8mm Copper Rod Casting Machine / Big Capacity Continuous Caster For Copper Rod

 

 

TECHNICALDESCRIPTION OF

COPPER ROD CONTINUOUS CASTING & THREE ROLLING LINE

 

1. Application and Composition

This plant works to produce low-oxygen copper rod in 8mm diameter by means of

continuous casting and rolling process, with cathode and copper scrap as the raw material.

The plant is composed of one set of tilting&refining furnace with 30 tons capacity,

five-wheel casting machine, drive unit, roller shears, straightener and burring unit, shaver,

rolling mill, coiler, and electrical control system. If cathode is used, a melting furnace(shaft

furnace) with 16-ton/hour capacity and 12-ton holding furnace are required.

 

2. Brief Process Flow

Charging copper scrap (grade 1 or grade 2) → melting and refining in tilting&refining

furnace → launder to protect molten copper → ladle → casting machine to get cast bar

→ roller shears → straightener → burring unit → shaver to treat cast bar → feed-in

unit → rolling mill → cooling unit to quench rod → winding unit to pre-shape rod →

star coiler to lay rod into coil.

 

3. Copper Scrap as raw material

Red copper scrap as the raw material must be Grade 1 or Grade 2.

3.1. Copper scrap on excellent grade (Pb<100, Sn<300, Ni<50, Zn<50, Fe<50 and Sb<20)

should be clean and non-alloy copper wires free from tin, containing no fragile burned

wires.copper contentno less than 98%

3.2. Copper scrap on grade 2 (Pb<1000, Sn<800, Ni<150, Zn<300, Fe< 500, Sb<100, S<200)

should be small director copper wires without insulation, usually containing telephone

wires, copper bus bar with varnish coating or paper insulation, and thick or thin, clean

copper bar.copper contentno less than 94%

Charging raw material requirement:grade1(copper contentno less than 98%) must be more than 50%,

grade 2(no less than 94%) no less than 30%,motor’s enamelled wire <20%(copper contentno less than 92%).

 

4. Main Technical Specifications

4.1. Diameter of rod: φ8mm

4.2. Capacity: 12~15tons/hr.

4.3. Weight of coil: 3.0~5.0tons

4.4. Overall dimension of plant: 40×7.8×6.1m (not including melting furnace and cooling

water circulation system)

4.5. Weight of plant: 85 tons (not including furnaces)

4.6. Total power of plant: 650kW (not including furnaces)

 

5. Components and Specifications

5.1. 30T tilting&refining furnace 1 set

5.1.1 Gas source requirement:( Description: the natural gas and liquefied petroleum gas (LPG)

are available, the following gas for example) 2

5.1.1.1 Calorific value: NG 8500 kcal/ Nm 3

5.1.1.2 Flux(combustion system): Q :450m 3 /h

5.1.1.3 NG supply pressure: P:0.15—0.2Mpa

5.1.1.4 Flux(reduction system): Q :300m 3 /h(working 2~3 hours)

Reduction system pressure: P:0.3—0.4Mpa

Or using living tree(wood) to reduce the oxygen in the liquid mixed metal.

5.1.1.5 Compressed air source requirement(share with CCR)

5.1.1.6 Flux: Q : 20m 3 /min

5.1.1.7 Pressure: 0.4MPa

5.1.1.8 Properties: Must be dry , no water and oiliness

5.1.1.9 Cooling water

5.1.1.10 Flux: Q : 100NM3/H

5.1.1.11 Pressure: 0.4MPa

5.1.1.12 Nitrogen

5.1.1.13 Pressure: 0.6Mpa Q:200NM 3 /H(only one hour)

5.1.2. Equipment composition:

This set of tilting furnace including furnace body, DC drive system, gas combustion

system , REDOX system,electric control system.

Customer own:smoke hoods,chimney flue(about 50M), dust collection

system,charging device(forklift),launder,NG regulator station,air compressor,cooling

water supply system,power supply system ,direct reading spectrometer,oxygen

nitrogen analyzer,metallurgical temperature and oxygen online detector,tools of lay

bricks,tools and devices of commissioning,all installation material.

5.1.3. Technical specification

5.1.3.1 Melting furnace type: titled type circular furnace

5.1.3.2 Copper melting time: about 9 hours

5.1.3.3 Oxidized time: about 2 hours

5.1.3.4 Reduction time: about 2 hours

5.1.3.5 Charging ways: forklift truck ends charging

5.1.3.6 Furnace effective capacity: not less than 30T

5.1.3.7 Raw material copper content no less than 98%+no less than 94%+no less than 92%

5.1.3.8 NG consumption of per ton rod low-oxygen copper rod: 90~100NM3

5.1.3.9 Furnace lining Mg-chrome bricks and mg-chrome castable, etc

5.1.3.10 Fuel NG

5.1.3.11 Ignition method manual

5.1.3.12 Dia of gas supply pipe DN100

5.1.3.13 The total power 80KW

5.2. Five-wheel Casting Machine 1 set

5.2.1. Diameter of casting wheel: φ1900mm

5.2.2. Speed of casting wheel: 1.84~2.814rpm

5.2.3. Delivery speed of cast bar: 10.17~15.56m/min

3

5.2.4. Cross sectional area of cast bar: 2300mm 2

5.2.5. Motor: 5.5kW (AC, variable frequency, speed regulated)

5.2.6. Pressure of cooling water: 0.3~0.5Mpa

5.2.7. Amount of cooling water: 170m 3 /h

5.2.8. Temperature of cooling water: < 35

Composed of casting wheel, press-down wheel, tension wheel, guide wheel, pouring ladle,

cooler, air blower, de-dusting brush, heater and carbonating device, cast bar taker, guide bridge,

carbonating device, drive mechanism, water regulator, pneumatic control system, all of which

are mounted on the same base plate except the guide wheel.

5.3. Roller Shears, 1 set

5.3.1. Motor: 15kW (AC variable frequency, speed regulated)

5.3.2. Length of cast bar cutting: 700mm

Composed of AC drive and needle cycloidal reducer two blades are fitted on the wheel of

the shears to cut the cast bar in a length of 700mm approximately.

5.4. Straightener & Burring Unit, 1 set

Composed of straightener and burring unit, with five wheels for straightener, two of which

on upper side and three of which on lower side fitted in alternative positions, the burring unit

has four blades to cut off the burr from the cast bar.

5.5. Shaver, 1 set

Motor 0.75kw

Shaver works to brush off chips on the surface of the cast bar after the burr is cut off, four

shaving rollers are individually driven by motors.

5.6. Continuous Rolling Mill(three roll) 1 set

5.6.1. Main motor: 450kW (DC)

5.6.2. Final rolling speed: 10m/sec. (max.)

5.6.3. Final diameter of rod: Dia. 8mm

5.6.4. Center height of rolling: 902.5mm

5.6.5. Quantity of total stands: 12 sets

5.6.6. Two-roller stands: 4 sets

5.6.7. Three-roller stands: 8 sets

5.6.8. Nominal diameter of roller: Dia. 255mm

Motorized feed-in device for rolling mill, with drive from the main transmission box, and

with pneumatic cylinder to clamp the cast bar and help to feed it into the first stand. 4 pairs of

stands with two rollers in 255mm diameter, 2 pairs of stand with vertical rollers, and 2 pairs of

stands with horizontal rollers work to roughen the cast bar, while 8 pairs of stands with rollers in

Y arrangement work to size the cast bar. The stands have upper drive and lower drive arranged

alternatively. In case of overloading during the rolling process, a pin in the safety shaft coupling

is cut off to protect the gears and the shaft.

5.7. Emulsion Lubrication System, 1 set

5.7.1. Emulsion pump: 80m 3 /hr, 15kW

5.7.2. Filter: GLQ-100

5.7.3. Chiller: 35m

The system is composed of chiller, filter, and two centrifugal pumps. Emulsion is pumped

through the centrifugal pump, filter, and chiller into the master pipeline on top of the gearbox,

and then flows into the stands via hoses to lubricate the gears, rollers, and inlet and outlet

positioners, and finally returns back to the emulsion tank via the return channel on the base of

the rolling mill.

5.8. Oil Lubrication System, 1 set

5.8.1. Gear pump: 5.5kW

5.8.2. Working pressure: 0.1~0.3Mpa

5.8.3. Filter: GLQ-80

5.8.4. Oil tank: 5m 3

This system is composed of oil tank, filter, and two gear pumps. Oil in the oil tank is

pumped through the filter into the master pipeline at the back of the gearbox, enters the gearbox

through three lines, and from oil nozzles lubricates the gears and rolling bearings by spray. Oil

finally returns to the oil tank from the low end of the gearbox.

5.9. Coiler, 1 set

It is composed of cooler, operation platform, clamp and delivery device, guide bridge,

circular winder, trolley, and alcoholic water supply system.

5.9.1. Drive unit

Drive speed: 11m/sec. (max.)

Drive motor 11kW (AC)

Two motorized clamp and delivery, with spring to adjust the pressure. AC motor drives a

clamp roller via V-belt to push the rod forward, while two pairs of gears driving another clamp

roller to push the rod simultaneously.

5.9.2. Rod winder

Coiling diameter: 1400mm

Winding motor: 4kW (AC, variable frequency and speed regulated)