In the smelting industry, carbon and graphite are used in several different forms. Carbon and graphite are used as both electrodes as well as for blocks. Carbon blocks can be found in use as sidewall blocks as well as used as cathode blocks.
Most of the carbon blocks used in the United States in aluminum smelting facilities are made outside of the USA. Smelting facilities in the USA rely on the suppliers to choose the highest quality products to ensure optimal performance, long life cycles and uniformity essential in the process.
Sidewall Blocks
In the development of the potshells or the tanks used for melting aluminum, blocks provide protection to the outer steel layer and also create a form a layer of material with thermal insulating properties. They also prevent heat loss, ensuring a more effective process.
These blocks are extremely large and can be formed in shapes which will weigh in at more than a ton. They consist of pitch and ground carbon and are specifically made to meet requirements for the given application.
Cathode Blocks
The cathode blocks are often much larger, weighing in at over a ton each. They are produced either as standard size or to the particular requirements of the customer. As these types of carbon blocks have to be conductive, they go through a significant baking process that is in excess of two weeks.
With both sidewall and cathode blocks, different materials used in the manufacturing can increase or decrease the quality. Excessive fillers or differences or variations in the baking process can produce more or less porous blocks, which will have an impact on the performance and durability as well as the life cycle.
Working with a top supplier importing both carbon and graphite blocks from recognized manufacturers working to industry standards will be critical to any smelting facility.