copper rod lines - properzi.com
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CopperRod Lines
Refining Furnace1Continuous Casting & Rolling Copper Line layout
The first Continuous Casting and Rolling Line (CCR Line) for Cu rod production, born from Mr. Ilario Properzi’s experiments in the 1950s, still remains
the essence and basis of the modern CCR Line. At that time the traditional production process, based on the hot rolling of wire-bars through the so-called Belgian Looping Mills, was very low with less repeatable rod quality. This new system led the world of copper rod production to a major breakthrough.
Over the years Continuus-Properzi, starting from the seed planted by Mr. Ilario Properzi, has developed an extensive portfolio of CCR Line configurations to satisfy all market requirements in terms of capacity (from 5 tph to 35 tph and even more) and copper rod diameters and qualities.For more than 30 years, Continuus-Properzi has designed, engineered, and commissioned Complete Plants for both ETP and FRHC Cu rod worldwide.The CCR Line sketched here below represents a typical line configuration that can be combined with a Shaft Furnace, to continuously melt cathodes and clean copper scrap, and/or a Refining Furnace or set of Furnaces, to melt and refine copper scrap (even of low quality) in batch mode or continuously. The lay-out of the selected Furnace set and CCR Line is designed according to specific customer requirements tailor made for each need.
Starting from the left side of the sketch, we have the following main equipment:
“1” Refining Furnace (set):Continuus-Properzi can supply Reverberatory Furnaces (to operate in batch) and/or a set of Furnaces (to operate continuously) to melt and refine copper scrap. Different solutions can be provided according to the
• Highest worldwide percentage of premium quality• Highest rod quality, both for ETP (Electrolytic Tough
Pitch) and FRHC (Fire-Refined High-Conductivity), exceeding the reference standards
• Rod quality repeatable and constant• Widest range of commercial Cu rod diameters• Maximum flexibility in processing Cu cathodes
and/or copper scrap, even of low quality, continuously or in campaign
• Increased mechanical properties using the 2-roll rolling process in the roughing mill
• Best geometrical quality using the 3-roll rolling process in the finishing mill
• Perfect coil shape in both concentric and orbital types
QUALITY OF PROPERZI ROD:
EXAMPLE OF PROPERZI ROD
Refining Furnace Shaft Furnace2Casting Machine3
• 100% engineered internally, tailor made, from lay-out to software
• Our equipment is manufactured and assembled at our headquarters in Italy
• Only the highest quality and safety in our equipment• Lowest operational costs in the industry• Lowest consumption of utilities• Incomparable longevity of our plants • Overall equipment efficency above 85%• Several models of casting machines, rolling mills and
coilers to satisfy all possible customer requirements• Rod can be coiled in concentric or orbital type coils• Complete technical assistance for training,
commissioning and start-up• Continuous customer service: remote and on-site• Longest availability of spare parts even several
decades after equipment supply• Prompt and precise Spare Parts service• Latest available technologies and automation, ready
for Industry 4.0
PLANT
ENGINEERING TAILOR MADE
copper scrap available, with the objective to maximize savings in operational costs while minimizing raw material expenditures, in order to grant constant and homogeneous quality of the FRHC copper rod. These furnaces can be combined, if required, with the Shaft Furnace described here below in order to give the system maximum production flexibility to alternatively produce ETP and FRHC rod on a daily basis or on a campaign basis according to the availability of scrap and cathodes.
“2” Shaft Furnace and Holding Furnace:this Furnace set is designed to continuously melt cathodes and clean scrap; the melting capacity is defined in accordance with the capacity of the CCR Line. The Shaft Furnace uses a uniform scattering of the cathodes inside the furnace, optimizing the thermal efficiency and reducing the gas consumption to the lowest level. The Holding Furnace has the main purpose to continuously receive the liquid copper from the Shaft Furnace and homogenize the liquid metal bath which feeds the Casting Machine.
“3” Casting Machine:a wide range of Casting Machine models, differing mainly in the casting wheel diameter and cross section of the cast bar, can be provided in accordance with the production rate and the environmental conditions.
“4” Automatic Bar Shear:to cut the bar automatically during the start-up and in the unlucky event of an emergency downstream.
“5” Bar Preparation Unit:this unit straightens the cast bar, removes the top corners of the cast bar, and facilitates descaling of the cast bar before it enters the rolling mill train.
“6” Rolling Mill:we have twelve Rolling Mill models, with 2-roll and 3-roll rolling stands, that can be combined in several rolling train combinations defined by considering the cast bar section (linked to the production rate) and the rod diameters to be produced. The Properzi unique
ORIGINAL SPARE PARTS
Holding Furnace2
Casting Machine
Bar Preparation Unit5
Automatic Bar Shear4
Cooling Unit8
• Inventor of the continuous casting & rolling system for non-ferrous metals
• More than 70 years of experience with numerous casting and rolling lines designed, manufactured and commissioned
• Widest knowledge of non-ferrous metals global market having operated in more than 60 countries
• Unique group of experts in terms of knowledge and experience
• Transfer of refining know-how • Always innovator of our innovation without
comparison• Our goal is customer satisfaction
COMPANY
CONTINUUS-PROPERZI MACHINE TOOL
combination of a Roughing Mill with 2-roll rolling stands that provide the necessary high reduction rate and a Finishing Mill with the legendary 3-roll rolling stands ensures rod diameter tolerance and quality surpassing the ASTM B49 specs.
“7” Pickling Unit:designed to minimize the thickness of the oxide layer of the rod.
“8” Cooling Unit:suitable to cool the rod before being coiled.
“9” Waxing Unit:a uniform quantity of wax is sprayed on to the rod in order to protect the rod from dust, dirt and oxidation during storage and shipment.
“10” Coiler:the Coiler model is defined according to the preferred coil type (concentric and/or orbital coils) and the production rate. The Coiler is provided with all the devices to palletize, strap, and unload the coils. These operations can be manual or automatic according to customer preference.
“11” Control Room & Electrical Control Cabinets:the widest range of the most common electrical/automation components can be incorporated in our design according to customer requirements/preference, including the latest market developments in automation and compatibility with Industry 4.0.
Rolling Mill Train6
Pickling Unit7
Coiler10
Waxing Unit9
MORE AND MORE ON…CONTINUUS-PROPERZI CCR COPPER ROD LINES
CCR COPPER ETP (Electrolytic Tough Pitch) ROD LINES –
PERFECT OUTPUT - PROPERZI ROD
Parameter Reference ValueChemical composition Cu+Ag % >99.95
Oxygen Ppm 150 ÷ 250
Elongation A200 % 42 ÷ 46
Tensile strength Kg/mm2 22 ÷ 24
Conductivity IACS % 101.0 ÷ 102.0
Twist test to failure No 54 ÷ 60
Best drawability mm 0.05
POPS test – surface oxides Ångstrom 100 – 200
Re-crystallization temperature °C 180
There are three types of Continuus-Properzi process for the production of FRHC copper:
PROCESS No. 1 is based on one reverberatory furnace usually feeding a rod line or a slab caster during approximately one shift per day (1st – 2nd – 3rd Class).
PROCESS No. 2 is based on a vertical (shaft) furnace and two holding refining furnaces feeding a rod line 24 hour/day (1st – 2nd Class).
PROCESS No. 3 is based on a reverberatory furnace usually feeding an ingot line during approximately one shift per day. Ingots are then diluted with cathodes in a shaft furnace for ETP rod production (1st – 2nd Class).
Parameter Reference ValueChemical composition Cu+Ag % >99.90
Oxygen Ppm 150 ÷ 250
Elongation A200 % 38 ÷ 43
Tensile strength Kg/mm2 22.8 ÷ 23.5
Conductivity IACS % 100.5 ÷ 101.3
Twist test to failure No 43 ÷ 50
Best drawability mm 0.25
POPS test – surface oxides Ångstrom 100 – 200
Re-crystallization temperature °C 280
1st CLASS (Cu › 99%)
PERFECT OUTPUT - PROPERZI ROD
CCR COPPER FRHC (Fire-Refined High-Conductivity) ROD LINES –
2nd CLASS (Cu › 96%)
3rd CLASS (Cu › 93%)
No. 1
Batch Process with maximum refining
No. 2
Continuous Process with limited refining
No. 3
Batch Process with limited refining
Copper scrap mix ≥93% Expected yearly output: from 12,000 t to 75,000 t
Copper scrap ≥97%Expected yearly output: from 25,000 t to 100,000 t
Copper scrap mix ≥96%Expected yearly output: from 12,000 t to 24,000 t
SMALL OUTPUT RATE• Production rate: from 5 tph to 10 tph• Expected yearly output: from 25,000 t to 58,000 t
MEDIUM OUTPUT RATE• Production rate: from 12.5 tph to 20 tph• Expected yearly output: from 61,000 t to 115,000 t
LARGE OUTPUT RATE• Production rate: from 25 tph to 40 tph• Expected yearly output: from 125,000 t to 250,000 t
CATHODS
FRHC
ETP
