2000T per Year 8-20mm Copper Rod Upward Continuous Casting Machine Line

2000T per Year 8-20mm Copper Rod Upward Continuous Casting Machine Line

The upward continuous casting machine is designed specifically for the production of high-conductivity oxygen-free copper rods, copper tubes, and other cross-section products. The system's versatility allows it to switch between copper rod specifications, including diameters ranging from Φ8mm to Φ20mm. With a production capacity of 6 tons per day, this system is ideal for medium to large-scale copper rod manufacturing operations. The system is engineered for 24/7 operation, with a total annual output of 2,000 tons per year.

Key Features of the Copper Rod Casting Line

The copper rod casting line is composed of several high-performance components, including:

1. Melting Furnace – A 300KG electric furnace with an 80kW power rating, designed for efficient melting of copper alloys.

2. Holding Furnace – A companion 80kW holding furnace ensures the molten copper maintains the correct temperature throughout the casting process.

3. Continuous Casting System – The system employs four casting heads, which allow for continuous production of copper rods with diameters between Φ8-20mm.

4. Advanced Servo Motors and Controls – The entire casting process is powered by Yaskawa servo motors and controlled by a Mitsubishi PLC with an intuitive touchscreen interface.

5. Liquid Level Tracking – The system includes real-time liquid level monitoring, ensuring precise control of the copper melt height for consistent casting.

Production Capacity & Performance

• Annual Output: 2,000 tons/year

• Updraft Speed: 560-2400mm/min

• Power Consumption: <345 kWh/ton of molten copper

• Take-up System: Features a synchronous take-up mechanism with a Siemens motor and Schneider frequency converter, ensuring uniform winding of copper rods without intertwining.

Energy Efficiency and Control

This casting line is designed for high energy efficiency. The power factor ranges between 0.95 and 1, which helps minimize operational costs. The use of a high-precision, gapless reducer and imported synchronous belt ensures smooth, efficient operation and consistent casting speeds. Energy-efficient temperature control systems, including Schneider electric appliances and Yike instruments, are used for precise melting and holding furnace temperature regulation.

Robust Construction and Materials

The entire production line is built with durable, high-quality materials. The melting and holding furnaces are constructed from A3 steel, while components such as the induction coils and crystallizers are made from T2 copper and stainless steel. The system also includes high-quality imported components, including the servo motors, PLC controllers, and frequency converters, ensuring the line's long-lasting performance.

Installation and Maintenance

The production line is designed for easy installation and minimal maintenance:

• Workshop Requirements: A minimum workshop height of 6 meters is required, with an area of at least 8m x 21m.

• Power Supply: A 180kW transformer is needed to power the system, with a standby power supply recommended in areas with frequent power outages.

• Water Supply: The line requires a cooling water system with an inlet pressure of 0.2-0.4 MPa and a flow rate of 14t/h.

Applications

The upward continuous casting machine line is ideal for manufacturers looking to produce high-quality copper rods, oxygen-free copper products, and copper tubes. Its advanced servo motor controls, real-time monitoring, and customizable casting speed make it a valuable asset for any copper rod production facility.

Main Components of the Production Line

Conclusion

The 2000T per year upward casting machine line offers exceptional efficiency, precision, and reliability for high-conductivity copper rod production. With its robust construction, advanced control systems, and high-quality components, it is an excellent choice for copper rod manufacturers aiming to scale production while maintaining quality and energy efficiency.