According to Texas-based ITC, the coating, during a 10-day preliminary trial, reduced electrode consumption by 25% to 30%. The trial was carried out on a 24-inch electric arc furnace (EAF) electrode at an unidentified Midwest mill. 

The company said it was a remarkable result and demonstrates the product’s efficacy in reducing oxidation and penciling of graphite electrodes. Further trials are expected to show additional benefits, such as reduced power consumption and greater efficiencies through shorter heat and tap-to-tap times. 

“We are thrilled to achieve such incredible results in extending the life of EAF electrodes, and we’re excited for the next phase of the trial, where we believe additional benefits realized by the meltshop will cause overall savings to be even greater, resulting in millions of dollars added to the bottom line,” said ITC Coatings president Justen Womack.

A key element of the project is a fully automated application system that can be inserted seamlessly into a mill’s electrode storage and handling. The system was developed in conjunction with EAFab Corp., a Pittsburgh-based design and construction firm focused on providing meltshop solutions. Development of the system was sponsored by the U.S. Defense Department’s Defense Logistics Agency.