Horizontal continuous casting is a method used in the production of copper plates, known for its efficiency and ability to produce high-quality products. The process involves several key stages and specialized equipment to ensure the consistent production of copper plates with desirable properties.
Production Process
Melting: The production of copper plates begins with the melting of copper cathodes or scrap in a furnace. This furnace can be an induction furnace or a reverberatory furnace, where temperatures reach above 1085°C, the melting point of copper.
Ladle Transfer: Once the copper is melted, it is transferred to a holding furnace via a ladle. The holding furnace maintains the molten copper at a consistent temperature and composition, ensuring a continuous supply of molten copper to the casting machine.
Casting Machine: The core component of the horizontal continuous casting process is the casting machine. This machine consists of a water-cooled graphite mold, through which the molten copper is fed. The horizontal orientation of the mold allows the copper to solidify as it is drawn horizontally, forming a continuous plate.
Solidification and Extraction: As the molten copper enters the mold, it begins to cool and solidify. The cooling process is carefully controlled to ensure uniform solidification. The partially solidified copper plate is continuously extracted from the mold by a set of withdrawal rolls, which pull the plate at a controlled rate, ensuring consistent thickness and surface quality.
Cutting: The continuous copper plate, once solidified, is cut into desired lengths by a flying shear or a saw. This cutting operation is synchronized with the casting speed to ensure precise length control without interrupting the continuous casting process.
Coiling: In some operations, the cut copper plates may be coiled for easier handling and further processing. This is particularly useful for thinner plates that can be rolled into coils without damage.
Equipment Involved
Furnaces: These include the initial melting furnace and the holding furnace. Induction furnaces are commonly used for their efficiency and precise temperature control.
Ladles: Used for transferring molten copper between furnaces and into the casting machine. Ladles must be capable of withstanding high temperatures and are often lined with refractory materials.
Graphite Mold: The mold in the casting machine is typically made of graphite due to its high thermal conductivity and resistance to thermal shock. The water-cooled design ensures rapid solidification of the copper.
Withdrawal Rolls: These rolls grip the solidifying copper plate and pull it through the mold at a controlled rate. They are crucial for maintaining the consistency and quality of the final product.
Cutting Equipment: Flying shears or saws are used to cut the continuous plate into specific lengths. These machines must be precisely synchronized with the casting process to ensure accuracy.
Cooling Systems: In addition to the water-cooled mold, the system includes spray or immersion cooling methods to further solidify the copper plate and control its temperature throughout the process.
Quality Control
Throughout the horizontal continuous casting process, various quality control measures are implemented. Temperature sensors and control systems ensure the molten copper remains at the optimal temperature. Surface quality and dimensional accuracy are continuously monitored using laser measurement systems and other non-destructive testing methods.
Conclusion
Horizontal continuous casting of copper plates is a sophisticated process that integrates advanced technology and precise control to produce high-quality copper plates efficiently. The process involves a series of well-coordinated stages, from melting and transfer to casting, solidification, and cutting, supported by specialized equipment that ensures the final product meets stringent industry standards.