Process for the Production of Lower-Carbon and Carbon-Free Electrode Honeycomb Body Material Composites for Use in Metallurgy

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This invention introduces a method for producing low-carbon or carbon-free electrodes with a honeycomb structure, specifically designed for use in metallurgical processes such as iron, steel, aluminum, copper, or silicon production. The electrodes are manufactured by extruding metals and oxides into a honeycomb shape, followed by thermal treatment and sintering. The resulting composite electrodes are more environmentally friendly and offer multiple functionalities, including reduced carbon emissions and enhanced chemical/physical stability during metal processing.

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• Electrodes for electric arc furnaces in steel mills, replacing traditional carbon electrodes.
• Anodes for aluminum smelting processes, reducing direct CO2 emissions.
• Electrochemical treatment of metal melts or slags in metallurgy, including refining or alloying.
• Plasma torch applications in metallurgical reactors, utilizing the electrode as a burner.
• Precise chemical modification of slags by controlled addition of oxides during processing.
• Electrodes for non-ferrous metal production (e.g., copper, silicon) where carbon contamination must be minimized.

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• Significantly reduces or eliminates carbon emissions from electrode consumption in metallurgical processes.
• Improves operational lifetime and durability due to enhanced oxidation and corrosion resistance.
• Enables controlled gas or solid addition into melts/slags during processing, allowing better process control.
• Prevents undesirable carbon contamination in final metals, improving product purity.
• Offers design flexibility through extruded honeycomb structures, optimizing thermal and electrical performance.
• Supports sustainability goals in metallurgy by replacing consumable carbon electrodes with long-life, inert alternatives.

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Patent Abstract

The invention relates to carbon-free electrodes for metallurgy, for example for iron, steel, aluminium, copper or silicon metallurgy, in aggregates for the preparation of metallic melts or for the treatment of metallic melts and/or slags, for example in electric arc furnaces or ladle furnaces, on the basis of metal or metals and oxide or oxides without or in combination with water cooling. According to the invention, the low-carbon or carbon-free electrodes are extruded as a honeycomb geometry by means of plastic shaping at room temperature or at a slightly elevated temperature up to about 300°C, then thermally heat-treated and sintered at temperatures between 600 and 2000°C. According to the invention, this produces an electrode/honeycomb composite with multiple functionalities.