CoperTubePlant

 

Specifications of factory

Iranian Babak Copper Company started the construction project of CAST DRAW copper tube production line (UP CAST) in 2011 and started its initial commissioning in 2014. This method is the newest and most advanced method of producing copper pipes in the world, which with the changes in technology, shortens the production process of pipes and thus reduces the cost of goods. This factory is built on a land with an area of ​​6 hectares and 10,000 m2 of infrastructure. Its casting technology is one of the most advanced technologies in the world, which was purchased from the Finnish company UP CAST and the pipe drawing equipment was purchased from the Austrian ASMAG. Due to the advanced technology, this factory has the ability to produce copper pipes with the best quality and in accord with world standards, especially the international standards of ASTM, EN, JIS to meet the full needs of domestic and the Middle East region industries.

Copper tubes production plant
Capacity 12000 TPA
Casting Product Mother Tube(diameter: 38*2.5 & 52*2.5 mm
Final Product Copper tube (diameter: 4.76-28.57 mm, thickness:0.35-2 mm
Number of products 40+
Method of production Cast & Draw
Location Shahr-e-Babak , Kerman
Area 60000

 

Copper producing process
The producing process of this factory is divided into three main sections: Production of mother tube through Up Cast, reducing the tube diameter to the desired level through drawing and shaping machines and eventually annealing the final product through bright annealing furnaces.
- Melting and Foundry:
Production of copper tube in this method begins with casting by UP CAST furnace. At this stage, the grade A cathode is melted in a 9 ton smelting furnace and after proper alloying (addition of copper phosphorus), the melt is transferred to a 14 ton holding casting furnace. After this step, the mother pipes (primary) with dimensions OD38 / ID33 and OD52 / ID47 are directly cast and transferred to special baskets by UP CAST method.
- Primary drawing:
The diameter and thickness of the primary pipes, produced in the previous stage, are reduced by two 120 kN traction devices manufactured by the Austrian company ASMAG, based on the product process design.
- Middle annealing:
Because the process of pulling the tube is done in the cold state, residual stresses are created in the tube and to release these stresses, the stretched tubes pass through the annealing furnace and their stresses are released. This furnace is also made by the Austrian company ASMAG.
Spinner Block
For final sizing, the drawn tubes in the previous step are transferred to two spinner block devices. This machine has the ability to produce pipes with a diameter of 4 to 30 mm. These devices are also made by the Austrian company ASMAG.
- Level Winder:
After downsizing, the tubes are transferred to this machine. At this stage, the tube passes through the Eddy Current device and the points of the tubethat may have a defect are marked. The Eddy Current device is a German company Foerster made. The number of these defects is controlled according to the standard. The tube is then wrapped in coils of 70-250 kg. All equipment of this device is made by ASMAG Austria.
- Finishing:
In this machine, the tubes are turned into branches or pancakes according to the customer's order. At this stage, the tubes passes through the Eddy Current device and the parts of the tube that may have a defect on it, are separated by the device. This machine has the ability to produce branch tubes up to 2.5 to 6 meters long and pancake tubes from 15 to 50 meters long. This device is also made by the Austrian company ASMAG.
- Final annealing:
To recover the physical properties of products such as machining, electrical and cooling properties, and also giving a shiny surface to them, at this stage, coil and pancake tubes are heated and maintained in an appropriate temperature in the final annealing furnace and then cooled-down to the environment temperature appropriately. To avoid the oxidation of tubes, the oxygen gas is vacuumed and nitrogen is pumped in the furnace instead.
- Finished products:
Finally the tubes are produced in 3 different shapes of LWC (level wound coils), Pancake and Straights according to the customer order and supplied to the market.