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This plant works to produce low-oxygen glossy copper rod in 8mm diameter by means of continuous casting and rolling process, with cathode or red copper scrap as the feedstock.
The plant is composed of 2 sets of reverberatory furnace with 80-ton 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 with 16-ton/hour capacity and a 10-ton holding furnace are required.
1. Brief Process Flow
Charging red copper scrap (grade 1 or grade 2) → melting and refining in reverberatory 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.
2. Red Copper Scrap as Feedstock
Red copper scrap as the feedstock must be Grade 1 or above Grade 2.
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 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.
Feedstock is charged into furnace according to the following proportion:
Scrap on grade 1 at 60% + grade 2 scrap at 40%
3. Main Technical Specifications
4.1. Diameter of rod: φ8mm
4.2. Capacity: 14~16tons/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 melting furnace)
4.6. Total power of plant: 600kW (not including melting furnace)
