New Developments for Wire Rod Production

by: Matti Nordman UPCAST OY Kuparitie 10 P.O. Box 60 FI-28101 PORI, Finland www.upcast.com

New ownership is leading the charge for innovations to the upward continuous casting method for producing copper and copper alloy rodthe results include improved costefciency, process reliability and rod quality.
throughout its history. Now under new ownership, the role of innovation will become even more important and evident than before. As a result, several new interesting developments have been recently introduced into the UPCAST system, and they are presented in the following sections.

The Upward Continuous Casting method, better known as the UPCAST system, was originally innovated and developed by Outokumpu in the late 1960s for the production of copper and copper alloys wire rod. In 2006, UPCAST celebrated the 35th anniversary of the startup of the rst production unit installed in Outokumpus Pori Foundry in Finland. Thanks to its modular construction, each UPCAST line is easy to upgrade or expand. Consequently, this rst production line has gone through several upgrades keeping it up-to-date and in continuous operation throughout the years. Today, 170 UPCAST casting lines have been delivered worldwide. The majority of these are for oxygen-free copper, but there are also around 40 systems in operation for producing copper alloys. To meet future challenges, the UPCAST legacy is today carried forward under the banner of a newly formed (2006) company called UPCAST OY. Continuous development has been a characteristic feature of the UPCAST technology

Double-Loop Inductors

With double-loop inductors, it is possible to cover a much wider power range than with single-loop inductors. Lower energy consumption as well as a longer lifetime for the inductor itself can also be achieved thanks to the more efcient owing of melt and heat associated with double-loop inductors.

Stepless Power Control for Inductors

This transistor converter-type power control technique has come of age offering a competitive alternative to the more traditional step control technique. The smooth power

General view of a modern double-furnace UPCAST line.

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Double-Furnace Line for 40,000 TPA

Introduction of a large 30 ton melting furnace powered by megawatt class double-loop inductors has enabled us to extend the maximum output of a double-furnace from 30,000 to 40,000 TPA. With two 20-strand casting machines and a high-speed portal-type cathode charging system, the increased melting capacity can be fully utilized.

Carrier-Type Cathode Charging For Double-Furnace Lines

Adaptation of our standard carrier-type cathode charging system, which has been used up to now only in our singlefurnace lines, is now available for use on double-furnace lines. Savings in investment costs occur when expanding from the single to the double-furnace arrangement. There is no need to lift cathodes onto the working platform, as the cathodes can be picked up from oor level. This also reduces the platform area around melting furnace.

Universal Double Coiler

High Capacity UPCAST melting furnace with double-loop inductors.

A wide range of rod diameters (8 to 25 mm) can be handled with this adjustable coiler. When casting several different rod sizes with the same casting line, utilization of this double coiler reduces investment needs and increases production exibility.

adjustment extends the inductors lifetime, reduces energy consumption and eliminates harmful effects of the harmonic resonance phenomenon.

Automatic Alloy Feeder

Single-Furnace Line for 12,000 TPA

An extension of our popular 10,000 TPA (tons per year), single-furnace line to 12,000 TPA capacity, consists of a new 12 ton melting/holding furnace, a single double-loop inductor, a new 12-strand casting machine and a carrier-type cathode charging system. The low investment costs associated with single-furnace casting lines has been pushed to a new level.

The alloy feeder is designed to be used in double-furnace lines for the production of alloyed coppers such as silverbearing and phosphor-deoxidized coppers. Operation is synchronized with the automatic melt transfer function and includes a feedback link, which guarantees accurate chemical analysis with minimal uctuation.

Primary Cooling Water Unit

An efcient double-loop cooling water system with a closed primary circuit is an essential part of any UPCAST line. A primary cooling water unit tailor-made for each casting line is now available as part of our supply.

Primary cooling water unit.

Casting with a high capacity single-furnace UPCAST

line.

These new features offer the operator of an UPCAST system a marked improvement in the cost-efciency and reliability of the process as well as in the quality of the produced WCTI wire rod. For details, visit www.upcast.com.
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