compacROD^® - the smart alternative for copper wire rod production

• The new compacROD^® plants feature innovative technologies for the melting and rolling processes.
• Plant capacity ranges from 30,000 to 50,000 tons of copper wire rod per year.
• As modular solution, compacROD^® can be precisely tailored to the needs of plant operators.
• The modular basis has been taken from the construction kit of the SMS group copper wire rod plants.

For the manufacturers of copper wire rod SMS group has a new product offer: the modular compacROD^® plant. Apart from hotrolled ETP (Electrolytic Tough Pitch) copper wire rod the plant is capable of producing FRHC (Fire Refined High Conductivity) copper wire rod. In this case, however, a refining furnace is required for processing contaminated scrap.

To ensure that processing costs are low while consistently maintaining high quality for the compacROD^® plant, SMS group relies on its many years of experience and state-of-the-art technologies for the melting and rolling processes. The shaft furnace from SMS group, for example, stands out for its exceptional efficiency due to its special design principle; with the effect that less energy is needed when feed material is melted.

The vertical furnace vessel is filled with cathodes for the melting process. A special charging system enables the cathodes to be loosely distributed. Gas burners are fitted in rows in the lower part of the furnace, and these are used to melt the copper. The hot offgases which rise up during this process are almost fully utilized in the upper furnace zone to heat up the charged material.

The effective use of thermal energy provides for high efficiency – in particular when compared to other melting processes. Another feature is the automatic burner control, which allows each burner to be regulated separately via the electronic Lambda control system. The “nozzle mix principle” applied here guarantees a high level of safety and creates uniform combustion conditions with low, stable oxygen content in the molten copper. The compacROD^® plant can also be equipped with an induction furnace as melting unit, so that electrical energy is used if there is no natural gas or LPG gas available on site.

The modular rolling line consists of several mill stands, all of which have the same design. Each mill stand features two roll rings and the roll gap is adjusted via a central spindle. The benefit: a centralized synchronous adjustment of both rolls ensures that a long service life is achieved. In addition to that, the roll gap can be adjusted significantly faster and more precisely. Individual frequency-controlled drives considerably reduce the consumption of electrical energy enabling individual speed adjustment.

The fact that all stands feature the same design also has a positive effect on maintenance activities. Despite fewer spare parts on stock, the availability of the rolls is maximized. The roll rings can also be changed quite simply with just a few steps. Costly, time-consuming workshop activities, like with three-roll stands, are avoided. It goes without saying, that the compacROD^® is also available with additional inline measurement devices and coil handling systems individually tailored to the needs of the customer.

• Cost-effective production with low process costs
• Modular configuration for customized solutions
• Highly efficient shaft furnace with cathode preheating system
• Advanced burner technology with Lambda control system on the shaft furnace
• Continuous production of the cast ingot using the wheel and belt method
• High-end rolling mill with separate individual drives
• Continuous use of frequency-controlled drives for enhanced efficiency
• Cooling and coiling equipment for high quality standards