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INNOVATION, ENERGY, EFFICIENCY

Carbide Industries story is deeply rooted in American history and the invention of the electric arc furnace.

 

The Carbide Industries story began in 1892, J.T. Morehead, T.L. Wilson, and J.C. King set out to refine aluminum—a metal more valuable than gold at the time. Using a new process that involved heating ore, lime, and coke in the newly developed electric arc furnace (EAF), they aimed to revolutionize aluminum production. 

Although their process failed to refine aluminum, it gave rise to a groundbreaking discovery: the discarded materials became the foundation of an entirely new industry, producing one of the most important chemicals of the 20th century—calcium carbide.

During World War II rubber was in high demand. To meet this critical need, the US government, academia and industrial laboratories came together to develop a synthetic rubber to meet the demand. A key ingredient in this effort, butadiene, was derived from acetylene gas generated from calcium carbide. The plant used during World War II to generate acetylene gas would later become Carbide Industries carrying forward a legacy of innovation and industrial progress.

North America’s Largest Submerged Arc Furnace.

Using the same basic process discovered in the 1890’s, modern calcium carbide involves heating a mixture of coke and lime at extremely high temperatures in an electric arc furnace (EAF). 

Carbide Industries’ story of success has resulted in an ultra-efficient submerged arc furnace (SAF) is the largest of its kind in North America. Designed for maximum efficiency, the SAF operates with the electrodes fully submerged in the charge of coke and lime, optimizing the production process and supplying the furnace with the energy efficiency required to achieve the nearly 4,000º F temperatures needed to manufacture carbide – 1,000º hotter than a steel furnace.

Molten carbide is continuously extracted from the furnace and cooled in special molds. After cooling, the carbide is crushed and screened to meet precise sizing requirements, ensuring a high-quality product is ready for use in a variety of applications.

The Carbide Industry Story Features Unparalleled Energy Efficiency and Quality in Every Batch

 

After being tapped from the furnace, calcium carbide is cooled to a few hundred degrees to prevent atmospheric moisture from compromising its purity. It is then transferred to the crushing and conveying system. From the moment the carbide enters the primary crusher until the shipping container is opened by the customer, it is kept under an inert nitrogen atmosphere to preserve quality.

Utilizing a computer-controlled system, carbide is produced in a variety of sizes ranging from fine powder up to 2-inch pieces, tailored to meet the desired reactivity needs for each customer’s process. Before shipping, all products are tested in an on-site laboratory to verify purity, particle sizing, and slurry content. Data is continuously monitored to maintain process control and certify the consistent quality of the product delivered.

Carbide Industries Locations

Carbide Industries Locations Worldwide

Carbide Industries – Corporate Office
4400 Bells Lane
Louisville, KY 40216

Carbide Industries – Calvert City
3204 Industrial Parkway
Calvert City, KY 42029