Selection & Comparison of Copper Rod Casting Machines

There are significant differences in process, efficiency, energy consumption, product quality, and applicable scenarios among various types of copper rod casting machines. The following is a comparative analysis of the main types:

Comparison of Copper Rod Casting Machines

Continuous Casting and Rolling Mill (Properzi method)

Process features: Hot rolling method, continuously casting and hot rolling molten copper into low oxygen bright copper rods (with oxygen content of 200-400ppm).
Advantages:
High production capacity (10-30 tons/hour). It is suitable for large-scale production.
Copper rod has good ductility and is suitable for drawing medium and fine wires.
Mature equipment and high market share.
Disadvantages:
High oxygen content requires subsequent processing for high demand cables such as ultra-fine wires and special wires.
High energy consumption (approximately 250-300kWh/ton).
Application: Conventional fields such as power cables and communication cables.

Upcast Continuous Casting Method

Process features: Oxygen free copper rod (oxygen content ≤ 10ppm), formed by vacuum melting and cold rolling.
Advantages:
The oxygen content is extremely low, and the conductivity is better (≥ 101% IACS).
Suitable for producing small-sized copper rods (Φ 8-20mm) with uniform organization.
Low energy consumption (about 150-200 kWh/ton) and high flexibility.
Disadvantages:
Low production capacity (1-5 tons/hour) and high investment cost.
Subsequent rolling or stretching is required, and the process is complex.
Applications: high-end electromagnetic wires, electronic copper foils, special cables, etc.

Dip Forming Method

Process features: After dissolving the electrolytic copper foil, it is directly formed to produce ultrafine copper rods (Φ 1-3mm).
Advantages:
High surface smoothness and good dimensional accuracy.
Suitable for fine wire (such as enameled wire).
Disadvantages:
The production capacity is extremely low (<1 ton/hour) and the cost is high.
Limited to special purposes only, with low popularity.
Applications: precision electronic components, miniature coils, etc.

Horizontal Continuous Casting Method (SCR Method)

Process features: Continuous casting followed by cold rolling to produce low oxygen or oxygen free copper rods.
Advantages:
The oxygen content is controllable (low oxygen or anaerobic) and the quality is stable.
The equipment occupies a small area and is suitable for medium-sized enterprises.
Disadvantages:
Medium production capacity (5-15 tons/hour), requiring subsequent processing.
Cold rolling can easily cause internal stress, affecting deep processing performance.
Application: Copper materials for mid to high end cables and electrical equipment.

Twin Roll Casting

Process features: Molten copper is directly formed into rods through rapid cooling and rolling.
Advantages:
Short process, energy-saving (about 200kWh/ton).
Fast production speed, suitable for thin specification copper strips/rods.
Disadvantages:
Poor organizational uniformity and susceptibility to cracking.
The applicable copper types are limited (such as purple copper, which has a better effect).
Application: Copper strip, specific specification copper rod.

Selection Suggestions

Large Scale Production
Priority should be given to continuous casting and rolling (Properzi) or horizontal continuous casting (SCR).
High End Anaerobic Demand
Upward continuous casting method is more optimal, but it needs to balance production capacity and cost.
Micro Wire
impregnation molding or upward drawing method+precision stretching combination.
Energy Saving Requirements
Double roll casting or upward drawing method.