Electrolytic Copper CCR

The production speed of the line is continuous and stable without waiting time for intermittent casting. The capacity of mainstream production lines ranges from 10 to 35 tons per hour, and advanced large-scale complete lines can achieve a monthly output of over 20,000 tons. Compared with the traditional separate ingot-casting-heating-rolling process, it eliminates auxiliary steps such as ingot cooling, transportation and reheating, greatly improving overall production efficiency and shortening metal turnover cycle. Meanwhile, thanks to high-level equipment automation, labor consumption per ton of product is significantly reduced, making it suitable for large-scale, long-term non-stop continuous production.

The production line manufactures low-oxygen bright copper rods with smooth finished surface and few defects such as scale, slag inclusions and surface peeling. The oxygen content is stably controlled within 200-400 ppm. More than 30 key indicators including electrical conductivity, tensile strength, elongation, torsion performance and surface roughness meet the requirements of international electrical-grade copper rod standards.

Under optimal process control conditions, the metal yield can reach 98.6%. Compared with products from conventional processes, the tensile strength of finished products is increased by 18%, and the elongation can reach 45%. The product features uniform grain structure and small batch-to-batch performance variation. It fully satisfies the strict processing requirements of downstream multi-head high-speed wire drawing machines with low wire-breakage rate during drawing. It is widely applied in manufacturing power cables, building wires, enameled magnet wires and other products.

Clean energy sources such as natural gas and LPG are preferred for melting. The line is equipped with a complete flue-gas dedusting system.Benefiting from "direct rolling with residual heat of casting billets", the billet reheating process is completely eliminated.

Compared with conventional processes, the comprehensive energy consumption is reduced by 40%, and the energy consumption per unit product can be further cut by 12%.Metal oxidation loss can be controlled within 0.8%, much lower than 1.5%-2.5% of traditional technology, which greatly reduces copper loss.

A circulating cooling system is adopted for process water with high water reuse rate. Pollutant emissions comply with the emission standard for copper,nickel,cobalt industry, realizing favorable green-manufacturing performance.

The entire production line adopts Siemens S7-1200/1500 PLC as the core to build a complete automatic control network. Equipped with multiple sets of sensors, the system collects more than 200 process parameters including furnace temperature, furnace atmosphere, air-fuel ratio, casting speed, rolling torque and cooling flow. It realizes automatic linkage adjustment of production speed, online cleaning, non-destructive testing, full-process condition monitoring and fault early warning.

Equipped with a touchscreen HMI for on-site local operation, the system can be connected to the WinCC SCADA platform to realize remote monitoring and full process parameter traceability. Key processes feature automatic process compensation and self-diagnosis functions, which effectively reduce quality fluctuations caused by manual operation and ensure consistent product quality during long-term continuous production.