EuroWire March 2015

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News
Technology
March 2015 56
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
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.
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:
Upward casting copper rod – simple and reliable
▲ ▲ Research and development plays a large part in Upcast’s future
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
operated vertical lift door.
Grieve Corporation – USA Website:
▲ ▲ The 871 box furnace
from Grieve