Oxygen-Free Copper Rod Continuous Casting Machine

SJR MACHINERY(SHANGHAI FTZ) LIMITED
Room 210, 2/F Hongnan Investment Building,

No.939 Jinqiao Road, Shanghai, China.
Tel: +86 21 61620655 ext:8009 Fax: +86 21 61050237
E-mail: songjingru@vip.163.com
www.smac.com.cn
Oxygen free copper rod

continuous casting
machine set
Model: SL04-Q2D-S-B-8
Technical specification

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.General Description
The oxygen-free copper material casting machine sets (hereinafter referred to as units) for the
production of oxygen-free large length bright copper rod, oxygen-free large length bright copper
tube and oxygen-free large length bright cooper flat blanks and other profiles.
.Craft process
Cooper cathodes melting furnace---- Transition warehouse---temperature holding----continuous
casting machine set (Crystallization Molding) casting rod----winding machine- for sale or further
processing.
Old copper cable scrap or copper cathode as raw material, directly put into the furnace of a
combination of the melting furnace, after frequency induction melted liquid, melted copper was
passed through a smooth transition compartment automatically overflows into the holding furnace
and by covering the surface of the charcoal, copper was steady reduction process, after the
reduction in the holding furnace copper solution by continuous casting machine crystallizer copper
rod casting liquid crystal rapidly, and after two continuous casting machine to pull the casting rolls
pulling the lever upward gap, casting rod from the caster traction mechanism pull back, the guide
wheel frame, take-up machine import limit device, and finally to be the cooper bar coil.
. Product Specifications
The raw materials need to meet the GB / T467-2010 No. 1 Standard copper cathode Cu-CATH-2
requirements.
Density 8.9kg/dm3
Elongation38%
The soft state resistivity0.01724mm2/m
Oxygen content10ppm
8mm casting rod after drawing smallest diameter up to 0.20mm
Note:
If the user use all bright wire as the raw material, the cast rod after drawing to ensure the finest
0.30mm, but it does not guarantee the resistivity, depending on the quality of scrap may be, because
the lead furnace refining furnace without smelting function, was unable to reduce resistance rate
function.
.Casting machine sets main parameter

1. Machine set modelSL04-Q2D-S-B-8
2. Annual capacity: The maximum annual production capacity is 2000T, by reducing input voltage
furnace (electric furnace has this function), can produce 1000T-2000T production.
3. Furnace structure: Two-body combination oven (a melting furnace, a holding furnace)
4. casting head4 unit
5. Casting road diameter8mm
6. The lead speed10002500mm/min
7. The lead pitch26mm adjustable
8. Traction frequency0800 times/minute

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9. Traction mode: single servo motor traction

10. Working hours per year7920h
11.Wire winding coil specification9001550800mm
12. Winding coil weight3000 kg
13. Voltage380V50Hz
14. Machine set capacity240KVA
15. cooper melting rate260kg/h
16. Maximum running power120150KW
17. Every ton cooper rod consumes:
Power360kWh/t
Charcoal20kg
18. Winding model: automatic winding, automatic wire winder.
19. Material feed mode: The whole electric cantilever electrolytic plate feeding.
20. Lead driving mode: AC servo motor driven by precision planetary gear reducer, rigid coupling
drive traction nip drive, gap-free timing belt between the pull roll
21. Lead copper rod clamping: cylinder clamping.
22. Servo Motor control mode: touch screen control.
23. Furnace electronics control mode: Electric voltage regulation (with three-phase balance device)
. Machine sets components and structure description.

Machine sets composed of the frequency sensors, continuous casting machine, the guide wheel
stand, the middle bracket, stopper, two head winder machine, water cooling system, electrical
system, feeding mechanism and temperature measuring system components.
1. Frequency induction furnace
Frequency induction furnace is composed of main furnace, furnace stand and sensors three major
components.
Furnace shell is steel structure, the internal is made of masonry bricks, insulation bricks and quartz
sand; furnace stand plays a supporting role throughout the stove, floored by anchor bolts secured
basis; the sensor is composed by the housing, coil, water sets, as well as the core composition melt
channel; high-pressure side sensor (primary) formed by the coil voltage from 90V to 420V
step-adjustable; inductor low-pressure side (secondary) by a short circuit coil melt channel

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composition, when power connected, under the action of electromagnetic sensors, the melt channel
internally generated high current, low voltage and melted the added copper; Q2 type induction
furnace composed by two induction sensor ( among which melting is 300kg induction systems,
thermal insulation is 150kg sensing system); water jacket and water cooling coils are water cooling
type using water circulation, provided by the cooling water pump.
2. Continuous casting machine
2.Continuous casting machine sets
Casting machine set is main machine of the complete set. It is composed by traction mechanism,
liquid tracking system, and crystallizer three parts. Its structure is Plano type four columns.
Traction mechanism composed by one side servo motor, gear and traction rollers, belt and other
components. It can be realized from 0 to 800 times per minute, 2 ~ 6mm pitch high-speed
movement of the gap, and the rollers by pulling the lever cast continuously drawn upward, a
traction drive mechanism can drive 4 sets traction rollers, each set are respectively traction 4 pcs
8mm casting rod.
Crystallizer is the key part of the upward casting machine. its role is to make the liquid copper
mold rapid cooling crystallization to solid copper, and realize the heat exchange. 4 pcs crystallizer
in a row mounted on the casting machine mounting plate. With mounting plate up and down, each
crystallizer can be replaced individually without affecting the normal operation of others.
Crystallizer cooling water and induction furnace cooling water are the same, have a dedicated
cooling system supply. Inlet and outlet water of Crystallizer are connected by the fast connector and
inlet and outlet pipes, enabling rapid cooling of the crystallizer, and every crystallizer is adjusted by
a valve.
Level tracking system is composed by the level tracking device and tracking transmission device.
with the liquid level is raised and lowered by means of a silicon carbide float hitting the block and
the role of micro-switches, the outgoing electrical signal of level to achieve automatic tracking
control to ensure graphite mold and a thermocouple was inserted into the depth of copper is
relatively stable, to ensure the continuity of casting production.

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3. Guide wheel stand

The guide wheel stand installed on the top of the casting machine, composed by support, vertical
guide wheel and roller. It makes the casting rod guide into the winder smoothly without any
interference.
4. Middle bracket
Middle bracket is installed between the guide wheel stand and the stopper. Its composed of support,
support roller, vertical guide wheel. Its role is to make the casting rod guide into the winder
machine smoothly without any interference.
5. Limit Stopper
5. Stopper
The limit stopper devise is installed before the winding machine. Its role is to achieve the lead
drawing speed and traction speed synchronization. It is composed of machine stand, 4 sets
extension devise, and potentiometer. The casting rod goes through the guide wheel, middle bracket,
and the extension devise. The extension devise control the potentiometer according to the casting
rod position.
6. Winding machine.
Winding machine is two head winder, composed of wire drawing traction, loop forming devise,
rotary table.
8mm winding machine: during working, the winding motor drive the traction roller through
reducer, make the cast rod into the receive stand, rolling to loop. This winding machine is the

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automatic tracking. The automatic winding machine sending out the signal through the servo motor
driver, process the data by PLC and forward to the winding machine motor inverter which can
achieve the automatic control of the winding machine speed and achieves the lead drawing speed
and traction speed synchronization. The accumulated error is corrected by the limit stopper.
8mm automatic winder using winding table power devise, this power transmission device via
PLC tracking winding motor, make the winding speed and winding table speed to match each other.
On the other hand, by controlling the winding motor speed through PLC, the winding table rotates
from fast to slow and from slow to fast regularly. so 8mm casting rod closing line to the inner tray
from the outer ring, the inner ring to the outer ring by the arrangement of the spiral layer by layer
into the ring and orderly, to achieve the automatically function, casting rod coil weight up to 3 tons.
This winding clamping mode is pneumatic type and manual type.
7. Cooling system
The crystallizer, induction water jacket, and coil using the same independent water supply
circulation system. The soft water is request in the water system. If there is no soft water, the water
shall be treated. The cooling water pool capacity is 80-100 m3 , cooling water temperature is 25
35. The crystallizer inlet water pressure is 0.20.4MPa. Water jacket, coil inlet water pressure is
0.180.2MPa.
To ensure the water supply for the crystallizer, induction water jacket, and coil, customer need to
prepare the emergency water supply system for recover the water supply in case of power cut off.
8. Electrical system
Electrical equipments need to be installed on the platform near the equipments.

Electrical system is mainly divided into four categories: furnace systems, continuous casting
machine, winding machine and a cooling water system.
Furnace system consists of two three-phase balanced voltage cabinets, one operation platform and a
sensor mounted in the lower part of the furnace (induction coil, the core and the melt channel).
Balanced voltage cabinet is composed of a three-phase voltage regulator, capacitance, and reactor.
Casting machine and servo motor share the same operation platform. Casting machine electrics

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systems consists of electric servo motors and lift motors and their control components. Lifting
motor is AC motor; the operating system is installed in an operation platform.
Winding machine eclectics system is composed of the PLC in electrical box and each winding
machine control board. Winding machine inner control panel controls winding machine motor and
winding table power transmission device motor.
9. Feeding system
Feeding system is a mechanical copper feed, which ensures a continuous supply of copper melting
furnace.
10. Temperature measuring system

Temperature measurement system consists of a copper fluid temperature measurement and cooling
water supply and return temperature measurement. The system is mounted in a temperature cabinet.
Copper liquid temperature measurement using thermocouple WRP-112 with SR3-8V-1C Japanese
SHIMADEN temperature instrumentation.
Cooling water supply and return temperature is reflects by the temperature indicator.
. Raw materials, auxiliary materials technology requirements

1. Charcoal requirements
Requirements for high quality white charcoal (commonly known as carbon steel, carbon pears)
Water content0.51%
other volatiles5%
Charcoal size3070mm
Not allowed using sulfur, iron, and not calcined charcoal.
Fracture should be shiny, bright white, crisp sound when brake.

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2. Insulation and refractory furnace building requirements

Frequency induction furnace used for melting copper is quartz sand (SiO2) as a lining material.
Quartz sand is as follows:
Refractory temperature1600
Proportion:2.322.65g/cm3
Average linear expansion coefficient13.510-620~100
Thermal conductivity: 1.27 to 1.7 kcal / hour
Relatively empty gas rate: 18 to 25
Thermal shock resistance:> 320
Chemical consist
Chemical
content %
SiO2 Fe2O3
>98 <0.05
Al2O3
<0.32
CaO
<0.32
H2O
<0.5
.Civil work construction and technical requirement.

1. Civil work construction requirement.
1workshop plan: see the plan drawing.
2Workshop requirement
Workshop with crane
Lengthno less than 30m
Widthno less than 8 m
Heightmore than 7m
Note
a. The plant shall include a finished raw material dumps, but does not include substations, pump
house, office etc.
b. Civil construction of workshop for a lead forward production line, if arranges two production
lines, the workshop width should be enlarged to 15m.
c. To be equipped with more than 3 tons crane 1 pcs, track elevation height more than 6.6 m.
d. If there is no crane or workshop height is not enough, further deliberations need to be discussed.
2. Cooling water requirement
(1) Cooling water system arrangement: see Figure cooling water system.
(2) Water quality requirement :(brief description: meet the requirements of boiler soft water)
Hardness: 2 ~ 5dH (Germany hardness standard) is equivalent to having Cao250 ~ 500ppm
PH: 7 ~ 8
Mechanical impurities: <10mg / L
Mechanical impurities particle size: <0.8mm
Sulfate ion content: <10mg / L
Free chlorine ion concentration: <3mg / L
Conductivity: <50 micro Siemens / cm
If the above requirement can not be reached, the water softening system should be configured.
(3) Cooling water capacity
This production line is divided crystallizer using water and induction sensors using water. Water
is soft water, recycling, added regularly.

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Crystallizer using water: 8T / h

induction sensors using water: 4T / h
Total: 12T / h
Pressure: 0.18 ~ 0.4MPa (coil, water jacket: 0.18 ~ 0.22MPa; Crystallizer 0.2 ~ 0.4MPa)
Circulating pool capacity: 80 ~ 100m3
According to the site requirement to determine the form of circular pools, it can be underground
or semi-underground.
See the pump reference system diagram.
(4).Water temperature requirement
Water inlet2535
Water outletCrystallizer55
induction sensor65
Normal temperature differenceinlet and outlet temperature differenceCrystallizer <15
induction sensor <30
(5). Emergency water
When a power failure or other accident happens, emergency water should be connected to
induction sensors and crystallizer within one minute. it is proposed to set up an alternate water
tower.
Cooling tower: To ensure the cooling water inlet temperature, forced cooling shall be used.
Generally, it is used to manage the glass fiber cooling tower; cooling tower should be medium
temperature or high-temperature cooling tower, cooling capacity 30m3 / hour.
3. Power supply
(1) Power Requirements: Voltage: 380V three-phase main circuit, control circuit 220V
Single-phase, frequency 50HZ
(2) Machine sets capacity:
a. furnace system: Melting induction sensors installed capacity of 150KVA
Heat holding sensors installed capacity of 80KVA
b. Casting Machine system: servo motor 2KW
Lift motor: 1.5KW
c.. Winding system: Traction motor: 0.75 KW 4 sets = 3.0KW
Cable motor: 0.75 KW 2 units = 1.5KW
d. Pump: 4KW 2 units = 8KW
e. Complete machine set capacity: Total 240KVA
f. operating power: 120 ~ 150KW
Note: This refers to the capacity of the equipment only, not including lighting and other electrical
equipment.
The lead forward continuous casting machine is for the continuous production, and definitely not
allowed the power cut of. It must be considered a backup generator or dual power supply. Backup
generator capacity, in the operating power units, it must at least to be 50% (only for furnace
insulation above). If for production, should increase generating capacity.

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. Main components
1. Traction servo motor, driver: Japan Yaskawa products
2. PLC: Siemens products
3. Human machine interface: Siemens products
4. Inverter: Japan Yaskawa.
5. Electronics components:
Contractor: Siemens
Indicator, button, relay, air switch: Schneider
Compensation capacitor: Chinese famous brand
Autotransformer, core: Chinese famous brand.
6. Reducer
1casting machine traction using high precision planetary gear reducer: German Newcut.
2Winding machine traction using high precision turbo reducer: Chinese famous brand.
3Casting machine lifting using high precision turbo reducer: Chinese famous brand.
7. Bearing
Casting machine traction bearing using Japan NSK
Other machine using China Wafangdian or Habin product.
.End user advanced preparation items.

1. Civil construction: workshop, crane, equipment foundation.
2. Water system
Cooling water poll: the water pool capacity shall be 80100m3, if the is one standby machine
sets reserved, the capacity shall be 100120m3.
Standby water source: the standby water source shall be 8 meters higher than the furnace. A
capacity of 58m3 standby water tower shall be suggested to built up.
Pump system (pipe), pipes between circulation water pool and inlet/outlet pipes.
Cooling tower system including cooling tower, water pump, valve, pipe.
3. Power supply.
a. Transformer and protection device.
b. Backup power and control.
c. The power cable, connection between equipments, wire, cable, and pipes before suppliers
equipment.
d. General electric control cabinet.
4. Air compressor and pipes.
5. Operation platform.
6. Raw material and Supplementary material: Copper, charcoal, etc.
. Equipment delivery packing list.

Refer to SL04-Q2D-S-B-8 the oxygen-free copper material casting machine sets packing list.
. Standards and test:

1. Equipment design, manufacturing and inspection shall be used for the corresponding national
standards and meet the technical parameters specified in the contract technical requirements and

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device descriptions.
2. Equipment design, manufacturing and testing shall use both metric and legal units of
measurement.
3. All purchased parts must comply with the requirements of annex to the contract, and provide
catalogue and factory certification, if additional information, should be provided in a timely manner.
4. The supplier shall provide the technical information free of charge.
Installation and commissioning.
1. The supplier sent technical personnel to the scene to guide the installation, commissioning and
operation training. The buyer need to provide everything needed for installation lifting, human,
common tools, civil construction and accommodation and other technical staff.
2. The supplier bears the cost of domestic personnel abroad. The buyer needs to cover the costs of
foreign travel, lodging expenses, commissioning costs is $ 100 / person / day.
3. After the installation is complete, the two sides confirm the machine meet the technical standards,
and then to determine the date and method of commissioning.
4. After the test is completed, the supplier representative informed the representatives may be
required equipment inspection; the two sides signed the acceptance report.
5. The date of installation: installation and commissioning under the buyers preparation work is
ready, mechanical tubing takes 25 days, electrical installation normally takes fifteen days, the
process furnace building, furnace, out products for fifteen days, synchronization can be organized
installation, installation and commissioning of a total period of 45 days. The supplier needs to
arrange 2-3 technicians to the scene to guide the installation and commissioning.
XIII. Warranty
1. The supplier ensures that the equipment complies with the provisions of the contract after the
warranty requirements of all plant equipment, equipment delivery 13 months (wearing parts, except
human factors damage).
2. The technical information provided by the supplier shall comply with the requirements of the
contract.
3. During the warranty period, the supplier shall provide free repair or replacement parts for the
defective parts caused by the suppliers quality failure. If the buyers responsibility caused the
damage, the repair cost borne will by the buyers side.
XIV. Technical data sheet and drawing supply:

The supplier will supply the following documents and drawings with 7 days after signed the
contract and the contract comes effective.

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Equipment foundation drawing

Water, compressor air, electricity overview plan drawing
The supply will provide the following documents and drawings when delivery the equipments.
Craft process and operation manual
Equipment general drawing and consumption drawings
Spare part list.
Electrical connection drawing and technical parameter
Electrical cable list

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www.smac.com.cn

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SJR MACHINERY(SHANGHAI FTZ) LIMITED

Room 210, 2/F Hongnan Investment Building,