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alumnium alloy rod CC-R line

alumnium alloy rod CC-R line
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Product Name:alumnium alloy rod CC-R line
Place of Origin:Peoples Republic of China
Post Date:March 4, 2013
Edit Date:March 4, 2013
Company Name :
Deyang Bochuang Electrotechnical Equipment Co.,Ltd.
Tel:86-838-2506545
Fax:86-838-2508161
E-mail:chenhongfudy@hotmail.com
Detailed Product Description:

 Application

By means of continuous casting & rolling, this line works to produce electrical common aluminum rod and Al-Mg-Si rod  ,8030alloy rod in a diameter Ø9.5mmorØ12mm, orØ15mm.

2. Brief Process Flow

 

 

 

Chemical composition analysis

 

Aluminum ingots

 

Melting furnace

 

Degassing& filtering

 

Casting

 

Rolling shear

 

Straitening

 

Al-Mg middle alloy

 

Al-Si middle alloy

 

Al-Zr middle alloy

 

Al-Re middle alloy

Induction heating

 

Rolling mill

 

Quenching

 

Winding device

 

Products

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


 

3. Main Components

This production line is composed of round energy-saving Melting furnace,on-line degassing & filtering system, 4-wheel casting machine (including casting ladle), rolling shears, straightening system,Times frequency induction heating device,continuous rolling mill, quenching device, two-position coiler, lubrication oil system, emulsion circulation system and electrical control system for rolling mill.

 

4. Main Technical Data

4.1. Diameter of casting wheel                Φ1600mm

 

4.2. Delivery speed                       7.8-15.4m/min

4.3. Casting bar section                     2400mm2

4.4. Motor for Casting machine              4kw (AC), 1000r.p.m

4.5. Motor for rolling machine               Z4-355-32, 355kw, 600r/p/m

4.6. Final rolling speed                     4-6.2 m/s

4.7. Capacity                             2.7-4.2 t/h

4.8. Output diameter                      φ9.5mm、Φ12mm、Φ15mm

4.9. No.s of stander                    15 (Y-type Up drive 8 sets; Y-type Down drive 7 sets)

4.10. Pass system                           Arc triangle – circle

4.11 roller named diameter                   Φ255mm

4.12 coiler diameter                     Φ2300mm

4.13 take-up weight:                        about 1.5-2.0 t/basket

5. Technical Specifications and Composition

5.1.Round energy-saving Melting furnace            2 sets

5.1.1. Technical Descriptions:

a. this parts adopts 2 sets of 12 T round melting furnace, and the aluminum material shall be charged in the furnace through charging device, 1 single furnace can do works like melting, heating, alloy preparation, refining & deslagging and casting water dispatching. Two sets of furnace can take turns to do melting and casting water dispatching, so that it can do continuous producing.

b. there is 1 set of permanent magnet blender for the 2 sets furnace to keep uniformity of alloy elements and liquid temperature, and reduce the burning loss of aluminum material.

c. full set of furnace unit has one set of Whirlwind wet dust catcher, it can collect flue gas and dust, and after wet spraying and whirlwind dust catcher to achieve environmental protection requirement.

5.1.2 Fuel: Natural Gas

5.1.3 After the furnaces went into a thermal equilibrium state, the self-produced scraps returns is ≤20%, and when the two furnaces reaching the rated capacity and continuous normal production conditions:

a. energy consumption: ≤56×104Kcal/t·Al   (from starting melting to liquid reaching 740℃)

b. melting speed: ≤3.5h/furnace   (from starting melting to liquid reaching 740℃)

c. net burning loss: ≤1.5%

5.1.4 Capacity: rated capacity is 12T, Max. capacity is 13.5T

5.1.5 Furnace Overhaul: shaft furnace barrel and air preheater ≥2 years; bottom furnace ≥4 years.

5.1.6 Furnace composition and characteristics:

  One single set of round melting furnace is composed of bottom furnace (including steel structure furnace body, furnace bottom steel structure and magnetic force window, refractory material brickworks, and holding&heat-barrier material), melting furnace shaft furnace barrel, charging bucket, casted iron furnace roof cover and Electric rev. Cover device, furnace roof operation stand, 4-railway vertical charging device, horizontal air preheater for melting furnace, air supply system, flue gas cover and flue gas discharging pipes, permanent magnetic blender, control system and furnace electrical control cabinet.

  1. Furnace outer cover steel structure: it welds of 6-8mm type Q235 steel plate and structural steel, and with good air tightness and enough rigidity.
  2. Refractory material use instructions:
    1. the part between non-magnetic work layer for furnace bottom and slag line should uses Super high aluminum bricks(LZ80), and per standard brick weight is ≥4.65kg; other parts use Level 3 high aluminum bricks (LZ55);
    2. The part between furnace roof and furnace month uses low cement steel fiber reinforced castable (GHK-80), and the slag dispatching part of furnace door uses high-strengthwearable castable.
    3. Such the complex parts like Melting pool, should use super non-sticky aluminum castable (RC-80)
    4. Water dispatching inner bricks should be sintered by American league ore silicon carbide materials, to ensure a longer service time and easy to change.
    5. Holding layer: should use cenospheres heat preservation brick (NG-0.8), holding castable (B-0.8, B-1.3, B-1.6), calcium silicate board (P-0.2) and high aluminum fiber felt.
    6. Furnace building mud: inner work layer should use super high aluminum phosphate (sodium silicate) mud (LN-80).
  3. Shaft furnace barrel brickworks: this inner lining is composed of phosphate & high aluminum wear-resisting brick, holding castable and thermal insulation fiberboard, to improve the service time and thermal insulation performance.
  4. Furnace door: it should use whole-casted cast iron hinge type furnace door (door size: 780*550mm), inner lining for furnace door should be made of high quality castable and heat insulation materials, and the door cover inside slot filled with refractory fiber. When close the door, it should through the manual locking device and refractory fiber seal to ensure the air impermeability of the door.
  5. Charging mouth, roof cover and Rev. cover device: the charging mouth is made of whole charging bucket and heat insulation castable; roof cover is composed of cast iron covering frame and inner lining high quality refractory castable; to ensure a longer service time and improve impact resistance performance, and Rev. cover device adopts electric winch to start switching.
  6. Air preheating system: this melting furnaces adopts efficient preheated horizontal barrel radiation heat transfer structure form,; inner barrel uses preheating barrel with SUS321δ5 and δ8 boiler steel, and with a heat insulation layer on the outer layer to improve the effectiveness and recycling of waste gas fuel achieve the purpose of saving energy and reducing consumption.
  7. Charging device and its characters:
    1. it adopts vertical guiding rail structure: it ensures stable operation, when the charging bucket moves on, the level shift is large and pour material smoothly;
    2. Hopper structure is suitable for forklift truck and travelling crane to charge whole bundle of aluminum ingots.
    3. It adopts frequency conversion double speed control to ensure a low speed to start hopper and batching turnings, and with high speed in between.
    4. High safety: there is a lock device to prevent hopper breakdown and fall down, and there also has whole defending network.
  8. Fuel burning disposition and fuel supply:
    1. fuel is natural gas, one single set of furnace has 2serts of gas burner, this burner adopts Beijing shenwu Burner, with high efficiency and long service time;
    2. Before the seller supply burner, the buyer should join the main control valve, side valve and gas supply pipes to the furnace.
    3. The rated gas pressure 0.03Mpa, common gas pressure is 0.03-0.09Mpa, the Max. gas consumption of single set of 12T furnace is 240Nm3/h.
  9. Water dispatch mouth:
    1. This part adopts changeable inside lining bricks, which adopts Al ore custom products to ensure a much longer service time and easy to change.
    2. Center height for water dispatch mouth should be lower, and the mouth bottom should have a little difference with the pouring ladle bottom on rolling machine. This method can ensure aluminum liquid flow into the slot and reduce a secondary slag-taking and air-taking due to the water dispatch washout.
  10.  Flue Gas Exhaust Pipes:
    1. This part adopts separate exhaust method between melting inside furnace and furnace mouth smoking pipes, and the smoke exhausted from the preheater shall be guided into the dust removal system in another way. (Generally, the seller only supplies the pipes within 10 meters, and the exceeded parts should be self supplied by buyer.)
    2. It set with large smoking hood at the furnace mouth to ensure most of smoke can be exhausted out, but it should depend on external force, or be exhausted by dust removal system induced draft fan.
  11.  Furnace control system: each set of furnace has melting furnace air blower switches, Rev. cover winding switches, furnace temperature degrees temperature measurement and display, aluminum liquid spot measurement (handheld type) etc.
  12. Magnetic window furnace bottom:
    1. Magnetic window and gallery adopts δ12-14mm stainless steel plate and stainless rib plate.
    2. Non-magnetic window adopts δ12、A3 steel plate and structural steel baseplate.
  13. Bottom type of Permanent magnet blender:
    1. Two sets of furnace share one set of type YC-D1000B permanent magnet blender.
    2. The blender is collocated with electric lifting system, electric dragging system and guide rail, air cooling system and over-temperature protection system.
    3. Blender control system including:
    4. Variable frequency speed regulation and positive &negative turn control (15 kw), electric lifting (1.5 kw), cooling air blower (1.5 kw), and start& stop switch, temperature test and over-temperature alert.
    5. Collocated with over-temperature alert and protection system.
    6. Using desk type control cabinet, and all the electrical control parts use touch screen and PLC controller, it’s easy to operate.
  14.  Wet cyclone dust removal system (users self-choose):
    1. composition: double spray room (spray pipe and spout), double levels cyclone dust removal (stainless steel barrel ), guide air blower & flue pipe, sedimentation basin & cleaning basin, pumps & water supply pipe and control.
    2. Work theory: the smoke after being sprayed from the double spray room, most dust particle shall be dispatched into sedimentation basin, and the other part shall be divided in the double levels cyclone dust removal depend on the force of guide air blower. Then, the clean smoke shall be dispatched into the main chimney outside the workshop, and wet dust particle shall fall into the sedimentation basin.
    3. Waste water dispatched from double spray room shall enter into cleaning basin visa sedimentation basin. And the pump is installed upside cleaning basin, with water cycle method to reduce water consumption.
  15.  Furnace roof Steel structure operation stand: this part adopts 12# U-steel to make upright and body frame; operation stand surface uses 3-4mm riffled steel plate; the hand rail is made of seam steel tube or galvanized tube. One set of furnace operation stand area is ≥25m2,and the loading capacity is ≥1.5T/m2,(the materials should be supplied by user.)

5.2 on-line degassing & filtering system:          one set

5.2.1 Degassing device

1) degassing box: 1854×1250×1416mm(outside size),1100×700×850(inside size)

2) When the input hydrogen amount is higher than 0.30cm3/100g, the device can degas more than 50%; on contrary, when the input hydrogen amount is lower than 0.30cm3/100g, the hydrogen amount shall be not more than 0.15cm3/100g.

3) degassing box capacity: 600±50kg (when insulating)

4) heating method: Silicon carbide dipped into the heater to heat.

5) aluminum liquid temperature control: ±5℃(in normal casting condition, and the entrance temperature is ±5℃).

6) furnace temperature control: automatically control to keep steady.

7) heating power: 20kw/220V

8) metal work temperature: 680-850℃

9) rotor rotating power: 1.5kw/380V

10) rotor rotating speed: 0-500rmp (adjustable)

11) blending degassing hydraulic rotating system: it’s vertical to move up and down with 180º.

12)degassing method: inert gas shall be degassed through the graphite rotor, it’s sealing degassing.

13) metal Max. handling amount: 6t/h

14)  running noise:  <70dB

5.2.2 Filtering device:

1) filtering box: 900×490×455mm(outside size),390×390×400mm(inside size)

2) filtering box capacity: 100±50kg

3) metal work temperature: 680-850℃

4) Honeycomb ceramic filter plate: 30ppi:381×381×50mm

5) Graphite rotor (by German SGL Co.): service time 60 days per piece.

6) throughput: 100-150kg/min

This on-line degassing & filtering system including: degassing device and filtering device. Degassing device to do heating through a “U” silicon carbide rod and covering a protection sleeve outside the heater, and automatically control the temperature; graphite rotor is stepless speed regulating; heater and graphite rotor can do separately hydraulic promotion, and there are possible holes for cleaning slag on the degassing box.

5.3. 4-wheel Casting Machine (paten No. ZL00244512.3, ZL2009 2 0082060.7):      1 set

It is composed of pouring ladle, flow regulating device, casting wheel, drive device (including drive motor), pinch roller device, steel tape tensioning device, idle gear, steel tape wet & dry device, ingots taker, ingots guiding bridge, water cooling device, water pressure display device and pipe ways. The main technical data as follows:

1) Named diameter of casting wheel:                 φ1600mm                                                       

2) Type of casting wheel in cross-section:        H shape

3) Rotation speed of casting machine:           1.66-3.3r/min     

4) Cross-sectional area of casting wheel:         2420mm2

5) Cross-sectional area of cast bar:              2400mm2                                                      

6) Cast bar delivery speed:                    7.8-15.4m/min                                                    

7) Motor power:             4kw (AC, n=1500r/min, with frequency speed regulation)

8) Pressure of cooling water:                   0.3-0.5Mpa                                               

9) The distance between pouring ladle top surface and ground is:  660mm                                              

 

In order to ensure that crystalline structure of cast bar is compact and even, the casting wheel is cooled from 4 sides by spraying water regulated in sector surface. For the section from one o’clock to ten o’clock along the circumference of the casting wheel, the inner cooling and outer cooling is separately divided into three zones and inner side and outer side cooling is separately divided into two zones. In order to make it easy that cooling water is regulated and maintained and steel tape is replaced, the inner cooling, outer cooling and outer side cooling are installed on a rotary door which can easily rotate out from the casting wheel. In order to ensure that the tension can be regulated, the steel tape is tensioned and pressed pneumatically. The tension wheel and hold-down wheel have a deviation adjustor for alignment and adjustment of steel tape from deviation.

Molten aluminum flows into the upper tundish via the launder at end of which there is an overflow port through which over much molten aluminum flows into a ladle for aluminum scrap to make the level of molten aluminum in the upper tundish relatively stable, at the same time functions as safety protector. The upper tundish is fixed on a tiltable platform, when it is necessary to stop casting immediately, tilt the platform to make the remaining aluminum in the tundish and launder flow into the ladle for aluminum scrap. At the bottom of another end of the upper tundish there is a discharge port through which molten aluminum flows into the lower tundish where molten aluminum is stored momentarily and flows into the groove of the casting wheel through the spout. There is a plug at the exit of the discharge port of the upper tundish, stop up the flow mouth from the outside to inside and control size of the flow mouth. This plug is fixed on a floater in the lower tundish, which is a leverage mechanism at another end of which there is a movable counterweight. The moment equilibrium of the lever motion is:

 M1+M2-M3=M4     M1: flow mouth pressure moment     M2: floater gravity moment

     M3: downside pouring ladle floatage moment   M4: weight keeper gravity moment

Dynamic process:

1) when the molten aluminum position inside the downside pouring ladle drop, M2 decrease, floater also drop, and the moment equilibrium loss balance; at the same time, under the force of M1 flow mouth pressure moment, the plug press down, flow mouth become bigger; when the molten aluminum position inside the downside pouring ladle rise, M2 increase, and touch the plug, it shall reduce the floatage at the flow mouth to reach a balance.

2) when the molten aluminum position inside the upside pouring ladle rise, M1 flow mouth pressure moment increase, and down press plug to increase the floatage at the flow mouth, and downside pouring ladle molten aluminum position rise, touch the plug, the floatage shall reduce to reach a balance.

At the beginning of casting the groove of the casting wheel needs to be filled rapidly, meanwhile the casting wheel is accelerating, so manual adjustment is needed; while after the speed of the casting wheel becomes stable, the level of aluminum in the upper tundish is also basically stable, automatic control can be basically achieved. This device has been applied for patent(ZL200920082059.4).

5.4 Cooling System for Casting Machine (user self-prepare):

Whole equipment needs 2 sets of pumps (one for standby); filter: 2 sets of pumps

(1 for standby); other parts like stop valve, bottom valve, pipes, flange etc.

 

 Pump power:              22 kw

Water pressure:        0.3-0.5MPA

Floatage:                100m3/h

Temperature:              ≤50℃

 

5.5. Rolling shears:                      1 set

1) Motor:                             15kW (AC, frequency speed regulation)                                           

2) Length of sheared cast bar:             700 mm                                  

It is driven by an AC motor with speed reduced by a cycloidal speed reducer. Two cutters are provided on each roller of the shears to perform cutting, and the cutting length is about 700mm.

5.6 Automatically straitening device:            1 set

This device is composed of drive mechanism, straitening mechanism and straitening part, with automatically straitening function and cast bar guiding function. There are five idler pulleys for straitening wheel,and they are dislocation installed, upside has 2 pulleys, downside has 3 pulleys.

5.7 Times Frequency Induction Heating Device:         1 set

This device is used for heating cast blank, and includes induction heater, intermediate frequency power cupboard, temperature test and temperature control system etc. The induction heater adopts sectional method, between each section there is supporting drive roller. Temperature control system is composed of import optical fiber thermometer measurement, intelligent instrument and analog conversion system. This device can adapt to the aluminum alloy ingot before rolling heating temperature process requirement: from 440℃-480℃to 490℃-520℃;and main cooling water pipe is stainless steel tube, the joint part uses copper connector. The device copper bar should be protected by Bakelite and with Safety cover shell on the surface.

Intermediate frequencies supply Max. output power:      300 kw

Rate of Intermediate frequencies supply:                350 Hz

Max. heating temperature for cast bar:                   70℃

Cooling water floatage:                         >15t/h

Cooling water pressure:                         0.3-0.4 mpa

Production speed:                                  8-12 m/min

Equipment outside size:                       2200×1260×1000mm(L×W×H)

 

  1. Measurement for this device is FA Optical Fiber Temperature Instrument which is made by Xian Guangsheng Co.
  2. This device has water temperature and water pressure alerting device. Once water pressure is not enough, it will cut off the power immediately, and when cooling water temperature is higher, there is sound and light signal alarming.
  3. In order to ensure cast bar get through successfully, and under meet the technological requirements condition, it shall increase induction size at its most possible. Inductor inner container outside diameter is Ф 95mm.
  4. Supporting bearing should be high-temperature bearing.
  5. Induction heater is moveable, when it doesn’t need, can be moved away, and set up an auxiliary supporting guiding rail.
  6. If the rolling mill emergency stops due to rods pile up, this device can automatically cut off the power.

5.8. Rolling Mill:                       1 set

1) Rolling type:                       three rollers in Y arrangement

2) Outlet diameter:                     Φ9.5mm, Φ12mm, Φ15mm

3) Number of stands:                  15, 13

4) Nominal size:                       Φ255mm

5) Transmission ratio between two neighboring stands:   1:1.25

6) Final rolling speed:                   6.2m/s (Max.)

7) Center height of rolling:               1052.5mm

8) Power of main motor:                 355kw(DC), 600r.p.m

This rolling mill is provided with motorized feeding. With the help of drive transmitted from the main transmission box, an air cylinder clamps the cast bar pushing into stand No.1. It consists of 15 stands with three rollers (nominal diameter 255 mm) in Y-shaped arrangement, with upper drive in 7 stands in even number and lower drive in 8 stands in odd number alternately arranged. The rolling pass schedule is in circular-curved triangle-circular arrangement. A main drive mechanism transmits drive from a 250 kW DC motor via a toothed coupling mated with a main shaft beneath the 12th stand on the gearbox. Between two neighboring stands speed ration is 1:1.25. Safety toothed coupling is provided between the gearbox and stands, when overload, a safety pin is cut off to prevent accident from taking place. Before and behind each stand fitted are entries and exit guides, which, for the stands of odd number, are of rolling type while for those of even number, are of sliding type. Detector and stopper for rod piled-up is fitted between two stands, when rod piled-up, the rolling mill will stop automatically.

The small stands of each stand are provided with spacers in different thickness in half type for adjustment, which makes it unnecessary to screw out all of the four fixed bolts for replacing of spacer. Range of adjusting is at ±0.5mm.

Both the long and short shafts are in diameter 70 mm which are as same as the sizes of those for aluminum alloy rod rolling mill and copper rod rolling mill, with high strength and long service life. The roller material is 5CrMnMo which is as same as that of aluminum alloy rod rolling mill and copper rod rolling mill, with a long service life.

5.9. Emulsion lubrication system for rolling mill:         1 set  

1) Emulsion pump:      IS100-65-200, Q=80 m3/h, H=50m, 15 kW, 2 sets (one for stand-by)

2) Pressure:              0.3-0.5Mpa

3) Filter:                GLQ-100, 1 set      

4) Plate heat exchanger:    35m2           

Emulsion lubrication system is of dual-pump system. emulsion flows into the general pipe on top of the gearbox in two routes via the centrifugal pumps, filters and heat exchangers to lubricate and cool the gears, rollers, entry and exit guides of each stand, then back to the emulsion tank through the return pipe via the return trough on the pedestal.

5.10. Oil Lubrication System for Rolling Mill:        1 set   

1) Gear pump:                CY-18/0.36-2, 5.5 kW, 960 r.p.m,   2 sets (one for stand-by)                      

2) Working pressure:           0.1-0.3Mpa 

3) Filter:                     GLQ-80, 1 set

4) Oil tank:                   5m3

Oil supply system is of twin systems. Oil in the tank flows into the general pipe behind the gearbox from the oil pump via the filter and into the gearbox in routes, and then lubricates the gears and rolling bearings with splash through the nozzles of the branch pipe and back to the oil tank from the downside of the gearbox via return pipe.

5.11. Quenching Device for Aluminum Alloy Rod:           1 set

This part includes 2 sets of water cooling system (1 for standby) and quenching system.

Quenching process is divided into eight sections; there is water-blow device at the exit of take-up guide tube; cooling medium is cycle water of casting machine, includes inlet & outlet water pipes and valves.

1) Cooling water temperature:           ≤35℃

2) Cooling water pressure:        0.3-0.5MPA

3) Length of quenching part:             6000mm

4) Temperature after quenching:        <100℃

5.12 Take-up Mill:                     1 set

This mill includes operation stand, clip-send device, Guide Bridge, Ring Cycloid Device, storing device and trolley etc.

1) Drive device: 

Drive speed:          8.9m/s (Max.)

Drive motor:         7.5 kW (AC, frequency speed regulation)

This device works by initiative clip & send rods, with spring to regulate pressure. The work process is one clip-send roller drove by an AC motor through V-belt, at the same time another clip-send roller shall be drove by two pairs of gears.

2) Winding device:

Coiler diameter:             Φ2300mm

Winding motor:             4 kW (AC, frequency speed regulation)

The rods shall thread into the worm gear by drive force, then after being pre-deformation at the spiral swing pipe circle into the basket on trolley.

3) Coiling trolley:

Coiling basket diameter:              Φ2300mm

 Coiling basket height:                 1500mm

 There are two coiling baskets on the trolley, and they are changed by the cylinder which is under the trolley.

5.13. Electrical Control System:             1 set

Low-voltage power (380V, 50 Hz) with 3-phase and 4-line is fed into the equipment with total power at about 950kW.

 

The casting machine, front drive unit, roller shears, rolling mill and transmission part of the coiler are provided with full digital AC or DC speed synchronization control which is from international advanced PLC plus touch screen to conduct and integrate the whole system, display and monitor all kinds of running parameters. Among which, 355kw main motor is provided with Siemens 6RA7087-6DS22 DC speed regulator with high protection coefficient and diagnosis function to trouble or fault; PLC is programmed with S7-300; Touch screen is provided with TP27010 color touch screen man-machine interface in which all kinds of running parameters are monitored and displayed, and through which process parameters can be set, modified and displayed and has a function of diagnosis to trouble or fault, also the speed, current and voltage display, synchronization control and trouble indication of the casting machine, rolling mill and drive unit.

The whole process flow of the production line is displayed in full animation and intuition, meanwhile there are branch system animation display such as cooling system, lubrication system and alarm for piled-up system, which makes it easy to give instruction for operation and check the running condition of the plant. Meanwhile the system gives a signal to abnormal current and speeds of motor, automatically gives an alarm to rod piled-up and automatically stops the plant. Main low-voltage electric elements such as intermediate relay, AC contactor and air-break switch in less than 32A are from Siemens or Schneider, while those in more than 32A are from Chinese famous manufacturer. Electrical control part is provided with 4+3 panel and desk combined, 4 electrical control panels are of integral type, connected through the bases, good look and easy for inner wiring and connection. The electrical control panels should be put in a special power distribution room while only the operation desks for the casting machine, rolling mill and coiler are put on the production site.

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