resistance. SDK provides technical services and advice to steel producers through its ECOPRO® program. Takahashi explained that it started in the U.S. and rolled out globally, overseen by a South Carolina-based head of global technical services.

In addition to electrodes, the program covers other aspects of the EAF process. SDK reports that successful collaborations so far include: increased productivity and reduced operating costs; improved power and process characteristics; reduced energy consumption; optimized carbon/oxygen injection and chemical energy consumption.

Most electrode producers follow a similar six-stage production process, but they vary in capacity and device efficiency, Takahashi noted. While an Industry 4.0 approach to monitoring plant performance and the potential benefits of using AI are among Takahashi's goals, he admits they are in the early stages of SDK evaluation. "The graphite electrode industry is very conservative," he said. "It's what they did in the '80s and '90s," he added.

As for most large international technology and equipment suppliers, apart from taking advantage of SGL Carbon's integration advantages, SDK's focus is to be a good partner in the steel industry and build long-term relationships with customers. "We want to provide our customers with products at reasonable prices when and where they want," he concluded.