The SMS group gas burner BB1000 enhances the performance of shaft furnaces through its expanded power range and optimized lambda control, ensuring superior efficiency. Its improved flame pattern effectively eliminates cold spots and adheres to DIN EN 746-2 standards. The burner is equipped with reliable flame monitoring and features a viewing glass for copper monitoring. Additionally, an optional camera is available, enabling operators to observe from their control station and promptly identify anomalies such as a clogging burner. This facilitates quick replacement, thereby reducing maintenance costs due to less frequent replacement of the burner stone. The old burner model is seamlessly exchangeable with the new BB1000.

The SMS camera system combines innovation with practicality, offering operators real-time monitoring of furnace activity directly from their control station. Compatible with both older burner models and the latest BB1000, this advanced solution ensures quicker detection of issues, such as cathodes obstructing the burner, enabling rapid intervention to minimize downtime and prevent extensive damage. Importantly, the camera is designed so that the direct sight into the furnace at the burner remains fully available, allowing operators to visually inspect the furnace on-site when needed. This dual functionality enhances operational efficiency while maintaining flexibility for on-site supervision.

The edge scalping machine improves wire quality by removing sharp edges from cast copper bars, preventing cracks, splinters, and oxides in the finished rod. Equipped with four scalping heads, it creates 45° chamfers and ensures short chips through targeted chip breaking. A new guiding concept enables precise bar tracking, while the oscillation drive operates parallel to the strand movement. The machine can be retrofitted, offering reduced maintenance, fewer wear parts, and lower energy consumption without altering the existing foundation structure.

The transfer launder unit optimizes copper transport from the shaft furnace to the holding furnace. A fully covered system with adjustable drive and blower regulation achieves significant energy savings and state of the art process control. Equipped with a single burner system, it ensures precise control and continuous flame monitoring. Additionally, the frequency-controlled air blower and automatic ignition system guarantee adherence to the latest safety standards. To simplify operation, the system incorporates an integrated slag box and an inspection orifice, offering uninterrupted visibility into the tap hole area.

The cooling line from the CONTIROD® series significantly improves wire quality by efficiently cooling it from 650°C to 70°C. This process employs two cooling segments using an alcohol and water emulsion to enhance wire quality while reducing operating costs. The optimized design without boxes facilitates effective descaling and cooling, with continuous monitoring of media flow rate and temperature. Additionally, the secure sealing of the cooling section minimizes health risks, and the inclusion of a bayonet lock allows for rapid access in the event of process issues.

The SMS hybrid nozzle enhances the cooling section of copper wire rod mills through the application of 3D-printed cooling and wiper nozzles. Its flow-optimized outlet openings reduce compressed air consumption while improving wire coverage, resulting in significantly higher media efficiency. The housing, constructed from more robust materials and using conventional manufacturing methods, offers flexible installation options and extends the lifespan of the component.

To minimize downtime in the event of a rolling mill crash, SMS group advises maintaining a spare pair of eccentric bushings. This solution, applicable to stands 360 and 220, reduces downtime from an average of 12 to 16 hours to less than 6 hours, enabling exchanges without halting the entire production line. Furthermore, defective eccentric bushings can be repaired at an SMS workshop, enhancing production availability and achieving cost savings. Repairing bushings is considerably more economical than replacing the entire mill stand.

The lamella separator by SMS group ensures sustainable filtration of metal chips during the rolling process, effectively removing copper oxide particles from lubrication, cooling, and corrosion protection media. This innovative filter design eliminates the need for consumables like filter fleece, reducing operating and maintenance costs while enabling the recycling of metal chips. The system minimizes foam formation, ensuring efficient filtration of oil-water and alcohol emulsions, whether mineral or synthetic. Particles settle due to density and are collected via a scraper conveyor.