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4+6 2-Roller Type Aluminum (Alloy) Rod Continuous Casting and Rolling Line (6-7.5T/H)

4+8 2-Roller Type Aluminum (Alloy) Rod Continuous Casting and Rolling Line (3.0-4T/H)

0102030405

Aluminium Ingot Casting Line

Payment Terms T/T, L/C, D/P, etc.
Delivery Time 150 Days
Place Of Origin China
Port Of Loading Shanghai, China
Shipping By Sea
Warranty Period 12 Months

product details

Main parts

INTRODUCTION

The aluminum ingot casting machine is specifically designed to cast molten aluminum liquid into ingots of the desired shape and size. It has the features of automatic distribution of aluminum liquid, adjustable ingot casting speed, automatic ingot stripping, high production efficiency, uniform weight of aluminum ingot and so on.

Aluminum scraps, old cans, cut sheets of car aluminum, aluminum chips, and dross are commonly used as raw materials in production lines. These practices offer significant environmental advantages, including efficient resource reuse, energy conservation, and a reduction in waste sent to landfills, as well as a decrease in environmental pollution risks.

Production Process

Melting furnace → Launder → Holding furnace → Launder → Filtration device → Continuous casting machine → Automatic slag scraping system → Robot stacking system → Automatic labeling machine → Automatic weighing system → Automatic packing machine → Finished ingot stack

features

* The length of the production line is 16-25m, and the number of molds is 216-328.
* The ingot weight can be 5kg, 6kg, 7kg, etc., it can be designed by customers.
* The capacity of the casting machine is 6.5-8 t/h, depending on the ingot weight.
* Aluminum ingot removal temperature: 220-250 degrees.
* Adopting frequency conversion control, the casting speed can be freely adjusted (0-3.4m/min).
* Adopting automatic clamping demolding mechanism, the demolding rate is over 99%.
* Cooling method: water spray cooling/water immersion cooling at the bottom of the mold.

Scope of application

The aluminum ingot casting machine converts scrap aluminum into standard aluminum ingots by melting and casting and plays a vital role in the aluminum industry. It is an essential raw material for smelting plants, foundries and any plant that uses aluminum as its core material.

Reverberatory Furnace

Waste copper rectangular fixed-type reverberatory furnace is a special smelting equipment that uses liquefied petroleum gas, heavy oil or natural gas as fuel and scrap copper as raw material to complete melting, oxidation (slagging), reduction and other smelting processes.

The reverberatory furnace is mainly composed of steel structure, refractory material, furnace door and transmission equipment, gas burner, air supply system and electronic control system.

The reverberatory furnace provided by us has advantages of simple structure, good adaptability to raw materials and fuels, long furnace life, convenient operation, easy control, high operation rate, suitable for large, medium and small scale production, and less water consumption in production and so on.

According to customer requirements, the capacity of the reverberatory furnace can be designed such as 40t, 60t, 100t, etc.

Wheel Casting Machine

The liquid copper which are refined by the reverberatory furnace cast in the crystal wheel cavity of the casting machine through launder and pouring pot. After water cooling, the liquid copper will rapidly condensed and solidified into the casting rod ingot.

The wheel casting machine is mainly composed of driving mechanism(body), crystallization wheel, compaction wheel, tensioner, pouring pot device, cooling device, drying device, ingot puller, lead bridge, carbon coating device, flow control device, and air-drying device, etc.

The crystallization wheel provided by us uses copper-chromium-zirconium. This crystallization wheel has advantages of high hardness, wear resistance, antiknock, good cracking resistance, high production efficiency, long service life, and long-term continuous production.

Continuous Rolling Mill

Continuous rolling of copper rod ingots manufactured by the casting machine.

The rolling mill provided by us adopts active feeding, the final rolling speed can reach (8.1～9.9) m/s, and the outer diameter of rod is 8mm. It has advantages of convenient operation, easy control, high production efficiency, stable rod diameter, bright copper rod, etc.

Commercial Parts

1. PLC programmable use Germany Siemens, Touch screen use Germany Siemens.

2. DC control system uses Germany Siemens.

3. Button use Schneider, Control Relay uses Omron, others use domestic China.

4. All frequency converters use Siemens (China).

5. All AC motors use Siemens Bede (China).

Raw Materials

The copper continuous casting and rolling production line provided by us can use scrap copper as raw material for copper rod production.

Scrap copper of grade 1 or above grade 2 are used in a certain proportion.

Among them: Scrap copper of grade 1 should be clean and non-alloy copper wires free from tin, containing no fragile burned wires which including bare, uncoated, alloy-free copper wire with no oxidation on the surface and no wool. The diameter of the copper wire is not less than 1.6mm.

Scrap copper of grade 2 should be small diameter non-insulated copper wires, usually containing telephone wires, copper strip with varnish or paper insulation, and thick or thin clean copper bar, also including clean, colorless, uncoated, tin-free, alloy-free copper wires and cables, free of wool and burnt brittle copper wires.

Scrap Copper Baler

Scrap copper needs to be packed into copper blocks by scrap copper baler before casting. The scrap copper baler is shown below:

The scrap copper baler adopts hydraulically driven, and has characteristics of simple structure, durable, convenient operation, fast packing speed, compact packing block and so on. The scrap copper can be extruded into various shapes such as cubes, cylinders, etc., which can not only reduce transportation and smelting costs, but also improve the speed of furnace operation. The packed copper block is shown below:

Installation And Commissioning

1. 14 days before the inspection before delivery at Manufacturer’s plant, the Buyer shall inform the plan schedule of installation, commissioning and test production to the Seller. The both parties will finalize this plan during the period of inspection visit.

2. All the civil work should be done by the customer according to the drawings from manufacturer. The buyer should prepare all raw materials, auxiliary materials, production tools, production workers and etc

3. Commissioning (checking the wire and cable connections, water supply, air supply, etc. and make corrections), adjustment of the equipment and start-up of test run.

4. For the installation/commissioning and test production, for specialist needed, time needed, allowance, please check following table:

Time	1-15D	16-30D	31-45D	46-50D	61-75D	76-90D
*F-A
F-B
CCR-C
CCR-D
*P-E
P-F
P-G

*F means furnace; *P means process.

**Furnace building; Furnace heating; CCR installation; Commissioning.

* Remark: The schedule is for a reference. The real time needed is according to the site.

faq

Q: Can I visit your factory?

A: All the customers from both home and abroad are warmly welcomed to visit our company and factory.

Q: Do you supply the installation and commissioning?

A: Yes, we do as followings:

-As soon as customer informed us the machines are put in the right place, we will send both mechanical and electrical engineer for machine start up.

-No-load testing: After machine installed completely, we make no-load testing first.

-With-load testing: Usually we will can produce 3 different wires to make load testing.

-Acceptance report: After the buyer confirms that machine can reach all specification under contract, the acceptance report will be signed for our record that machine will be in guarantee period.

Q: What information should I offer to get a detailed quotation from you?

A: For single machine: Usually we need to know inlet wire size, outlet wire size to be produced, productivity, pay off and take up size to choose the right machine.

For new cable plant or new cable production line, we need to know the datasheet of cables to be produced, the productivity, the standards to be followed, etc to design all machines needed.

Q: Can you supply the auxiliary equipment along with the machines?

A: Yes, definitely.

We has supplied heat exchanger, copper/aluminum powder filter machine, cooling tower, chiller, air compressor, drawing dies, pointing machine, cold welders, bobbins etc. with our machines.

Q: Could you do the design for the whole plant?

A: Yes, this is our advantage.

With the data sheet of cable to be produced, the standard your cables should follows, the productivity you expected. Our engineer on production technology and machinery will make design of production machines, test equipment, accessories like bobbins, dies, rewinding lines and materials needed.

Q: How can I know the status of my order?

A: We have our OA system on tracking the production.

For any of your request we can send photos and videos of your order, also we can use FACETIME to let you know the production.

Q: How do you work on the inspection before delivery?

A: We will make dynamic balance testing, levelness testing, noise testing, etc. during production.

After production finished, usually we make no-load running of each machine before delivery. Customers are welcomed to attend the inspection.

Q: What exhibitions will you attend, can we meet in the fair?

A: Dusseldorf International Wire and Cable Fair;

Wire South America Fair;

International Wire and Cable Fair in Shanghai;

International Istanbul Wire Fair, etc.

wire Southeast Asia Fair, etc.

Ingot casting machine

The main frame of the ingot casting machine is made of international channel steel or rectangular tube, and all electrical products are international brands.
The ingot casting machine adopts aluminum liquid automatic distributor, and the weight of aluminum ingot is uniform. The frequency conversion control adopted can freely adjust the ingot speed (0-3.4m/min).
The ingot weight are 5kg, 6kg, 7kg, etc. The ingot models are designed according to different needs of the customers. Depending on the size of the ingot weight, the capacity of the ingot casting machine is 6.5-8t/h.

Gantry type ingot stacking machine

The gantry stacking machine completely replaced the manual ingot stacking. The whole process is controlled by PLC program, which can realize fully automatic or semi-automatic operation. It packages the aluminum ingots cast by the ingot casting machine and forms them neatly, which is easy to transport, thus improving work efficiency and liberating labor.

Robot stacking system

Use 4-axis / 6-axis stacking robots of imported brands (Kawasaki, Yaskawa, ABB, etc.) to ensure stable operation of the equipment. Compared with the gantry type ingot stacking machine, it does not need pit and occupies small area and the stacking of ingots of two casting machines can be realized in synchronization. Through the touch screen setting, the user can set the number of stacking layers at any time according to the order requirements during use, making the stacking more simple and flexible.

Automatic packing machine

The neatly stacked aluminum ingots are transported to the packing station, and automatic online packing is completed through the packing machine. It is efficient, intelligent, time-saving and labor-saving.

Automatic scraping, spraying robot

It is composed of 6-axis robot, PLC, scraper device, etc. The system has stable performance and low maintenance cost. At the same time, it runs synchronously with the ingot line to achieve fully automatic operation, completely replacing manual work, improving production efficiency, and avoiding safety accidents in which operators are burned by high-temperature aluminum liquid.

Automatic Aluminum Ash Treatment Equipment

When used with the aluminum melting furnace, it separates and recycles metalic aluminum from the ash produced during smelting. This increases aluminum's utilization rate, reduces losses, and lowers costs.

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