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35 TPH Copper Rod Production Line Solution

Integrated Continuous Casting & Rolling Solution for 8mm Low-Oxygen Bright Copper Rod

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Solution Overview

High-Capacity Integrated Copper CCR System

This 35 TPH copper rod production line makes Φ8 mm low‑oxygen bright copper rods for wires, cables and conductors. It integrates continuous casting, rolling, non-acid cleaning, cooling, coating and coiling. Equipped with a 2440 mm casting wheel and 11-stand mill, it delivers stable continuous production for large copper rod plants via PLC/HMI process control.

Rated output: 35 TPH, producing Φ8 mm low‑oxygen bright copper rod
Casting unit: five-wheel continuous caster with cooling and loop auto-control
Rolling mill: 11 separately driven stands including 3 rough and 8 finishing stands
Auxiliary & control: integrated cleaning/coating, PLC/HMI for monitoring and data logging

Coppe

35 TPH Copper Rod Production Line Solution

From molten copper to finished 8mm rod coils, the line is engineered as one connected production system. The equipment sequence is matched around casting stability, rolling reduction, rod surface treatment, coil formation and line-wide speed coordination rather than treating each machine as an isolated unit.

Solution Overview

The reference line is configured to produce Φ8 mm electrical-grade low-oxygen bright copper rod at 35 TPH. The continuous caster forms a 5430 mm² copper cast bar, which is prepared and progressively reduced through the roughing and finishing mills. After rolling, the rod passes through non-acid cleaning, cooling and protective coating before automatic coil formation and downstream transfer.

Molten Copper → Continuous Casting → Cast-Bar Handling → Rough Rolling → Intermediate Shearing → Finish Rolling → Non-Acid Cleaning & Cooling → Protective Coating → Coiling → Coil Transfer

Production Line Automation
Modules

Casting & Rolling Speed Coordination

Production Line

Process Monitoring & Data Acquisition

Production Line

Fault Detection & Interlocking

Production Line

Core Equipment

Equipment	Role in the Solution
Five-Wheel Continuous Casting Machine	Converts molten copper into a continuous 5430 mm² cast bar with controlled cooling and stable casting conditions.
Rotary Shear & Scrap Handling	Cuts cast bar during startup or abnormal rolling conditions and allows casting continuity while downstream equipment is cleared.
Mobile Hydraulic Shear	Supports cast-bar cutting and removal of partially rolled scrap in the casting and rolling areas.
Cast-Bar Preparation Unit	Guides and prepares the cast bar before entry into the rolling section.
3-Stand Roughing Mill	Performs the initial reduction of the cast bar and prepares it for finish rolling.
Intermediate Rotary Shear	Provides cutting and discharge between roughing and finishing sections when required.
8-Stand Finishing Mill	Progressively rolls the material to the specified Φ8 mm finished copper rod.
Non-Acid Cleaning Line	Cleans and cools the finished rod with an alcohol-based cleaning solution before coiling.
Rod Cleaning, Cooling & Coating System	Reduces surface oxide, cools the rod and applies a protective coating to delay oxidation during storage and transport.
Copper Rod Coiling System	Forms the finished rod into constant-diameter coils and supports automatic coil change by selected coil weight.
Roller Conveyor System	Transfers completed copper rod coils toward downstream handling and packing.
Lubrication & Emulsion Systems	Provide lubrication and cooling media for roughing and finishing mill operation.
Process Monitoring & Data Acquisition	Provides real-time monitoring, historical trends, alarms, reporting and networked process data.
Electrical Control System	Coordinates drives, PLC, HMI, sensors, interlocks and line-wide speed synchronization.

Production Process

The solution follows a continuous process route designed to maintain material flow and stable production from casting through finished coil handling.

Stage 01

Continuous Casting

Molten copper is introduced into the five-wheel continuous caster. The casting wheel and steel belt form the mold, while zoned cooling controls solidification and mold temperature distribution. Automatic cast-bar loop control coordinates the caster with the rolling section

Stage 02

Cast-Bar Cutting & Preparation

During startup or abnormal conditions, the rotary shear can continuously cut cast bar until rolling requirements are met. A mobile hydraulic shear supports cast-bar clearing and removal of partially rolled scrap.

Stage 02

Rough Rolling

The cast bar enters three individually driven roughing stands. The no-twist roughing arrangement reduces the cast-bar section and prepares the material for the finishing mill. Adjustable guides and fault detection support stable transfer between stands.

Stage 02

Intermediate Shearing & Tension Control

Between roughing and finishing, the intermediate shear can remove material during a finishing-mill fault while allowing the roughing section to continue operating. The transfer section also supports tension control between rolling stages.

Stage 02

Finish Rolling to Φ8 mm

Eight individually driven finishing stands progressively roll the incoming material to Φ8 mm copper rod. The cantilever no-twist design, adjustable roll gap and guide system are intended to support stable rod dimensions and smooth transfer between stands.

Showcase of Excellence

Designed Around the Complete 35 TPH Process

The reference configuration uses a 2440 mm casting wheel, a 5430 mm² cast-bar section and an 11-stand rolling arrangement consisting of one 412 mm roughing stand, two 305 mm roughing stands and eight 204.5 mm finishing stands. Finished coils are designed around a 1600 mm outer diameter, 800 mm inner diameter and a reference coil weight of 2–4 tons.

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Stable Continuous Production

Automatic cast-bar loop control, individual stand drives and line-wide speed coordination support continuous production from caster to coiler.
Controlled Rolling Process

Three roughing stands and eight finishing stands provide staged reduction from cast bar to Φ8 mm rod, with individual drive control and guide adjustment for process flexibility.
Cleaner Rod Surface

The non-acid cleaning, cooling and coating process is designed to reduce surface oxide, maintain a bright rod surface and delay oxidation during storage and transportation.
Process Visibility

PLC/HMI monitoring provides real-time process data, alarms, drive status, trends and historical information so operators can respond quickly to abnormal conditions.

Frequently Asked Questions

Need answers for copper production‑line, furnace configuration or custom‑project concerns? Send us an inquiry to get expert‑tailored suggestions.

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What does the 35 TPH copper rod production line produce?

The reference solution is designed for continuous production of Φ8 mm low-oxygen bright copper rod for downstream wire, cable and electrical conductor manufacturing.

How is the rolling mill configured?

The reference rolling section has 11 individually driven stands: one 412 mm roughing stand, two 305 mm roughing stands and eight 204.5 mm finishing stands.

How does the line maintain coordinated production?

The electrical control system uses PLC/HMI communication and variable-frequency drives. In linked operation, the main production drives follow the casting speed through a coordinated speed chain, while individual stands can be fine-adjusted for process requirements.

How is the copper rod cleaned after rolling?

The finished rod passes through a non-acid cleaning and cooling process using an alcohol-based solution. The system is designed to reduce surface oxide and cool the rod before coiling, followed by a protective surface coating to delay oxidation.

Can the line monitor production data and alarms?

Yes. The reference process monitoring system supports real-time process visualization, historical variable monitoring, alarms, trends, reporting and drive-status monitoring through HMI/PLC integration.

What coil size is used in the reference solution?

The reference design specifies approximately 1600 mm outer diameter, 800 mm inner diameter and 2–4 tons coil weight.

Are all utility systems included in the production line supply?

Not necessarily. The final supply boundary is project-specific. In the reference scheme, some utilities such as casting water, process water, oxygen/acetylene and compressed air are identified as buyer-provided systems, while the final interfaces are confirmed in the technical agreement.

What information is needed to prepare a project proposal?

Please provide your target capacity, finished rod specification, raw material and melting route, workshop layout, power supply, cooling-water conditions, available utilities, required coil size and any local installation or automation requirements.

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