Upward Continuous Casting System
Model L12 14.4 K:
No of lines: 12
Output rod diameter: 14.4 mm
Output: 10,000 TPA
Year of Mfg.: 1983
Condition of the line: Currently installed not in operation. Line was decommissioned in the year 2000.
380V 3Ph 50 Hz
Including the following accessories and components:
Holding / casting furnace
Withdrawal unit machine
Spare lining bricks and inductors
Two units of cooling tower
HENRICH rod breakdown machine (hard drawn from 14.4 to 8 mm. diameter)
Strecker butt melding machine
KROLLMANN pointing machine.
2. MELTING FURNACE
2.1 Equipment description
Melting furnace lies on supporting structure. It can be tilted by two hydraulic cylinders. The nominal holding capacity of the furnace is about 7.000 kg of Cu and melting capacity in normal operation about 1500 of Cu per hour. The first melt is usually transferred with the first melt pot from the holding furnace.
The furnace inductor is operated with switches, push-buttons, signal lights and electric indicators on the control desk standing on the floor close to the furnace. The furnace is composed of following main parts:
- furnace steel construction lined with refractory material
- inductor with refractory lining
connection box for cables and water hoses of the inductor
- hydraulic tilting equipment
- regulating transformer, other electric equipment and capacitors
- control desk
2.1.1 Melting furnace steel construction
The furnace is constructed of following main parts:
- two foundation beams cast in concrete
- two support props on beams
- furnace frame
- charging door
The furnace frame is made of welded steel with fixing supports for hydraulic cylinders and tilting bearings. Tilting axis is located concentrically with the center line of tapping spout.
The furnace frame has following openings:
- one opening with mounting flanges for inductor connection
- one opening with pouring spout for melt transferring
- one opening on top of the body for charging
The top of the furnace is partly covered by a steel plate supporting and protecting the refractory lining. The charging opening is covered by a door operated by pneumatic cylinder.
2.1.2 Inductor LRI 10
This channel type inductor works like a transformer.
Voltage is fed to its primary coil and melting power
is generated to the secondary coil (molten copper loop inside the inductor). The voltage is fed through the regulating transformer, with twelve voltage steps and with maximum power rating of about 2 x 565 kW.
The inductor supply consists of following parts:
- steel shell with welded cooling pipes and studs for lifting
- iron core in two L-shaped parts
- water-cooled copper coil
- water-cooled support cylinder of Cu
- water-cooled frame for furnace connection
- channel pattern of solid Cu (to be assembled in the inductor)
The water for cooling the inductor is distributed from the connection box including all valves, temperature and flow indicators necessary for the controlled cooling of the inductor.
The inductor unit has to be disassembled, lined and reassembled according to point 2.2.2 -2.2.4.
2.2 Refractory lining of melting furnace and inductor
Both the furnace and the inductors are lined with refractory materials suitable for oxygen free copper. The furnace is lined with bricks and the inductor with mix.
The furnace lining is composed of insulation bricks refractory bricks and high alumina bricks and cements.
The cooling frame of the inductor is fixed against the bottom flange of the furnace. The openings for the inductor is covered by brick laying support and the first bricks are laid at this opening.
2.2.2 Inductor lining
The melting furnace inductor is lined with insulation board and dry refractory' mix which is vibrated compact inside the inductor concealing the channel pattern which when melted forms the channel for the inductor secondary coil.
2.2.3 Connection of inductor and furnace
The ready prepared inductor and the dried furnace are connected. The furnace is tilted so that the furnace bottom is in vertical position. It is worth while to have an extra support holding the furnace in this position in case of failure in the hydraulic system. (A strong steel bar holding the furnace up.)
A thermocouple is fixed to the channel pattern of the inductor and led out between the connecting surface and flanges of the furnace and the inductor With this thermocouple the temperature of the inductor channel will be monitored during the heating for the right follow-up. Before fixing both refractory surfaces (furnace and inductor) are painted with special compound supplied by ASEA.
The inductor is lifted up and turned so that the lined face lies exactly in the same vertical position as the furnace bottom. The inductor is carefully brought to the furnace and fixed to the cooling frame by bolts. See also the instructions made by ASEA.
The ready assembled furnace unit can be tilted down and water and electric connections fixed. There are water cooled cables for inductor coil and water hoses for other water cooled parts of the inductor. These are hanging between the furnace and the connection box. All the connections can now be tested.
2.3 Control desk (B1)
There are in UPCAST L 12 14,4 K -8500 TPA a panel of three desks standing on the floor adjacent to the casting line. One of these desks is for melting furnace.
The control desk is equipped with switches, signal lights, indicators and temperature regulator for manual and automatic power feed and operation of the furnace.
Following indicators for the furnace are included:
- kWh-meter (inside the electric room)
- A-indicators (3), one for each phase, secondary current of transformer (inside the electric room)
- power-factor indicator (cos ), secondary current (control desk)
- V-indicator, inductor voltage (control desk)
- A-indicator, inductor current (control desk)
- kW-indicator, inductor power (control desk)
- V-indicator, control voltage on each phase (electric room)
- temperature regulator and digital indicator (control desk)
- lamp lights indicating the voltage step (control desk).
For the operating of the furnace there are alarms indicating if for some reason the functions are not in order. When the alarm is indicating there is a buzzer sound and a flashing light. By depressing the acknowledging push-button the sound can be cut off (short depressing) and the flashing light turned
into steady light (depressing about 1,5 s), which is cut off when the fault is repaired. This, of course, has to be done as soon as possible and meanwhile, if necessary, the power input reduced.
The alarms for the melting furnace are:
- overtemperature, transformer
- melt temperature, high or low
- no voltage on inductor
- overload on inductor
- overload on tap changer
- low flow, cooling water
- overtemperature, cooling water
3. LAUNDERING SYSTEM
The system is composed of protection gas generator and launder itself. Both are lined with refractory materials. The protection gas for the launder is generated by burning charcoal with decreased amount of air. The protective and even a little deoxydizing element in the gas is carbon monoxide (CO), about 10 to 15 % of the gas content. The charcoal must be dry and clean otherwise hydrogen will be generated more than is allowed.
3.1 Gas generator
The gas generator should be installed in a well ventilated place, rather in a separate room with forced ventilation to outside. Connecting pipe is led to the launder.
The gas generator consists of following main parts:
- refractory lined furnace
- blower with electric motor and regulating valve
- cyclone with emptying valve for water and dust
All parts are assembled together on a base standing on floor. The furnace has two doors, one on top for charging charcoal and one at front, down for ash removing. The blower is connected to the lower part of the furnace below the grate on which the charcoal burns. Gases generated inside the furnace are led through the cyclone to the launder through connecting pipe. The pipe might get dirty and even blocked in the long run, so it is good to foresee
the cleaning possibilities by assembling flanges at the pipe angles.
There is a small tank connected to the gas chamber of the generator. This tank should be filled with water or in cases when freezing is possible with oil to the marks on the measuring stick. This liquid forms an emergency valve if for some reason an explosion takes place inside the generator.
The launder is connecting melting furnace to holding furnace for well protected melt transfer. It is sealed around the pouring tube of the melting furnace and bolted and sealed on the cover plate of the holding/casting furnace. The launder is divided into two parts for easy maintenance of the lining. The upper part is fixed gas tight on the lower part by bolts. The lower end of the launder has a door with hinges providing access to the holding furnace for slagging etc. There is also a cover at the upper end for easy removal of possible solidified pieces of Cu after each pour. There are two windows one at the end towards the melting furnace for observing the pouring through the pouring tube and one on the door for observing the melt running into the holding furnace. The windows are of wired glass which get dirty and break so they need to be changed quite frequently for controlled observation.
4. HOLDING/CASTING FURNACE
4.1 Equipment description
Holding/casting furnace is divided into two chambers by brick wall. One for the melt transferred through the launder from the melting furnace and the other for die coolers for casting of the wire rod. Normally the first melt, when starting up the UPCAST-line, is taken into the casting furnace first, and the first melt for the melting furnace is melted in the casting furnace and transferred to the melting furnace in the first melt pot.
The casting furnace lies on two rails along which it can be moved when required. It can be tilted by two hydraulic cylinders at the tilting/emptying point. The furnace inductor is operated with switches, signal lights, electric indicators and automatic temperature and power feed regulator on the control desk. The furnace is composed of following parts:
- furnace steel construction with refractory lining
- inductor with refractory lining and cooling air blower
- hydraulic tilting equipment
- tilting cradle on wheels
- regulating transformer with other electric equipment and capacitors
- control desk
4.1.1 Holding/casting furnace steel construction
The furnace frame is made of welded steel with two consoles for hydraulic tilting. It has a mounting flange in the bottom for inductor connection and a spout at one side for emptying the furnace when tilted. The furnace is fixed to the tilting cradle by two hydraulic cylinders. The cradle lies on four wheels along the rails.
4.1.2 Inductor for holding/casting furnace
This channel type inductor works like a transformer. Voltage is fed to its primary coil and heating power is generated to the secondary coil (molten copper loop inside the inductor).
The voltage to the inductor is fed through the regulating transformer with six (6) voltage steps and with maximum power rating of about 150 kW.
The inductor is delivered preassembled
The inductor consists of following 'items:
- steel body of several parts bolted together (including lifting lugs)
- iron core with fixing supports
- copper coil
- cooling/support cylinder of Cu
- connection cylinder for cooling blower
- insulation material (ply wood, mica, etc.)
- channel pattern of solid Cu (to be assembled in the inductor)
The inductor is stored on a special stand where it lies well supported. For lining work it has to be disassembled. Number each item in order to be able to reassemble them again.
4.2 Refractory lining of holding/casting furnace
The furnace is lined with bricks and insulation mix. The inductor is lined with ramming mix.
4.2.1 Furnace lining
The furnace lining is composed of insulation mix(castable) , high alumina bricks and cement and insulation board. The lining work is performed according to the drawing 142.6781b.
4.2.2 Inductor lining (casting furnace inductor)
Inductor shells either lined with insulation board
(one layer 10 mm) and bricks and rammed or it can be
lined with insulation board (two layers, each 10 mm) and rammed. See the attached photographs.
5. CASTING MACHINE
The withdrawal machine supported above the holding furnace consist of three main parts each
- coolers with graphite dies
- withdrawal equipment
- height position control equipment
For every strand of the casting machine there are individual primary and secondary-coolers. The secondary coolers are mounted to the frame of the withdrawal equipment by cooler fixing devices. With these the cooler units can be lifted up from the melt for changing. The primary coolers with the graphite dies are connected to the secondary coolers by quick couplings.
Dies are made of high quality graphite (normally grade ATJ or better). The inside surface of the die is made smooth and precise in diameter by honing. The dies wear out during casting and must be changed before the quality of the cast rod becomes unsatisfactory. The lower end of the primary cooler is protected with sleeves.
5.2 Withdrawal equipment
The withdrawal equipment is a set of pinch rolls and driving mechanism assembled to a supporting frame for 12 Strands.
The drive to the pinch rolls is generated by a hydraulic power back through hydraulic motor, eccentric disk and transfer equipment. The drive mechanism is common to six strands of the machine. Both sides of the machine with six strands have their own individual drive mechanism. For each strand there are two pairs of pinch rolls. Idle pinch rolls, pressing the rod against the drive pinch rolls by pneumatic cylinders, are operated with valves.
The withdrawal speed (combination of forward strokes and stops) can be regulated by hydraulic flow control valve (number of revolutions on the ec,centric disk). Some fine regulation can be done with the adjustment on transfer lever.
5.3 Height position control equipment
The withdrawal equipment is connected to the height position control equipment with four control screws. These screws are driven by an electric motor through gears taking the withdrawal machine up and down according to the melt level in the furnace (see point 5.2.6).
6. COILING EQUIPMENT
There are six (6) double coilers for twelve (12) strands. Each coiler takes two strands through speed control equipment which automatically adjusts the coiling speed to match the casting speed.
The bending radius of the wire is automatically regulated in order to get compact coils up to 4000 kg. The rods are coiled into coiling racks.
6.1 Speed control device
The frame is common to twelve strands. Each strand has individual control equipment fixed on the frame and connected to the coiler by hydraulic piping. Control arm and roller are following the hanging of the rod before it enters the coiler regulating the speed of the coiler through hydraulic flow control valve.
6.2 Double coiler
The coiler is a unit for two strands. The driving power is generated by hydraulic power pack driving individual pinch rolls for both strands through hydraulic motors and gears. Bending radius controls are common to both strands. Electric control box is also common to both strands. The rotating coil vans can be locked on either end of the coiler rails.
If you have any questions or would like to receive further information on the above equipment please contact Mark or Mike Mathiasen. (860)873-1423 email firstname.lastname@example.org
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