Casting Plants for Copper and Copper Alloys

The Casting Process transforms the liquid metal contained within a special Furnace into semi-finished products (billets, slabs, rods, bars, strips, wires, tubes) and / or remelting forms (ingots), after adequate cooling. This process is used for both non-ferrous and ferrous Alloys.

The Casting Process is based on two different technologies:

- Continuous Casting: is recommended for high production volume.
- Semi-Continuous Casting: is recommended for diversified production, particularly, for the production of special Alloys.

GMS designs, builds and supplies complete Continuous Casting Plants of both horizontal (HCC) and vertical (VCC) type for non-ferrous Alloys, on a “turnkey” basis (EPC package). The Continuous Casting Plants are aimed at the continuous production of billets, pipes, strips, wires, rods.

GMS Plants are supplied with automation and control systems designed to guarantee the Operator the complete management of the process, product quality and repeatability, ensuring the highest level of safety and the most competitive transformation costs.

Continuous or Semi-Continuous Casting Technology are applied for following metals:

NON-FERROUS METALS

Copper and Copper Alloys

Aluminium and Aluminium Alloys

FERROUS METALS

Steel and Steel Alloys

Grey Iron

Ductile Iron

PRECIOUS METALS

Gold

Silver

01.

Horizontal Continuous Casting Plants (HCC)

HCC Plants are recommended for high productivity of final products within similar range of Alloys, for billets with a diameter of less than 450 mm, bars or pipes.

This Technology does not require complex foundations.

The HCC Plant has a high automation level, so that the Operator plays a supervisor role following the process from the Control Room.

The GMS “Casting Management System” software controls the cooling parameters, continuously checking the heat removed by the water. The control of the removed heat enables repeatability and complete control of the process.

The repeatability of the process is also guaranteed by the recipes that are recorded by type of Alloy and product dimensions. These recipes contain all the parameters necessary for production.

HCC Plant – Brass billet secondary cooling

HCC Plant – CuNi tube production

GMS HCC Line

HCC Plant – Crystallizer for Bronze bars production

HCC Plant – Brass billet production

02.

Vertical Continuous Casting Plants (VCC)

VCC Plants are recommended for large production volumes, for production of billets and slabs, especially, for billets of a diameter exceeding 400 mm. An important advantage of this Technology consists in a uniform crystal grains distribution of cast products.

GMS owns the know-how to create special VCC plants for production of thin tubes of special Alloys.

The VCC Plant has a high level of automation, so that the Operator plays a supervisor role monitoring the process from the Control Room.

The repeatability of the process is also guaranteed by the recipes that are recorded by type of Alloy and product dimensions. These recipes contain all the parameters necessary for production.

Complete VCC Plant for Copper billets production

VCC Plant for Copper and Copper Alloys bars and tubes production

03.

Vertical Semi-Continuous Casting (VSC)

VSC plants are recommended when production is diversified both in terms of dimensions and types of Alloys. GMS technology makes this type of Plant versatile, suitable for rapid production changes.

VSC Plants are recommended for production of billets and slabs, especially, for billets of a diameter exceeding 400 mm. An important advantage of this Technology consists in a uniform crystal grains distribution of cast products.

Another peculiarity of the VSC Plant is the high hourly productivity.

GMS Technology is conceived for production of special Alloys in “Dry-Cast mode”, i.e., using only the Primary Cooling System. The water-cooled Pit made of Stainless Steel is specially designed by GMS. This technology guarantees perfect operation while casting in “Dry-Cast mode”.

In addition, GMS pre-heated Tundish allows the introduction of a cored wire in order to produce special Alloys (for example, CuZr).