Oxygen-Free Copper Rod Upward Continuous Casting Line
Produce oxygen-free copper rod directly from copper cathode. Verified configurations cover 1,000-20,000 t/y, approximately 8-35 mm rod and 2-32 casting strands.
Also called an OFC rod upcast plant, copper rod upward casting machine or vertical copper rod casting line, it integrates induction melting, holding, water-cooled crystallization, servo traction and rod take-up. Applications include magnet wire, fine wire, cable conductors, copper strip, tube, busbar and shaped products.
Unlike a low-oxygen copper CCR line, upcasting draws rod vertically and has no casting wheel or hot continuous rolling section. Final properties depend on cathode quality, furnace atmosphere, casting control, downstream processing and verified testing.
Oxygen-Free Copper Rod Line Overview
The oxygen-free copper rod machine uses a power-frequency induction furnace to melt copper cathode. Molten copper enters the holding and casting section, where water-cooled crystallizers solidify the copper in an upward direction. The solidified rods are pulled continuously and collected into coils by synchronized take-up machines.
A small copper processor may select a 1,000 or 2,000 t/y system, while a larger conductor or cable manufacturer can choose a nominal capacity of up to 20,000 t/y. The final configuration is selected according to required output, rod diameter, number of strands, electrical supply, available plant space and whether the rod will be taken directly to wire drawing or first processed by a cold rolling mill.
Upcasting vs Copper Rod CCR: Select the Correct Process
| Comparison |
Upward Continuous Casting Line |
Copper Rod CCR Line |
| Main production route |
Induction melting -> holding -> upward crystallization -> traction -> coiling |
Melting/refining -> wheel-and-belt casting -> cast-bar treatment -> hot continuous rolling -> coiling |
| Typical positioning |
Oxygen-free copper rod and quality-sensitive downstream processing |
High-volume low-oxygen copper rod, commonly 8 mm |
| Rolling section |
No hot continuous rolling section; optional downstream cold rolling |
Continuous hot rolling is part of the CCR route |
| Common downstream users |
Magnet wire, fine wire, conductor, copper tube/strip/bar processing |
Wire and cable conductor production and general copper wire drawing |
H2 Available Models from 1,000 to 20,000 T/Y
Technical note: Capacity figures are based on reference operating conditions and approximately 7,920 working hours per year. Actual output depends on rod diameter, strand configuration, copper cathode quality, operating schedule and production conditions.
How the Upcast Copper Rod Plant Works
Copper Cathode Feeding and Induction Melting
Copper cathode is fed into the power-frequency induction melting furnace. A low-voltage, high-current electromagnetic induction system provides controlled melting while the furnace structure and refractory insulation help maintain stable thermal conditions. The melting and holding sections are configured according to the required hourly melting rate, from at least 150 kg/h for the SYLZ-1000T to at least 2,500 kg/h for the SYLZ-20000T.
Upward Continuous Casting and Crystallization
Molten copper enters the casting section and is drawn upward through graphite moulds installed in water-cooled crystallizers. Rapid heat removal converts the molten copper into solid copper rod. A liquid-level tracking mechanism helps maintain the correct crystallizer position and stable immersion depth. The mould, cooling conditions, pulling speed and pulling pitch can be adjusted for the selected rod diameter and strand arrangement.
Servo Traction and Speed Synchronization
The traction unit uses a servo-controlled drive, precision reducer, traction rollers and pneumatic clamping system. Operators can set pulling speed, pulling pitch and related parameters through the touchscreen and PLC. Automatic speed synchronization coordinates the casting machine and take-up equipment, helping control copper rod tension during continuous production.
Automatic Copper Rod Take-Up
The double-head take-up system collects the cast copper rod into coils. PLC, touchscreen and inverter control synchronize take-up speed with casting speed and support automatic rod arrangement. Reference coil weight is 4 metric tons or above, depending on configuration and customer requirements.
Main Technical Parameters
The listed data is intended for preliminary model selection. Final specifications will be confirmed according to required capacity, rod diameter, electrical standard, raw material and production conditions.
Main Equipment Included in the Line
Copper cathode feeding system
Power-frequency induction melting furnace
Copper holding furnace
Upward continuous casting machine
Water-cooled crystallizers
Servo traction system
Automatic speed control system
Double-head copper rod take-up machines
Cooling-water circulation and monitoring system
PLC and touchscreen electrical control system
Temperature, pressure, water-flow and alarm devices
Operating platform and line accessories
The final scope of supply can be adjusted according to the factory layout and equipment already available at the customer’s plant.
Key Features
The appropriate rod diameter and downstream processing route should be selected according to the finished conductor and its quality requirements.
Cooling Water Requirements
Stable cooling is essential for crystallization. Reference inlet-water temperature is 25-35 degrees C. The crystallizer circuit typically requires higher water pressure than the induction coil and furnace water-jacket circuits. Water quality, temperature, flow and pressure should be reviewed during engineering. An emergency water supply is recommended so cooling can be restored rapidly if the main power or circulation system is interrupted.
How to Select the Correct Capacity
1,000-4,000 T/Y,Suitable for new copper rod projects, specialized conductor production, limited factory space or lower initial output requirements.
5,000-8,000 T/Y,Suitable for medium-sized wire, magnet wire and cable conductor manufacturers requiring a stable internal supply of oxygen-free copper rod.
10,000-20,000 T/Y,Suitable for larger copper processing plants and high-volume wire and cable manufacturers. These configurations use higher melting rates and more casting strands.
Capacity selection should be based on realistic annual demand rather than maximum theoretical output alone. Planned maintenance, product mix, rod diameter, downstream drawing capacity and future expansion should also be considered.
Information Required for a Technical Proposal
Required annual copper rod output
Required rod diameter or diameter range
Copper cathode specification
Final application of the copper rod
Required number of production shifts
Local voltage and frequency
Available factory dimensions
Cooling-water conditions
Required coil weight
Existing downstream rolling or wire drawing equipment
Based on this information, we can recommend a suitable SYLZ model, casting-strand arrangement, furnace capacity, take-up configuration and production-line layout.
Frequently Asked Questions
1.Can one line produce different copper rod diameters?
Different rod diameter configurations are available. The exact range depends on the selected model, crystallizer, graphite mould and strand arrangement. Confirm all required diameters before finalizing the line configuration.
2.Is the listed capacity guaranteed under every production condition?
The listed output is a reference nominal capacity based on catalog operating conditions and approximately 7,920 annual working hours. Actual output depends on raw material, rod diameter, strand utilization, maintenance and operating efficiency.
3.What is the difference between the 1,000T and 20,000T models?
The main differences are melting rate, installed capacity, number of casting strands, number of take-up machines and monthly output. Both use the same basic upward continuous casting process.
4.Can the line be supplied for a voltage other than 380 V and 50 Hz?
Electrical components and power distribution can be engineered for the customer’s local voltage and frequency. The required electrical standard must be confirmed before manufacturing.
5.Does the line include the cooling-water system?
The cooling and monitoring scope can be included according to project requirements. Water quality, inlet temperature, pressure, flow and emergency cooling arrangements must be confirmed during engineering.
6.What equipment is required after the upcast line?
The next processing step depends on the finished product. Copper rod may be sent to a copper rod cold rolling mill, rod breakdown machine, intermediate wire drawing machine or multiwire drawing machine.
7.How is this line different from a copper rod CCR line?
This line draws copper rod upward through water-cooled crystallizers and has no hot continuous rolling section. A copper rod CCR line normally casts a larger bar and hot-rolls it continuously, commonly into 8 mm low-oxygen copper rod.
Request Your Upcast Line Configuration
Tell us your required annual capacity, rod diameter, final application, electrical standard and factory dimensions. We will recommend a suitable oxygen-free copper rod casting line from 1,000 to 20,000 t/y and prepare a preliminary equipment configuration and layout proposal.
