copper rod continuous casting and rolling line

1.      Equipment Name

Low-oxygen Copper Rod Continuous Casting and Rolling Line (including Shaft Furnace and Holding Furnace)

2.      Application

It’s used to melt, cast and roll copper.

3.      Main Technical Parameters

Copper rod bundle dia.:  Ф1600mm～Ф1700mm

Copper rod bundle weight: 3-5t

Production line capacity: 1100Kw (excluding melting furnace and holding furnace.)

Raw material: copper cathode

Product’s Quality: it is in accordance with the GB/T 3952-1998 《Electricity Copper Wire Bar》T1 Standard of China as well as the above requirements.

Overall Dimensions: 58×7.8×6.1m (excluding melting furnace, holding furnace and recycle cooling & filtering system. )

Total weight of equipment: 106t (excluding melting furnace and holding furnace.)

4.      Composition and Requirements

The plant is composed of 1 set of shaft furnace with 18t/h capacity, 1 set of rotary holding furnace with 10t capacity, five-wheel casting machine, drive unit, roller shears, pieces spindling machine, straightener and burring unit, shaver, feeding device, rolling mill, emulsion lubrication system for rolling mill, oil lubrication system for rolling mill, cooling system for copper rod, back drive unit, rod rewinding device, waxing device, coiler, lifting platform and take-up roller way, packing machine and packing way, and electrical control system, etc.

1)      Shaft furnace & Holding furnace

Raw material: copper cathode

Producing capacity:  16-18t/h

Outer dia. Of furnace cover: Φ2400 mm

Melting speed: 16-18t/h

Inner furnace control: CO analysis machine by Siemens.

Copper level monitoring inside furnace: Monitoring system.

2)      Five-wheel Casting Machine:   1 set

Casting wheel dia.: Φ2100 mm

Material for casting wheel: Cu-Ag alloy

Speed control: by PLC

Cross-section area of casting wheel model lumen: 2170mm²      

Steel belt dimension: 13000×3.0 mm

Casting ladle control: pneumatically+ PLC

Tension method for steel belt: pneumatically+ PLC

Safety measures: under power-off condition, casting ladle will reset automatically. (Controlled by PLC)

Main motor:  5.5 Kw     AC Frequency conversions & speed regulated

3)      Casted-bar   Drive Unit:  1 set

Drive-roll dia.: Φ200 mm

Drive-roll control: pneumatically

Main motor: 4 Kw AC Frequency conversions & speed regulated

Speed control: synchronizing controlled by PLC

4)      Rolling shears:  1 set

Control method:  pneumatically + PLC.

5)      Straightener and burring unit:  1 set

Control method: pneumatically + PLC.

6)      Shaver: 1 set

Power & control:  0.75kw ×3 AC; pneumatically + PLC

7)      Feeding machine: 1 set

Drive-roll dia.: Φ250 mm

Drive-roll control: pneumatically + PLC

Main motor: 2.2Kw

Speed control: synchronizing controlled by PLC

8)      Rolling mill: 1 set

Producing capacity: max.16-18 t/h

Rod dia.: Φ8.0 mm

Rolling number:  12

Rolling speed control: synchronizing controlled by PLC

Main motor: 75Kw (1#, 2# stand), 355Kw (3#-12#stand); Siemens Full digital DC speed regulated.

Lubricating method: concentrated and recycled lubricating

Lubrication pump: 22Kw×2 AC

Protecting shell move control:  hydraulically + PLC

9)      Copper rod cleaning device: 1 set

Deoxidizing device: spraying type, with stainless steel nozzle and pipes.

Cooling device: spraying type, with stainless steel nozzle and pipes.

Drying device: spraying type, with stainless steel nozzle and pipes.

10)   Arc-shaped roll way: 1 set

Guiding wheel dia.: Φ100 mm

11)   Rod drive unit: 1 set

Main motor: 11Kw, AC

12)   Waxing device: 1 set

13)   Coiler:  1 set

Coiling type: flower type

Coiling bundle dia.: Φ1700 mm

Speed control: synchronizing controlled by PLC

Coil bundle weight: 3000-5000kg (adjustable)

14)   Rod rewinding device: 1 set

Rewinding motor: 11Kw, AC

Speed control: synchronizing controlled by PLC

15)   Lifting platform: 1 set

Control method: hydraulically + PLC

16)   Packing device: 1 set

Control method: hydraulically + PLC

17)   Tray, delivering, pressing and lifting roll way:  6sets

Motor: 3.0kw ×6 AC

18)   Hydraulic system: 1 set

Oil efficient capacity: 1.2 m³   

System pressure: 10 Mpa

Flow: 120 L/min

Hydraulic oil temperature: 30~45 ℃

Medium: high temperature antiwear hydraulic oil

Filtering accuracy: 20µ m

Pressure control accuracy: ±0.5Mpa

19)   Electrical control system: 1 set

   This system is composed of 3-phase 4-line system 380V, 50Hz, and low voltage power supply network; the total equipment power is about 700Kw. Including general electrical control, automatic display of temperature of the cast bar, speed synchronization control among the casting machine, drive unit, rolling mill, and coiler. Motor for the rolling mill is controlled by Siemens DC speed regulator. Control panel, console, and temperature sensors are supplied, and the whole system is jointly controlled by PLC touch-screen, which monitors all parameters in the operation process.