Copper Anode Casting Wheel

The Copper Anode Casting Wheel, also known as a double-disc casting machine, is designed for high-efficiency copper anode production in fire-refining and smelting plants. The system integrates quantitative pouring, dual-disc casting, mold spraying, spray cooling, anode extraction, and transfer operations.
With servo-controlled casting accuracy (±3 kg), stable cycle control, and full automation, the equipment ensures consistent anode quality and long-term reliable operation.

The complete casting wheel system includes:

• Quantitative casting system
• Dual-disc casting wheel
• M20 heat-resistant cast iron molds
• Mold and anode spray cooling system
• Anode extraction and transfer system
• Automatic mold spraying system
• Electrical and instrumentation system
• Two-layer insulated control room

Each module is engineered for continuous casting duty in high-temperature smelting environments.

3.1 Quantitative Casting System

• One intermediate launder (servo-actuated)
• Two servo-controlled pouring systems
• Continuous weighing with load cells (Mettler Toledo)
• Intermediate launder lined with refractory (buyer supplied)
• Casting ladle weighing structure with four load sensors
• Technical notes:
• Pouring time: 12–18 seconds
• Intermediate launder capacity: 3500 kg molten copper
• Ladle weighing capacity: 750 kg

 

3.2 Casting Wheel Center System

• Two casting wheel centers
• Forty M20 heat-resistant molds
• Flat-type structure for easier visibility and access
• Driven by a stable servo/PLC system
• Center bearing diameter: 2400 mm
• Wheel movement time: 9–12 seconds per index position.

3.3 Mold & Anode Cooling System

• Dedicated cooling zones for molds and anodes
• Adjustable upper and lower spray cooling
• Mold temperature monitoring with automatic flow adjustment
• Cooling parameters:
• Cooling zone capacity: 8 molds
• Water pressure: 0.5–0.8 MPa
• Cooling water flow: 2 × 300 m³/h

3.4 Anode Extraction & Transfer System

• Servo-driven gripping and alignment correction
• Pneumatic clamps (waterproof design)
• Automatic transfer to water-cooled tank
• Cooling tank parameters:
• Size: 5000 × 2300 × 2000 mm
• Flow: 2 × 100 m³/h

3.5 Mold Lifting & Locking System

• Scissor-arm servo mechanism
• Prevents stress transfer to casting wheel
• Ensures precise mold stabilization
• Specifications:
• Maximum lifting force: 5 tons
• Required space: approximately 4 × 5 m

3.6 Automatic Mold Spraying System

• Servo sweeping nozzles for mold surface
• Fixed nozzles for anode ear-lug region
• Weight-monitored feeding hopper
• Adjustable cycles and flow
• Spray cycle: 2–8 seconds
• Spray pressure: 0.2–1.0 MPa

3.7 Control System

• Dual operator stations controlling two casting wheels
• Omron PLC, Omron servos, Mettler Toledo load cells
• SMC pneumatic modules
• IP65 field protection, IP54 control room protection
• Full Chinese HMI interface

Functions include:

• Casting
• Cooling
• Spraying
• Disc rotation
• Extraction
• Stacking
• Alarm & interlock protection
• Auto/manual switching

3.8 Two-Layer Control Room

• Upper level: operator room with HVAC and HMI
• Lower level: MCC and pneumatic cabinet
• Dual-layer insulated steel structure (Q235B + SS304)
• Fire-rated rock wool (≥30 mm)
• Noise reduction and heat isolation
• Winter heating and dehumidification

 

Control room reference size:
5100 × 2800 × (2850 + 2400) mm

4.1 Precision Quantitative Casting

Real-time measurement and servo control ensure copper charging accuracy within ±3 kg.

4.2 Double-Disc High-Capacity Casting

Dual-disc design shortens cycle time, improves continuity, and increases output.

4.3 Automated Mold Temperature Control

Upper and lower spray cooling systems automatically adjust based on mold temperature.

4.4 Servo-Driven Anode Extraction

Accurate gripping, automatic alignment correction, and stable transfer to cooling tanks.

4.5 High-Durability M20 Molds

Cast iron molds with smooth surfaces and long service life; average filling capacity ≥150 tons per mold.

4.6 Automated Mold Spraying System

Uniform coating with servo sweep technology ensures consistent mold preparation and extended mold life.

4.7 Industrial-Grade Control Platform

Omron PLC, Omron servos, Mettler Toledo sensors, and SMC pneumatics ensure long-term stable operation.

• Copper fire refining
• Copper anode furnace casting
• Copper scrap recovery casting
• Anode production for electrorefining
• Large-scale smelting casting shops

PRS provides engineering drawings, layout design, and complete anode casting wheel solutions tailored to your smelting project requirements.

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