Copper Rod Continuous Casting and Rolling Line with Copper Cathode or Scraps

• After-sales Service: Installation and Commissioning
• Warranty: Two Years
• Rolling Shape: Wire Rod
• Product: Copper Rod
• Roller Position: Vertical
• Roller Number: Three
• Model NO.: UL+Z-1800+255-12
• Layout: Continuous
• Type: Hot Rolling Mill
• Raw Material: Copper Cathode, Scraps
• Productivity: 12 ~ 15t/H
• Furnace Capacity: 20t ~ 100t
• Transport Package: as Per International Standard
• Specification: 40mx7.8mx5.1m(not including furnace)
• Trademark: DYPM
• Origin: China
• HS Code: 84552130
• Production Capacity: 30sets/Year

Product Description

1. Equipment application
1.1 This line can be equipped with different kinds of melting furnaces according to various raw materials (copper cathode or copper scraps);
1.2 This line is designed to produce ø8.0mm low oxygen and glossy copper rods by means of continuous casting and rolling.

2. Equipment composition
The line is made up by casting machine, tractor, scrolling shear, straightener and edge shaver, scratch machine, cast bar brushing machine, continuous rolling mill, rod cooling and surface treatment unit, take-up device, waxing device and electric control system.

3. Technological Process Flow
Raw material charging→Melting and refining→Continuous casting→Front haul-off→Shearing→Straightening and burr shaving→Continuous rolling→Cooling and waxing→Coiling→Glossy copper rod.

4. Equipment features
4.1 Casting wheel is type of "H", and to be cooled on each side. External cooling, internal cooling and side cooling are all divided into three sections. Each section's supplying for water is separately adjusted, and its pressure can be shown in the pressure gauge so that make ingots even cooled, grain refined and high technological adaptability.
4.2 The tension of steel belt is pneumatic control. Tension can be easily adjusted by adjusting the air pressure. The tension of steel belt is constant after it is set which makes for the stable die chamber.
4.3 It is with the unique rolling method combining 2-high mould with 3-high mould, which can increase the deformation of ingot in the high-temperature stage.
4.4 The production line is provided with the function of continuous reverting for rod surface and fast cooling to assure the light and temperature of finished rod can be controlled.

5.  Main technical specifications
5.1 Casting wheel dia.:  ø1800 mm
5.2 Casting bar section:  2350 mm²
5.3 Rolling type: two-roller and three-roller
5.4 Rolling pass: 12 (the front four passes are two-roller type, the rest eight passes are three-roller type)
5.5 Roller nominal diameter:   ø255 mm
5.6 Outlet rod diameter:        ø8.0 mm
5.7 Max. finish rolling speed:   9.8 m/s
5.8 Max. production capability:  15 t/h
5.9 Main motor power:      450 kw
5.10 Coiling type: orbital type coiler
5.11 Coiling diameter:          ø1250 mm
5.12 Bundling diameter:          ø1650 mm
5.13 Max. bundling weight:   5 T
5.14 Total installed motor power:        550 kw
5.15 Consumption of compressed air:      50 m³/h
5.16 Emulsion consumption:100 m³/h,   pressure: 0.3~0.5 MPa
5.17 Oil lubrication system:18m³/h,     pressure: 0.1~0.3 MPa

6. Technical data of each component
6.1 Continuous casting machine
6.1.1 Casting wheel diameter:   ø1800 mm
6.1.2 Casting wheel rotational speed: 1.5-2.6 r/min
6.1.3 Cast bar outlet speed:          280mm/S
6.1.4 Cast bar sectional area:          2350 mm²
6.1.5 Cooling water consumption          170m³/h
Cooling water pressure             0.3-0.6 MPa
Cooling water temperature           <40 ºC
6.1.6 Casting wheel driving motor:  Y132M1-6      5.5kw     

6.2 Front haul-off device
6.2.1 Max. traction speed:         18 m/min
6.2.2 Motor power:              5.5 kw

6.3 Rolling shears
6.3.1 Shearing length:          700 mm
6.3.2 Motor power:            15  kw
6.4 Straightener and burr shaver
6.4.1 Max. straightening speed:        18 m/min
6.4.2 No. of shaving blade:  2

6.5 Cast bar brushing machine
6.5.1 No. of brushing rollers:       4
6.5.2 Motor power:             Y90S-6(B5)  N=0.75kw

6.6 Continuous rolling mill
6.6.1 Max. finish rolling speed: V. max=9.8 m/s
6.6.2 Outlet rod diameter:       ø8.0
6.6.3 Production capacity:      12-15 T/h
6.6.4 Rolling center height:           1802.5mm
6.6.5 Roller nominal diameter:         ø255 mm
6.6.6 No. of rolling stand:      Twelve rolling stands in total
         Horizontal rolling stand:  two sets
         Vertical rolling stand:  two sets
         Y-type upper transmission three-roller rolling stand:  4 sets
         Y-type lower transmission three-roller rolling stand:  4 sets
6.6.7 Main motor:          Z4-355-32  450kw  750 r/min
6.6.8 Feeding device:  Cylinder 10A-5  CBB100B100(RY-T)
6.6.9 Emulsion consumption: 100m³/h
Emulsion pump: IS100-65-200 Q=100 m³/h  H=50m  22kw  2900 r/min  two sets(one set for standby)
Heat exchanger area:   60m²   one set
Filter     GLQ-100  one set
6.6.10 Oil lubrication system
        Gear pump:  2CY-12/0.33-2  5.5kw  960 r/min  two sets(one set standby)
        Work pressure:   0.1-0.3 MPa
        Filter:                 GLQ-80  One set
        Oil tank:             V=4 m³
        Oil temperature:     <45 ºC 

6.7 Rod cooling and deoxidizing device & coiler
6.7.1Coiling type: orbital type rod coiler
6.7.2 Coiling diameter:           ø1250 mm
6.7.3 Bundling diameter:           ø1650 mm
6.7.4 Max. bundling weight:   5 T
6.7.5 Cooling alcohol water circulation system
Alcohol water pump:   IS100-65-200B Q=90 m3/h  H=41m  15kw  2900 r/min
two sets (one set for standby)
Filter:   GLQ-100  one set  motor power 1.1kw
Chiller: (Plate type, 100m²)   one set

7. Electrical control system
Technical descriptions:
7.1 The main electrical parameters:
Inlet wire power: Three-phase 380V   50HZ

1. Casting machine:

Casting machine motor: AC  motor 4KW                       1 set
Front haul-off  motor: AC  motor 4KW                       1set
Note: The driven motor for casting machine and front traction all adopt the SIEMENS AC variable frequency speed control device.

1. Auxiliary machine:

   Scrolling shear motor:  AC 15kw                        1 set
   Scrolling shear brake motor:   B062Z    80w    2500r/min     1 set
Note: The driven motor for Scrolling shear adopts the SIEMENS AC variable frequency speed control device.
c. Rolling mill:
DC motor of rolling mill:  450kw  1 Set
Emulsion pump motor:  22kw   2940r/min    2 sets
Oil pump motor:         18.5kw       2sets

Note: The DC motor for rolling mill is driven by SIEMENS series DC speed regulator
d. Coiler:
Rod winding motor:  AC      3kw     1 set
Basket shifting driving motor: 2.2kw 1set
Note: The motor for rod winding motor is driven by the SIEMENS AC variable frequency speed control device.


7.2 Electrical drive and control composition:
The electrical drive and control is composed by power supply cabinet, drive cabinet, relay control cabinet, main operation panel, rod coiling operation panel, etc.
Main electrical unit in system:

1. SIEMENS DC speed regulating device: 1 set
2. SIEMENS AC speed regulating device: 6sets
3. HMI Touch Screen:  Weinview 10.7" color:  1set
4. SIEMENS PLC controller:S7-200SMART series 1set

7.3 Electrical drive and control descriptions:
The bilateral data switching between HMI Touch Screen and PLC through the way of ethernet communications, to monitor and control of the system through the program control of PLC. PLC uses RS485 serial port communication mode to  achieve bilateral data switching with each transmission DC / VVVF device, and control and monitor the unit status of each device, so as to realize the three level computer control system.
When the whole line is linked together, the line speed is based on the speed of the casting machine, and the front tractor and the rolling mill can automatically track the speed of the casting machine. The scrolling shear is single machine speed control mode. The linkage speed unit is set with speed fine tuning (The program of PLC is adjusted by electronic potentiometer, calibration and compensation speed error). That is, the full line speed synchronization control is carried out according to the "speed chain" of the PLC program.
The system can monitor and control the speed of each motor, the working state of each speed regulation device, the failure alarm, the working condition of each auxiliary machine, the fault alarm and the system work. In addition, the speed of each motor is displayed.

7.4 Electrical technical data:
Electrical schematic diagram:   1 copy;
Electrical wiring diagram:   1 copy;
Electrical operation manual: 1 book;
Siemens DC speed regulating device operation manual: 1 book;
Siemens AC frequency converter operation manual: 1 book;

7.5 Characteristics of electrical control system
The main motor is in type of Siemens (produced in TianJin) DC fully-digital speed adjusting while other motors adopt frequency controlling. By adopting PLC and man-machine interface for the complete line control, it can check and display the running parameter of machines as well as indicate the breakdown. And can retrieve historical data and records, set the process parameters, etc.
PLC adopts SIEMENS current mainstream products, and won't be outmoded within 5 years.
The electrical system is powered by a three-phase four wire 380V, 50Hz, low voltage network, and the total equipment power is about 850kW. The 450KW DC motor, which is controlled by the SIEMENS DC speed control device, has the characteristics of over flow over voltage protection and function of fault diagnosis. The motor of the casting machine and rod winding machine is AC motor, which is controlled by the AC variable frequency speed control unit. Intermediate relay, AC contactor below 32A adopt of Chinese domestic well-known brands. PLC is programmed by SIEMENS controller. Touch screen adopts advanced human-machine interface, color touch screen, all kinds of operation parameters are centralized monitored and displayed, and control process parameters can be set, modified, and displayed through human-machine interface. In terms of casting speed, rolling speed and traction speed, the matching program can be set up on electrical basis to ensure synchronous production line, fine adjustment during operation, and make operation simple and convenient.

8. Supply List for Copper Rod Continuous Casting and Rolling Machine

SN	Name		Unit	Quantity	Remark
1	Φ1800 5-wheel type casting machine		Set	1
2	Front haul-off device		Set	1
3	Rolling shears		Set	1
4	Straightener and burr shaver		Set	1
5	Cast bar brusher		Set	1
6	Continuous rolling mill		Set	1
7	Oil lubrication system	Oil tank	Set	1
		Filter	Set	1
		Oil pump	Set	2
8	Emulsion system	Filter	Set	1
		Plate chiller	Set	1
		Emulsion tube distributor	Set	1
		Emulsion pump	Set	2
9	Alcohol water cooling and  circulation system	Alcohol pump	Set	2
		Plate chiller	Set	1
		Filter	Set	1
10	Waxing Device		Set	1
11	Rod cooling and deoxidizing device & coiler		Set	1
12	Electrical control system		Set	1
13	Cooling water pump for casting machine		Set	2	22kw   2900rpm
14	Pressure gage(with gauge seat)		Set	1
15	Thermometer(with gauge seat)		Set	1
16	Spare Parts				See Attachment List

9: Self-provided facility and equipment by the Buyer
1. Compressed air unit;
2. Emulsion pool: 50m³(including strainer device);
3. Cooling alcohol water pool: 50m³;
4. Outside water supply pipeline system (including cooling tower);
5. Gas system;
6. Operating platform for casting machine (to be built on site);
7. Steel belt welding equipment, shearing equipment and hand grinder;
8. Oxygen, Acetylene supply system;
9. LPG supply system;
10. Welding machine;
11. All the equipment and tools for the on-site installation and commissioning;
12. The pipes and valves of water supply system, oil lubrication system & emulsion lubricating and cooling system in casting machine. The water supply system of crystallizing wheel cooling water recirculation system and cooler of machine changing hot water (including cooling water pump (provided by Seller), discharging water pump (i.e. hot water pool turn over pump provided by Seller) , cooling tower, valve and pipe);
13. Buyers should provide electric dryer fabrics among equipment cabinet, control cabinet and body control point, also should provide the electric wires connecting control cabinet;