Precision Manufacturing, Quality Forged

At Zhangzhou Zhenda New Material Co., Ltd., we leverage advanced production processes and stringent quality management to ensure every product meets exceptional standards. Our facilities are efficient, environmentally conscious, and highly automated, covering every stage from raw material selection to final product delivery.

1. Silicon Metal Production Process

Our Silicon Metal production begins with a rigorous selection of raw materials, ensuring superior quality from the very source.

1. Raw Material Selection: We meticulously source high-purity, high-silicon-content quartz stone (silicon dioxide, SiO2) globally, alongside premium reducing agents (such as petroleum coke, wood chips). All raw materials undergo strict physical and chemical parameter testing upon arrival to ensure they meet our stringent internal specifications.

2. High-Temperature Smelting: Precisely proportioned quartz stone and reducing agents are fed into advanced closed or semi-closed electric arc furnaces for high-temperature smelting. At extreme temperatures exceeding 1800°C, silicon dioxide is reduced by carbon, yielding high-purity liquid silicon. This process is meticulously controlled for furnace temperature, current, and material ratios to optimize silicon purity and energy consumption.

3. Cooling & Solidification: The molten silicon is tapped from the furnace and allowed to cool naturally under specific conditions, gradually solidifying into high-quality silicon ingots. Cooling rates are strictly managed to ensure uniform ingot structure and stable crystalline properties.

4. Crushing & Processing: The cooled silicon ingots are then transferred to our crushing line. Through multi-stage crushing and screening equipment, they are processed into various particle sizes to meet market and customer demands. Standard sizes typically range from 10mm to 100mm, with capabilities for finer custom-sized particles as required by clients.

5. Quality Inspection & Packaging: Before packaging, every batch of finished silicon metal undergoes comprehensive spectroscopic analysis and various physical property tests in our well-equipped laboratory to ensure purity and consistency across all parameters. Qualified products are robustly packaged according to international standards, with custom packaging options available, ready for safe and efficient global shipment.

Our streamlined and highly efficient Silicon Metal production process ensures exceptional product purity, consistent batch quality, and optimal performance across diverse industrial applications, including casting, aluminum alloys, organosilicons, and the electronics industry.

2. Silicon Carbide Production Process

Our Silicon Carbide (SiC) products are manufactured using the Acheson process, a well-established and highly efficient high-temperature synthesis method.

1. Raw Material Preparation & Proportioning: The primary raw materials include high-purity quartz sand (SiO2) and petroleum coke (carbon source). These materials undergo rigorous screening, drying, and crushing before being precisely mixed according to accurate stoichiometric ratios to ensure complete synthesis reaction. A small amount of sawdust is also added as a burn-out agent to improve the permeability of the furnace charge.

2. Acheson Furnace High-Temperature Synthesis: The mixed raw materials are loaded into specially designed resistance furnaces, known as Acheson furnaces. Graphite electrodes installed in the center of the furnace act as heating elements. As current passes through the electrodes, extremely high temperatures of 2000-2600°C or even higher are generated. In an oxygen-deficient environment, the quartz sand and petroleum coke undergo a carbothermal reduction reaction, producing crude silicon carbide crystals.

3. Cooling & Unloading: After the reaction is complete, the furnace requires several weeks of natural cooling. Once cooled, the furnace charge is carefully removed, and the silicon carbide crystalline blocks (furnace core) formed around the electrodes are extracted. Unreacted or partially reacted outer layers of the charge are recovered and recycled.

4. Grading & Processing: The extracted silicon carbide crystalline blocks undergo physical and chemical treatments including crushing, grinding, acid-alkali washing (to remove impurities), and multi-stage screening. This process precisely separates them into silicon carbide grains or micro-powders of various sizes, purities, and morphologies. Depending on application requirements, we can provide abrasive grade, refractory grade, metallurgical grade, and other specific specifications.

5. Quality Control & Packaging: Before dispatch, all finished Silicon Carbide products undergo comprehensive testing for physical properties (particle size distribution, bulk density, true density) and chemical properties (SiC content, free carbon, free silicon). Qualified products are professionally packaged according to customer specifications, ensuring quality integrity during transportation.

Our Silicon Carbide products, renowned for their exceptional hardness, wear resistance, high-temperature stability, thermal conductivity, and chemical inertness, are widely applied in abrasives, refractories, ceramics, metallurgical deoxidizers, and other fields.

3. Graphitized Petroleum Coke (GPC) Production Process

Graphitized Petroleum Coke (GPC) is a high-quality carbon material produced by high-temperature graphitization, transforming regular calcined petroleum coke into a substance with a graphite crystalline structure.

1. Raw Material Preparation: High-quality calcined petroleum coke (CPC) is selected as the primary raw material. The CPC undergoes strict screening to ensure its ash content, sulfur content, volatile matter, and other parameters meet the stringent requirements for graphitization.

2. Batching & Forming (for specific types): Depending on the intended application of the final GPC, the calcined petroleum coke can either be graphitized in bulk, or it can be mixed with binders like pitch and then formed into specific shapes (e.g., carbon electrodes, graphite electrode blanks) through pressing or extrusion.

3. High-Temperature Graphitization Treatment: This is the core step. The calcined petroleum coke or its formed products are loaded into specialized graphitization furnaces (e.g., Acheson furnaces, internal series furnaces). Through electrical heating, the internal temperature of the furnace is raised to 2500°C to 3000°C or even higher. At such extreme temperatures, the amorphous carbon atoms within the calcined petroleum coke rearrange to form highly ordered, layered graphite crystals. This process typically lasts from several days to several weeks.

4. Cooling & Unloading: After graphitization is complete, the furnace undergoes a prolonged natural cooling process to ensure the stability of the products properties. Once cooled, the furnace charge is removed.

5. Crushing, Screening & Fine Processing: The extracted blocky graphitized coke undergoes multi-stage crushing, rigorous screening, and impurity removal. This precisely separates GPC products of different particle sizes, purities, and electrical resistivities. Additional washing, drying, or surface treatments may be performed according to customer requirements.

6. Quality Control & Packaging: Every batch of GPC product undergoes comprehensive testing for critical parameters such as electrical resistivity, ash content, sulfur content, true density, and porosity. Qualified products are packaged according to international standards, ensuring safe transportation and product integrity.

Our Graphitized Petroleum Coke (GPC) products, characterized by their high carbon content, low sulfur and nitrogen, low electrical resistivity, high purity, and excellent electrical and thermal conductivity, are widely used in steelmaking recarburizers, foundry recarburizers, friction materials, lithium-ion battery anode materials, refractories, and various other fields.