Rautomead rs cu of technology
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Rautomead Limited Compiled Oct 2013 BF Continuous Casting Technology
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For over 30 years Rautomead Limited has specialised in the design and manufacture of continuous casting equipment for non-ferrous metals and alloys. There are now more than 300 Rautomead machines in operation in over 45 different countries worldwide. Rautomead plants are being successfully applied to production of oxygen-free copper, a wide range of copper-based alloys, precious metals and zinc. Forms include wire rod, straight length bars, flats and hollow sections. According to material and section, the casting process selected may be vertical upwards, vertical downwards or horizontal. The machines may be used either as integrated melting, holding and casting machines, or may be arranged to be fed with pre-alloyed molten metal. The Rautomead Continuous Casting System is based on electric resistance heating of its furnaces, with graphite containment crucibles, graphite heating elements and casting dies. This technology is particularly suited for production of high purity, high quality oxygen-free copper and copper alloy wire rods (copper silver, copper magnesium, copper tin). The upward casting equipment may be used to manufacture rods of all diameters between 8.0mm and 30mm diameter and is suitable feedstock for wire drawing and continuous rotary extrusion processes. End use applications include: superfine wire, automotive wires, contact wire and trolley wires for high speed trains, data communication cables, CTC and transformer strips as well as enamelled wires. Rautomead’s R&D facility at the factory in Dundee (casting equipment, technicians, design and operational experience) is available to companies who wish to commission experimental and research work to develop technology and tooling for the manufacture and processing of new alloys and materials. Rautomead’s partnership with the University of Dundee provides access to sophisticated laboratory equipment as well as support with analytical evaluation and academic contributions to the R&D effort. www.rautomead.com [email protected]
Transcript of Rautomead rs cu of technology
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead Technology Presentation
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead LimitedDundee Scotland
Founded 1978
Sir Michael NairnChairman
Brian Frame MD
Employees = 50
Machines Sold more than 350First 1978
Of these :-
Vertical Upwards = 77First 1995
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead – Head Office, Dundee, Scotland UK
Including: R&D casting facility + Spare Parts Stores
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead – Unit 7A Nobel Road FactoryMachine assembly & pre shipment testing
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Experts in Continuous Casting Technology
• Rautomead are the ONLY supplier of continuous casting technology to offer different equipment for each and all different end use applications:
• UPWARDS casting for WIRE ROD
• UPWARDS casting for TUBE SHELL
• HORIZONTAL casting for BILLET
• HORIZONTAL casting for STRIP
• DOWNWARDS casting for SMALL HOLLOW
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Wire Rod Casting Technology
CuOF CuMg BrassEnamelled wires Contact wires for EDM machining Fine wire high speed trains Connector pinsConform feedstock: Data cables Wire brushes CTC & Transformer strips
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS3000 – 8mm Cu-OF Redraw Rod
8.0mm dia 5,700 tpyr 0800 type coilers
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS3000 Conform Feedstock
12.5 – 22mm dia 5,700 tpyr 0832 type coilers
CuOF 5 ppm oxygen clean, bright surface. No surface defects or contamination “soft rod” 170 N/mm2
Cu Ag silver content 100 – 2,000ppm automated feed and composition control
Control of quality “in house”
“Just in time” production of rod, minimise inventory.
CuOF preferable to ETP rod for Conform products, minimal defects.
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS3000 Conform Feedstock for Transformer Strip
And Busbar strip
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS3000/6 8-22 Designed for Flexibility: CuOF, or CuMg or CuAgCan interchange between alloys.Automated feed systems for CuAg and for CuMg are available
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Automatic Cored wire feed system for Mg addition
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS3000/CuMg – 30mm CuMg for HS Railway Contact Wire
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Experience with copper Magnesium Production Continuous cast rod to Contact & Catenary wires
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Copper Magnesium (0.14%) Production Continuous cast rod to Small diameter Cable
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Copper magnesium alloy wires
• Higher strength
• Reduce diameter without sacrificing mechanical
performance
• Reduce weight of harness
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Grain feeder for silver granules automated composition control 100 – 2000ppm
For shaped wireEg conformed comutator sections
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead Technology for
Upwards Continuous CastingOf
Cu-OF and Cu Alloy Rod
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS3000 - Specification
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Typical RS3000/6 layout – footprint approx. 33m x 7m x 7m
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS3000 machine features: Automatic Cathode Feed
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS 3000 machine features Withdrawal Carriage, Tooling and Fluidics
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS 3000 machine features Withdrawal Carriage Drives
Servo drive 12.7 to 30mmIndexer drive 8.00 to 12.7mm
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS 3000 machine features Coilers: for maximum flexibility select 0832 coilers : any rod from 8.0 – 30mm dia
RS3000 8-30mm Coilers RS3000 8-12.5 Coilers
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
RS 3000 machine features Coilers: up to 4 tonne coil weight
8mm – 30mm CoilerBending rolls form coil shape of large dia rodsBase rotation speed coils 8mm -12.5mm rods
8mm – 12.5mm CoilerCoiler base rotation, PLC controlled forms uniform coil shape.
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead Graphite Technology for
Upwards Continuous Casting
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead RS Furnace Technology
Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-
• Containment (Crucible & Valve)
• Casting (Dies and Packers)
• Heating (Low Voltage resistance
heating elements).
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead Furnace Technology
Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-
• Containment (Crucible & Valve)
• Casting (Dies and Packers)
• Heating (Low Voltage resistance
heating elements).
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Rautomead Furnace Technology
Rautomead Technology for Continuous Casting is unique because it uses GRAPHITE for :-
• Containment (Crucible & Valve)
• Casting (Dies and Packers)
• Heating (Low Voltage resistance
heating elements).
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Features of RL technology specifically benefit production of high quality wire rod
• Graphite crucible• Graphite Casting Dies• Unique cooler design• Graphite Electric resistance
heating (low voltage)• Inert gas protection• Integrated melting and
casting• Easy to Maintain Furnace
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Crucible - Vibrated Moulded Graphite has minimal Directional Properties
Rautomead Limited
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Continuous Casting Technology
Crucible - De - Oxidation of Copper
Rautomead Limited
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0
10
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1 2 3Time - Hours
(Retention time in Graphite)
Ox
yg
en
pp
m
2 ppmX
Oxygen Reduction
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Actual Data Recorded Over 12 Months Running
0
1
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3
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6
7
8
9
10
01/0
9/20
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15/0
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01
29/0
9/20
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13/1
0/20
01
27/1
0/20
01
10/1
1/20
01
24/1
1/20
01
08/1
2/20
01
22/1
2/20
01
05/0
1/20
02
19/0
1/20
02
02/0
2/20
02
16/0
2/20
02
02/0
3/20
02
16/0
3/20
02
30/0
3/20
02
13/0
4/20
02
27/0
4/20
02
11/0
5/20
02
25/0
5/20
02
08/0
6/20
02
22/0
6/20
02
06/0
7/20
02
20/0
7/20
02
03/0
8/20
02
17/0
8/20
02
31/0
8/20
02
Oxy
gen
(p
pm
)
Cu-OFE
Cu-OF
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Heating Elements & Sight Glass – cold Heating Elements – heated & glowing
Heating System - Graphite Heating Element Assembly
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Heating System - Graphite Heating Element AssemblyPrimary3 Phase AC380v - 415v
Secondary3 Phase AC35v- 50v
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Heating System - Graphite Heating Element Assembly
Heating Elements Close coupled to Crucible for Efficient Heating
Convention – Low heat TransferandRadiation – High Heat Transfer
Keeps Furnace Temperature Low – Less Losses
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Casting chamberTemperature Typ. 1175-1185 deg C
Charging chamber, cathode feedTemperature Varies
Heating Elements - Targeted Heating Optimises Casting Metal
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
SUPERCOOLER TOOLING ASSEMBLY
SECONDARY COOLING
WATERINLET
WATEROUTLET
COOLINGWATER CHANNELS
THERMALINSULATION
CERAMICHOT END CAP
GRAPHITECASTING INSERT
COPPER ALLOYPRIMARY COOLER
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Die Grade Graphite – 8 -12.5mm Casting - SGL R4820
Honed Finish of boreProlongs Die Life
Die Fitted to Cooler with taperEnsures Good Contact
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
VERTICAL CASTING SYSTEM
OPTIC SENSORS
IMMERSION THERMOCOUPLE
FLOATASSEMBLY
GRAPHITE FLAKE
MOLTENMETAL
WATER COOLINGSERVICES
SUPERCOOLERTOOLING
ASSEMBLY
CONSTANT IMMERSION
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Vertical Casting System
• Melt Thermocouple
• Float Assembly
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
It is recommended that cathodes of not less than 60 kgs be used. Maximum cathode size:1100 x 1100 mm squareMaximum cathode weight: 160 kgs Cathode surface to be: Grade 'A', dry, clean, bright, flat, unoxidised and free from electrolyte nodules.
Note : The Casting machine will reduce oxygen levels in the copper but will not remove impurities.
Cathode Feedstock
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Full deposit Cathode – acceptable quality . No nodules, surface smooth and little sulphates
Cathode Feedstock
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
OLEN ISA Electro-Refined Cathode
Cathode Feedstock
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
• 1st preference – Electrorefined ISA Cathode Stainless Steel Starter - No Lugs
Approx 60Kgs constant
• 2nd preference – Electrorefined Full Deposit Copper Starter Sheet – Lugs 40kgs to 120 kgs variable
Beware nodules and heavy sulphur deposits
• SX-EW - Electrorefined or ISA to be avoided
Cathode Feedstock
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Up to 10% in house arising's permissible
Must be bailed (compressed)
In House Arisings (reject rod and wire) Feedstock
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Why choose Rautomead ?• Rautomead Equipment and technology will produce the highest quality
continuous cast product.
• Maximum flexibility for production: CuOF and conductor copper alloys
• RS graphite system can interchange between alloys with minimal losses
• Specific customer references for:• CuMg rod manufacture 0.57% • CuAg rod for commutator strip• CuOF rod for CTC * transformer strip• CuOF rod for enamelled wire
• The complete system is designed and supplied by Rautomead (furnace, controls, casting die, withdrawal system) as a comprehensive integrated system, assembled and tested at Rautomead before shipment.
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Why choose Rautomead ?
• Expand product range to include: CuOF, CuMg, CuAg, DHP, CuSn alloys in addition to existing ETP copper rod
Become a “one stop shop” and supply the market for copper rod, wire, shaped wire or strip: Any size and any alloy
Rod producers with big volume ETP capacity PLUS Rautomead for alloy or CuOF rod include Aurubis Belgium Elektrokoppar Sweden LaFarga LaCambra Spain Freeport McMorran USA Transkat Russia Lamifil Belgium Sarcheshmeh Iran Er Bakir Turkey Mitsubishi Japan
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Why choose Rautomead ?Customer reference specifically for CuMg rod production includes:
NKT Cables GermanyNKT Cables ChinaLamifil BelgiumCRCEB ChinaFujikura ChinaElektrokoppar SwedenLa Farga LaCambra SpainEr Bakir TurkeyTranskat Russia
Customer reference specifically for CTC strip or transformer strip or shaped busbar
Essex Gmbh GermanyAurubis BelgiumNgo Han VietnamTusco Trafo Thailand
Rautomead Limited
Compiled Oct 2013 BF
Continuous Casting Technology
Thank You
www.rautomead.com
Rautomead LimitedDundee Scotland
