EuroWire March 2015

News Technology

Upward casting copper rod – simple and reliable

Since 1968 many new developments have taken place to the concept of upward casting copper rod, and systematically the technology has been further developed to meet the current requirements of customers and markets. Today´s Upcast process is simple and reliable with easy operation through an advanced control system resulting in a low lifecycle cost. With the consistent and systematic research and development work, the capacity of the lines has become bigger, more rod diameter sizes are possible and the lines operate safely and reliably for many years. The invention of Upcast SGTube casting process took place a few years ago – small grains, bigger gains – and the Cu tube upward casting technology reached new levels. As new applications for copper alloys are being developed, the utilisation of Upcast technology within the copper alloys field is rapidly increasing, too. There are a few things, however, that have always driven the research and development, and the implementation of the new features brings cost savings and guarantees cost efficiency to the customers; the quality of rod has to remain at the level received or rather become better with every development; the process has to remain environmentally friendly – always greener. With this work the original continuous casting technology has again been taken to the next level: with the new coolers and the latest furnace, inductor, automation and control system designs Upcast can now offer even more efficient, consistent and reliable Cu rod production

▲ ▲ Research and development plays a large part in Upcast’s future

A wide capacity range both in single- and double-furnace configurations is available with a possibility for upgrade. The majority of delivered Upcast lines are for Cu-OF rod and mainly with most common cast rod diameter of 8mm. Rods with bigger diameters are used for manufacturing a variety of finished products, eg bus bars, shaped profiles, trolley wires, electroplating anodes, etc. Cu-OF rod with its excellent formability is well suited for all electrical applications. Cast and form process combines Upcast Cu rod casting with Asmag´s ASCON continuous rotary extrusion ending with the drawing, stretching, cutting and packing. This reduces the investment costs and offers a reliable full-process solution with low operational costs. Upcast hybrid technology is based on using the same equipment for casting both Cu rod and Cu tube. This has been achieved by modifying certain product-specific parts of the SGTube casting machine and coilers to facilitate easy changeover. The flexibility of the product mix makes the hybrid system a cost-effective solution for companies with a diverse product portfolio and a certain capacity requirement for both products. There is no need to have two separate lines and, in the worst case scenario, neither one being fully utilised all year round. Upcast OY – Finland Website : www.upcast.com

process. Higher speed means more capacity with less cost and results in improved cast rod quality. The possibility of using clean and dry Cu recycled material in the process has become more important, and Upcast has accepted the challenge and can now design a solution for different needs. All this is available for existing customers due to the upgradability of casting lines. Rod production lines are of modular design. Both single- and double-furnace configurations are possible. With a double-furnace configuration – having separate melting and casting furnaces – it is possible to reach 40,000 tpa output, while 12,000 tpa is possible for a single-furnace configuration.

2,000°F gas-heated box furnace The No 871 is a 2000°F(~1093.3°C) gas-heated box furnace from Grieve, and is currently used for heat treating and high temperature testing. 650,000 BTU/HR are installed in three modulating natural gas burners with a floor mounted combustion air blower. Workspace dimensions are 30” wide x 48" deep x 30" high. The unit has 7" insulated walls comprised of 5" of 2,300°F ceramic fibre and 2" of 1,700°F block insulation. The 6½" floor insulation is made of 4½" of 2,300°F firebrick and 2" of 1,900°F block insulation. The plate hearth is made of firebrick and supported by firebrick piers. Controls on board the furnace include a Partlow MRC 7000 recording and programming temperature controller and an electrically

▲ ▲ The 871 box furnace from Grieve

operated vertical lift door. Grieve Corporation – USA

Website : www.grievecorp.com

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March 2015