Industrial Applications
Natural graphite is an excellent conductor of electricity and heat. The strength of its crystalline molecular structure also allows it to withstand extremely high temperatures, and it is not affected by a majority of reagents and acids. These properties are ideal for use in a wide range of traditional industrial applications as follows:
Casting Molds, Dies and Tooling
The most common applications for graphite within this area are in the manufacture of crucibles and molds, graphite heating elements, heat treating furnace fixturing, chemical processing equipment, molten metal extrusion, pressure casting, vertical and horizontal continuous casting, centrifugal casting, graphite susceptors, heat shields and furnace linings.
Chemical and Electro-Chemical Process Technology
Plant availability combined with greater operational reliability and lower emission rates are of key importance to our customers. Aggressive and volatile media in chemical processes rely on corrosion resistant graphite materials to ensure that these manufacturing operations are safe and reliable. Here are a few of the products that use graphite in chemical processes:
- Vessels and components (e.g. support grids) made of graphite for chemical plants
- Graphite blanks for manufacturing heat exchangers
- Graphite spreaders in distillation columns
- Vessels and Reactors, Bushings & Bearings, Packing Rings & Seals, Roller Guides, Valves, Rotors & Vanes
- Graphite anodes and cathodes for chlorine-alkali electrolysis
- Electrodes for chemical separation processes
- Graphite anodes and cathodes for electrolysis of lithium, sodium, magnesium and fluorine
- Anodes for corrosion protection of pipe lines
Dispersons
Graphite dispersions are used in applications that require a uniform and fine distribution of graphite on the surface of a carrier material. Depending on the individual application, properties such as sedimentation stability, surface tension, wetting behavior and adhesive power on different surfaces, drying time, viscosity, pH value and ionogenity all play varying roles of importance. In order to improve dispersing effects, formulations may also contain protective colloids, preserving agents, and other additives. The following are applications for graphite dispersions:
- Hot metal forming
- Coating systems
- Matrix coating
- Glass, Rubber, Can, Seed, Raiway and Switch, and Power Line coating
Ferrous Metallurgy & Continuous Casting Technology
The use of graphite in ferrous metallurgy and continuous casting has been one of the traditional areas of application. The following are just a few of the places graphite is used:
- Graphite Trays & Boats, Crucibles, Fluxing (Degassing) Tubes, Molds & Dies, Furnace Parts, Foundry Accessories, Canisters & Aluminum, Extrusion Boards Anodes, Crucibles, Ingot Molds, Custom Molds.
- Large sized blanks and graphite dies for continuous casting of stainless steel and grey iron.
- Large sized blanks and molds for pressure casting, continuous casting, centrifugal casting and wheel casting; graphite plates for cooling of complex grey iron shapes.
Glass and Ceramics Industry
Graphite is used to produce precisely machined components used in the continuous production of plate glass in float glass systems. It is an ideal material given the high temperatures and heavy loads that characterize the production processes in glass manufacturing. The following are common products using graphite in the glass and ceramics manufacturing industries:
- Tin bath linings, cooling equipment and top rollers, guidance systems for the tin bath, gas guide systems and insulation felts for the production of float glass
- Scoops for distribution of glass drops, molds and various accessory parts made of carbon, graphite or carbon composites for container glass production
- Graphite dies and plungers for hot pressing processes for the production of e.g. boron nitride products
- Furnace components for manufacturing high performance ceramics
Heat Treating Industries
High-temperature processes such as the heat treatment of metals under vacuum or inert gas rely on graphite in numerous situations. In these environments materials must be suitable for temperatures up to 2,200°C, exhibit high creep resistance, and be chemically inert. The following are typical examples of materials using graphite in heat-treating:
- Flexible and rigid felt for thermal insulation
- Flexible graphite foils and CFC for heat shields
- Laminated sheets for electrical heating elements
- Dies and support plates for brazing processes
- Charging systems and furnace equipment made of graphite for hardening, sintering, brazing and coating processes
- Molds made of graphite for manufacturing aerospace components
- Boats, crucibles and other containers, liners, heaters, heating tubes for cemented carbide production
Medical Technologies
Owing to its excellent properties, graphite is also used for the manufacture of the rotating anodes used in X-ray tubes. The high quality standard of the graphite and consistency in its mechanical properties make us a reliable supplier.
- Graphite discs as heat sinks for X-ray anodes
- Dental crucibles for melting precious metal alloys
- Operating materials for manufacturing of mechanical heart valves
Non-ferrous Metallurgy
A primary application for graphite in this area is the aluminum production process. The following are common products that rely on graphite in this area:
- Large sized blanks, graphite dies and plates for continuous casting of non-ferrous and precious metals
- Large sized crucibles and heating systems for melting and holding processes
- Fluxing tubes, gas distribution and gas injection systems for purification of aluminum melts; plates and belts for run-out tables for aluminum profile extrusion; crucibles and boats for aluminum casting; electrodes for aluminum surface cleaning
- Electrical contacts, dies and support plates for brazing processes
- Crucibles for gas analysis of metals
- Aluminum casting rings made of graphite
Refractory Manufacturing
Refractories are heat-resistant materials that constitute the linings for high-temperature furnaces and reactors and other processing units. These can range from simple magnesia-carbon bricks to complex geometric shapes used to line boilers and furnaces of all types – reactors, ladles, stills, kilns, etc. – and are required for heating applications above 538°C. In addition to being resistant to thermal stress and other physical phenomena induced by heat, refractories must also withstand physical wear and corrosion by chemical agents. Depending on the application, refractories must resist chemical attack; withstand molten metal and slag erosion, thermal shock, physical impact, catalytic heat, and similar adverse conditions.
Since the various ingredients of refractories impart a variety of performance characteristics and properties, many refractories have been developed for specific purposes. Specifically, refractories are produced from natural and synthetic materials, usually non-metallic, or combinations of compounds and minerals such as alumina, fireclays, bauxite, chromite, dolomite, magnesia, graphite, and zirconia. These refractories are available in a wide variety of shapes and forms roughly divided into brick or fired shapes and specialties or monolithic refractories. Refractory linings are made from these bricks and shapes, or from specialties such as plastics, castables, gunning mixes or ramming mixes, or from a combination of both.
Flake graphite, preferably high-purity, coarse-flake grades, provides good oxidation and corrosion resistance and the orientation of the flakes improves structural strength in various carbon-based castable refractories like ramming and gunning mixes and shaped refractories such as resin-bonded magnesia-carbon (mag-carbon) brick. Flake graphite is also used in alumina-graphite continuous casting ware, zirconia-graphite refractories for continuous casting, and silicon carbide-graphite refractories. The following is a brief discussion of various refractory types using natural graphite:
- Magnesia-carbon (mag-carbon or mag-graphite) refractories - developed in the 1970s, mag-carbon refractories consist of fused magnesia and crystalline flake graphite bonded with synthetic resin. Graphite contents vary between 15 - 25% with small flake sizes of between 0.15 to 0.71mm and carbon contents of 87 to 90% being preferred. In fact, the graphite grade has the most important influence on brick characteristics together with ash content, particle size and shape. Magnesia-carbon refractories are preferred in high temperature environments where corrosion is a problem, in particular in basic oxygen steel converters, electric arc furnaces, and slag zones in steel lines, ladles, and nozzles.
In basic oxygen steel converters, mag-carbon bricks are now the standard lining materials since they can withstand a much greater number of heating cycles than traditional pitch-bonded dolomite and fired magnesia dolomite bricks. They consequently need replacement much less often. In electric arc furnaces, mag-carbon bricks have also largely replaced the traditional mag-chrome bricks, particularly in slag zones. In the same way, mag-carbon refractories are increasingly used in steel ladle slag zones, replacing the more traditional alumina and zircon refractory linings. They can cope with the higher temperatures and dwelling times in the ladle more easily. This is where refining and trimming of the steel is now normally carried out.
- Alumina-graphite refractories - these refractories have excellent resistance to thermal shock and corrosion attack which is essential in continuous casting, shrouding tubes of slab and bloom casters, submerged entry nozzles, and torpedo ladles. The use of graphite in these refractories, which have to withstand contact with molten steel at 1,600°C, improves their thermal shock and corrosion resistance. High purity graphite with a large flake size is preferred.
- Zirconia-graphite refractories - the lifespan of alumina-graphite refractories is extended with a coating of zirconia or zirconia-graphite. A fused zirconia-graphite coating combines the extreme corrosion resistance of stabilised zirconia with the thermal shock and conductivity properties of flake graphite. However, the high cost of zircon has encouraged some refractory manufacturers to use spinel instead.
- Silicon carbide-graphite refractories - flake graphite is added to silicon carbide to enhance its thermal conductivity, shock resistance, and resistance to wetting by molten steel. These refractories, which commonly contain 3% carbon, have become increasingly popular in the manufacture of heater tubes and immersed pyrometer sheaths in zinc and aluminium applications.
INDUSTRIAL APPLICATIONS - general specifications for graphite used in industrial and high temperature applications.
PRODUCT FEATURES
PRODUCT RANGE
Benefits
Characteristics
Standard Graphite
Selected Graphite
Graphite Combination
Spherical Graphite
- High resistance to thermal shock
- High resistance to chemical attack and corrosion
- Reduced tool wear
- Good malleability and machinability to permit easy shaping.
- High thermal and electrical conductivity
- High purity
- High crystallinity
- Chemically inert
- High compressibility
- High flowability
- Low coefficient of thermal expansion
- Low hardness
- Low wetability
- Favourable porosity
Industrial purities and high crystallinity ranging in size from 10-1,000 microns.
Refractories: -40 +100 mesh
Purity: 85-99.5% C. Tap Density: .7-1 g/cm3
Real Density: 2.2 g/cm3+
High purity, high crystallinity, natural graphite milled and classified.
Combination of high purity graphite with expanded graphite, carbon black, carbon fibers and others so as to achieve high performance in special applications.
INDUSTRIAL APPLICATIONS - industrial application specifications based on flake size.
LARGE FLAKE
MEDIUM FLAKE
SMALL FLAKE
Flake Size:
Moisture:
Fixed Carbon:
Applications:
+72 mesh
0.50 Max
Up to 96%
Refractories, Crucibles, Exfoliation, Fluxes, Concast, etc.
Flake Size:
Moisture:
Fixed Carbon:
Applications:
+120 mesh
0.50 Max
Up to 96%
Gaskets, Stopper Heads, Exfoliation, Fluxes
Flake Size:
Moisture:
Fixed Carbon:
Applications:
+50 -200 mesh
0.50 Max
Up to 94-98%
Magnesia Carbon Refractories, Crucibles, Refractory Masses, Castables, Stopper Heads, etc.
- Alumina-graphite refractories - these refractories have excellent resistance to thermal shock and corrosion attack which is essential in continuous casting, shrouding tubes of slab and bloom casters, submerged entry nozzles, and torpedo ladles. The use of graphite in these refractories, which have to withstand contact with molten steel at 1,600°C, improves their thermal shock and corrosion resistance. High purity graphite with a large flake size is preferred.
- Zirconia-graphite refractories - the lifespan of alumina-graphite refractories is extended with a coating of zirconia or zirconia-graphite. A fused zirconia-graphite coating combines the extreme corrosion resistance of stabilised zirconia with the thermal shock and conductivity properties of flake graphite. However, the high cost of zircon has encouraged some refractory manufacturers to use spinel instead.
- Silicon carbide-graphite refractories - flake graphite is added to silicon carbide to enhance its thermal conductivity, shock resistance, and resistance to wetting by molten steel. These refractories, which commonly contain 3% carbon, have become increasingly popular in the manufacture of heater tubes and immersed pyrometer sheaths in zinc and aluminium applications.
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INDUSTRIAL APPLICATIONS - general specifications for graphite used in industrial and high temperature applications. |
|||||
| PRODUCT FEATURES | PRODUCT RANGE | ||||
| Benefits | Characteristics | Standard Graphite | Selected Graphite | Graphite Combination | Spherical Graphite |
|
|
Industrial purities and high crystallinity ranging in size from 10-1,000 microns.
Refractories: -40 +100 mesh
Purity: 85-99.5% C. Tap Density: .7-1 g/cm3
Real Density: 2.2 g/cm3+ |
High purity, high crystallinity, natural graphite milled and classified. |
Combination of high purity graphite with expanded graphite, carbon black, carbon fibers and others so as to achieve high performance in special applications.
|
|
|
INDUSTRIAL APPLICATIONS - industrial application specifications based on flake size. |
|||||
| LARGE FLAKE | MEDIUM FLAKE | SMALL FLAKE | |||
|
Flake Size:
Moisture:
Fixed Carbon:
Applications:
|
+72 mesh
0.50 Max
Up to 96%
Refractories, Crucibles, Exfoliation, Fluxes, Concast, etc.
|
Flake Size:
Moisture:
Fixed Carbon:
Applications:
|
+120 mesh
0.50 Max
Up to 96%
Gaskets, Stopper Heads, Exfoliation, Fluxes
|
Flake Size:
Moisture:
Fixed Carbon:
Applications:
|
+50 -200 mesh
0.50 Max
Up to 94-98%
Magnesia Carbon Refractories, Crucibles, Refractory Masses, Castables, Stopper Heads, etc. |
|
Latest Graphite Prices
2012 Industrial Minerals Graphite Prices per Tonne
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