CONTIROD®®*TECHNOLOGY

TECHNOLOGY
High sustainability
High sustainabilityand
andtop
topquality
qualityfor
forcopper
copper rod
rod

Constant
Constantimprovements
improvementsininthethetechnology
technologyandanddesign
designofofCONTIROD
CONTIROD ®®
plants as as
* plants well as the
well know-how
as the of SMS
know-how group
of SMS are are
group the the
key
to each
key plant plant
to each operator’s success.
operator’s At theAtsame
success. time, time,
the same production costs costs
production are kept
areto a minimum.
kept to a minimum.

BENEFITS
BENEFITS AT
AT A
A GLANCE
GLANCE

CONTIROD®technology
CONTIROD ®
* technology is highly sustainable
is highly sustainableandandprofi table. It guarantees
profitable. It guarantees
 less downtime and less interruptions of the production
less downtime and less interruptions of the production process process
 high
high plant
plant availability
availability thanks
thanks toto reliable trouble shooting
reliable trouble shooting
 energy-effi
energy-efficiency thanks to lower fuel- and less electrical
ciency thanks to lower fuel- and less energy consumption
electrical energy consumption
 diverse
diverse product
product dimensions
dimensions suchsuch as
as round
round and
and fl at sections
flat sections
 great cost advantages
great cost advantages
 safe
safe operation
operation and
and reduced
reduced maintenance
maintenance time.
time.

*CONTIROD® is a registered trademark of Aurubis Belgium

HIGH EFFICIENCY WITH
ECOPLANTS
CONTIROD
CONTIROD®®*guarantees
guaranteesminimal
minimalgas
gasand
and electricity
electricity consumption
consumption

SMS
SMS group
group hashas advanced
advanced the the of wire 1995.
before rod – from approximately
The ultra-modern 100 kWh/t® before
CONTIROD of SMS1995.
groupThe
CONTIROD ®
®* process to make it ultra-modern CONTIROD ®* of SMS group achieves significant
CONTIROD process to make it achieves significant improvements by applying frequency-
significantly
significantly more
more energy-efficient.
energy-efficient. improvements by applying
controlled AC drives for all frequencycontrolled
combustion air blowers AC drives
and for
This
This success
success is is based
based on on innova-
innova- all combustion
rolling air blowers
mill drives. The use and rolling mill drives. 3-phase
of variable-frequency The use of
tions
tions in
in melting,
melting, casting
casting and
and rolling
rolling variable-frequency
AC drives for the fans3-phase
of theACmelting
drives for the fans
furnace and of
forthe
themelt-
process.
process. The newly designed melt-
The newly designed ing furnace and for the individually driven stands of the
individually driven stands of the rolling mill offers an average rolling
ing furnace ensures a more
melting furnace ensures a more efficient heat heat
efficient transfer fromfrom
transfer the mill offers an average
saving potential of 67%. saving potential of 67 %.
combusted
the combusted gas to
gastheto raw material
the raw and and
material alsoalso
comprises
comprises an
automatic
an automatic scaling lossloss
scaling control system.
control system.TheThe result is both
result is botha
minimization of the oxidation of the liquid copper
a minimization of the oxidation of the liquid copper and a re- and a reduc- Power consumption
Power consumption (kWh/t)
(kWh/t) of advanced CONTIROD®®*lines
lines
tion in the
duction in gas consumption
the gas consumptionthanks to optimized
thanks to optimized combustion
combus-
conditions. Together
tion conditions. these
Together measures
these measures achieve an average
achieve fuel
an average
consumption
fuel consumptionsavings potential
savings of 27of%.
potential 27%.

All ® lines make use of the automatic

All advanced
advancedCONTIROD
CONTIROD®*lines make use of the automatic
combustion
16 t/h
combustioncontrolcontrolofofthe
thefurnace
furnacesystem
systemvia vialambda
lambdavalue.
value.
These
These state-of-the-art
state-of-the-artfurnace
furnaceinstallations
installationsproduce
producebestbest
results
resultswithwithlow
lowfuel
fuelconsumption.
consumption.The Thecombustion
combustionsystem
systemis
based on faultless combustion of the fuel gas
is based on faultless combustion of the fuel gas while thewhile the che-
mical composition of the fuel gas is permanently
chemical composition of the fuel gas is permanently moni- monitored
25 t/h
by a gas
tored by analyzer. In this In
a gas analyzer. way,
thisoxygen intake intake
way, oxygen in the liquid
in thecop-
per is kept low, which is very important for a highquality
liquid copper is kept low, which is very important for a high- final
product. The fuel gas consumption is reduced
quality final product. The fuel gas consumption is reducedto a minimum
due
to a to optimized
minimum duecombustion
to optimizedconditions.
combustion conditions.
35 t/h
Also impressive is the reduction in electrical power consump-
Also impressive is the reduction in electrical power con-
tion: SMS group reduced the average value below 40 kWh/t
sumption: SMS group reduced the average value below
40 kWh/t of wire rod – from approximately 100 kWh/t
*CONTIROD® is a registered trademark of Aurubis Belgium
HIGH QUALITY –
LOW PRODUCTION COSTS
State-of-the-art solutions for reliable results

More than
than half
half of
of the
the worldwide
worldwide copper
copperdemand
demandisisforforcast
cast Resources are
Resources are thus
thus optimally
optimally used
used and the environment is
and rolled
rolled copper
copper wire
wire rod,
rod, used
used as
as the
thestarting
startingproduct
productfor
forthe
the protected. Moreover,
protected. Moreover, customers
customers profit
profit from more process
electrical and electronics
electronics industry.
industry. With
With decades
decades of ofexperience
experience flexibility and
flexibility and low
low processing
processing costs.
costs. The shaft
shaft furnace
furnace is
is
and worldwide
worldwide references,
references, SMSSMS group
grouphas
hasaaleading
leadingmarket
market also used
also used as as melting
melting furnace
furnace for vertical continuous cas ting
casting
position with its
its CONTIROD
CONTIROD®®* plants.
plants.Constant
Constant improvements
improvements plants.
plants.
in technology
technology andand design
design asas well
wellas
asprocess
processknow-how
know-howare arethe
the
key
key to
to success
success andand deliver
deliverthe
thehighest
highestproduct
productquality,
quality,whilst
whilst
ensuring that
that production
production costs
costs are
are kept
kept to
toaaminimum.
minimum.

ACHIEVING MORE MORE WITH WITH CONTIROD CONTIROD®®*

CONTIROD * ®
CONTIROD ® plants
plants impress
impress copper
copper rodrod producers
producers with their
with
high high
their production flexibility
production for wire
flexibility rod and
for wire flat sections.
rod and flat sections.
group has
SMS group has already
alreadyrealized
realizedwire wirerod rodwith
withdiameters
diametersofof8 to
8 to 23 mm. The annual capacity of CONTIROD ®* plants is
23 mm. The annual capacity of CONTIROD plants ®
is between
between
30,000 30,000
t and t and
400,000 400,000
t. This t. This corresponds
corresponds to a casting to a casting
rate
rate between
between 7 t/h60
7 t/h and and
t/h.60
The t/h. The casting
in-line in-line casting and plants
and rolling rolling
plantsadvantages
offer offer advantages
throughthrough the continuous
the continuous process:process:
the copper the
copper is rolled to its final dimensions immediately
is rolled to its final dimensions immediately after casting. The after casting.
The modular
modular plantplant
design design
allows allows for exact
for exact tailoring
tailoring to theto the
custom-
customers´
ers´ requirements.
requirements. At the sameAt the same
time, thetime,
high the highofdegree
degree
of standardization
standardization reduces
reduces thetheneed need for spare
for spare andandwear wear
partsparts
to
to a minimum. The comprehensive automation
a minimum. The comprehensive automation system ensures system ensures
stable production
production conditions
conditionsand
andgood
goodoperator
operatorcontrollability.
controllability.

SUSTAINABLE PRODUCTION: PRODUCTION: MINIMAL MINIMAL

USE OF OF RESOURCES
RESOURCES
SMS group
SMS group uses
uses aa high-power
high-power shaftshaftfurnace
furnacewhich,
which,ininad-
addi-
tion totocopper
dition coppercathodes,
cathodes,alsoalsoallows
allowsfor
forthe
theuse
useofoflarge
large
amounts of
amounts of clean
clean scrap
scrap –– the
the residual
residual material,
material,which
which accu-
mulates during production, as well as scrap
accumulates during production, as well as scrap fromfrom the the
cable
drawing plants can be recycled.
cable drawing plants can be recycled.

THE CUSTOMER´S PERSPECTIVE

PERSPECTIVE

“We have
“We have been
been producing
producing high-quality
high-quality copper
copper wire
wire rod
rod on CONTIROD®®plant
onaaCONTIROD * plant from
from
SMS group since 1999. The technology and the results are convincing: the
SMS group since 1999. The technology and the results are convincing: the customers customers
appreciate our
appreciate our quality
quality and
and flexibility.
flexibility. Thus
Thusweweincreased
increasedourourcapacity
capacityfrom
from18 18toto3030tons
tons
per hour
per hour to
to consolidate
consolidate our
our position
position onon the
the wire
wire rod
rodproduction
productionmarket.
market.””

Halil Göker,
Halil Göker, General
General Manager,
Manager, ErBakir,
ErBakir,Turkey
Turkey

*CONTIROD® is a registered trademark of Aurubis Belgium

 MELTING RATE

7to 60t/h
Continuous operation! Charging lift
Shaft furnace

Holding furnace

Casting machine

Edge scalping machine

Pendulum shear

HIGH
HIGH FLEXIBILITY
FLEXIBILITY –– THROUGHOUT THROUGHOUT
THE
THE ENTIRE
ENTIRE PRODUCTION
PRODUCTION PROCESS PROCESS
The
The high
high quality
quality of
of the
thefifinal
nal products
productsisisthe thekey
keysuccess
successfac-
tor of the CONTIROD ®
plants.
® That is
factor of the CONTIROD * plants. That is ensured ensured by thebyprecise
the
interaction betweenbetween
precise interaction all components in the plant.
all components in theOne of One
plant.
the main
of the features
main of SMS
features of SMSgroup´s CONTIROD
group´s CONTIROD ®
solution: the
®* solution:

state-of-the-art machines
the state-of-the-art machinesare highly flexible
are highly in technology
flexible in technology
and
and design,
design, already
already starting
starting with
withthethecharging
chargingequipment.
equipment.
The
The scope
scope of of supply
supplyencloses
enclosesaanew newflflexible
exible charge
chargesystem
system
for
for cathodes
cathodes and and clean
cleancopper
copperscrap.
scrap.Scrap
Scrapboxes
boxeswith witheasy
easy
locking
locking devices
devicesenable
enablequickquickhandling
handlingofofthetheclean
cleancopper
copper
scrap.
scrap. At
At the
the end
endofofthetheproduction
productionline,line,the
thecoiling
coilingequip-
equip-
ment
ment works
works forfor each
each plant
plant operator’s
operator’s requirements regardingregard-
ing
coilcoil sizes
sizes andand weight.
weight.

BENEFITS OF SMS GROUP SHAFT LOWEST POSSIBLE

LOWEST POSSIBLE OXYGEN OXYGENPICK PICKUP UP
FURNACES ENSURES BEST QUALITY
ENSURES BEST QUALITY FOR COPPER ROD FOR COPPER ROD
During the
During the melting
melting process,
process, utomatically
automaticallycontrolled
controlled
 High thermal efficiency – lower fuel consumption nozzle mix
nozzle mix burners
burners avoid
avoidthat
thatoxygen
oxygenisisadded
addedtotothe theliquid
liquid
 Low oxygen content in liquid copper copper. AA covered
copper. coveredand andgasgasheated
heatedlaunder
laundertransfers
transfersthe theliquid
liquid
 Easier maintenance of zero regulator free burner copper from the shaft furnace to the holding
copper from the shaft furnace to the holding furnace. The furnace. The
supply system holding furnace
holding furnace ensures that the shaft furnace continues continues runn-
 Less downtime and less interruptions of produc- ing during
running production
during stops
production in the
stops rolling
in the line.line.
rolling It allows for a
It allows
tion process constant
for temperature
a constant temperatureof theofliquid copper
the liquid and assures
copper and assures the
 Possibility of individual regulation of each nozzle lowest oxygen pick up possible. Thanks to the
the lowest oxygen pick up possible. Thanks to the Hazelett Hazelett Twin-
mix burner. Belt Caster,
Twin-Belt the copper
Caster, rods rods
the copper feature a fine-grained
feature a fine-grainedand and
homo-
geneous casting
homogeneous structure
casting with equal
structure distribution
with equal of oxygen
distribution of
and impurities
oxygen – one of– the
and impurities onemost
of theimportant facts for
most important optimum
facts for
product quality.
optimum product quality.
 Foil packing

Coil press

Rolling mill

Coil forming

Cooling line

OPTIMAL
OPTIMAL PRODUCTIONPRODUCTION RESULTS RESULTS AT AT
THE HEART
THE HEART OF THE PLANTOF THE PLANT
The
The centerpiece
centerpiece of CONTIROD®®*plant
the CONTIROD
of the plantisisthe
the
rolling
rolling mill. It reflects the whole scope of benefits ofof
mill. It reflects the whole scope of benefits
CONTIROD ®
CONTIROD® *tetechnology.
chnology. WWith
ith itsits
indindividual
ividual drdrive
ive
technology, the plant holds many advantages:
technology, the plant holds many advantages:

Individual drive system for each rollstand as basis

 Individual drive system for each rollstand as basis
for higher rolling quality
for higher rolling quality
Fine-grained and homogeneous rolling structure
 Fine-grained and homogeneous rolling structure
Less process costs for roll rings thanks to minimum
 Less process costs for roll rings thanks to mini-
wear and tear
CUTTING-EDGE EQUIPMENT FOR mum wear and tear
High flexibility regarding final product dimensions
HIGH PRODUCTIVITY  High flexibility regarding final product dimensions
such as round and flat sections
Plant operators use PLC systems
systems to
to control
control the
the complete
complete such as round and flat sections
Robust frequency-controlled AC-motors reduce
CONTIROD®®*plant. A visualization system with diagnostic
plant. A visualization system with diagnostic  Robust frequency-controlled AC-motors reduce
maintenance time and energy consumption.
signaling and monitoring software
software prevents
prevents the
the plant
plant from
from maintenance time and energy consumption.
problems and potential interruptions.
interruptions. Thus,
Thus,the
theelectrical
electrical
control system guarantees:

 Good
Good accessibility
accessibilityof
ofprocess
processdata
datafor
fortrouble
troubleshooting
shooting
Less downtime
 Less downtime for
for the
the line
line
 Higher plant availability
Higher plant availability
 Low maintenance for AC-drives, high speed control
 ow maintenance for AC-drives, high speed control of
L
of rolling speed.
rolling speed.

PERFECT RESULTS WITH HAZELETT

TWIN-BELT CASTERS
 Fine-grained and homogeneous casting structure
with equal distribution of oxygen and impurities –
important fact for rod quality
 High cost advantage when using more copper
scrap as raw material.

*CONTIROD® is a registered trademark of Aurubis Belgium

 COMPETITION
AHEAD OF COMPETITION
40-year history
In the 40-year history of CONTIROD®®*
of CONTIROD many
many innovations
innovations have
have been
been introduced
introduced to theto the entire
entire processprocess line.
line. The The result:
result:

Satisfied customers
and successful
production worldwide!

THE CUSTOMER´S PERSPECTIVE

“When we built our new plant, we looked at a number of suppliers and compared them
carefully: SMS group offered the best engineering solution and enabled us to achieve
best product quality. Now, four years after commissioning, SMS group is still a real busi-
ness partner for us. We can really rely on the employees’ skills and first-class services.“

Graham Cheetham, General Manager (Manufacturing), Dubai Cable Company Pvt. Ltd.
(Ducab), VAE

*CONTIROD® is a registered trademark of Aurubis Belgium

SUSTAINABLE PRODUCTION AT ing cross-section
casting cross-sectionof 8,610 mm²mm²
of 8,610 and and
a casting speed
a casting of roughly
speed of
EASTERN COPPER roughly 10 m/min. The standard finished wire rod size is diam-
10 m/min. The standard finished wire rod size is 8.0 mm
The Chinese copper wire
wire rod
rod manufacturer
manufacturer has has already
alreadycom-
com- eter.
8.0 mmThediameter.
main drivesTheofmain
the mill andofthe
drives thefans
mill all
andhave
the variable-
fans all
missioned the second continuous copper copper wire
wire rod
rod plant
plant from
from frequency
have 3-phase AC motors
variable-frequency 3-phase reduce the energy
AC motors reduce consump-
the energy
SMS group. The
The latest
latest plant
plantisisone
oneof ofthe
thelargest
largestand
andmost
most tion. The modern
consumption. Theelectrical systems systems
modern electrical and automatic process
and automatic
modern of its kind in
in China
China –– at
at distinctly
distinctly improved
improvedsustain-
sustain- control by SMS group ensure smooth and reliable
process control by SMS group ensure smooth and reliable operation.
abilty in comparison to its predecessor
predecessor technology.
technology. The plant is
operation. completed
The by an automatic
plant is completed compacting,
by an automatic strapping
compacting,
and foil packing
strapping and foilline for theline
packing wire
forrod
thecoils.
wire rod coils.
The totally optimized CONTIROD® ® * process ensures the high-
process ensures the high-
est product quality with signifi cantly
cantly improved
improved sustainability.
sustainability. Fuel
Fuel consumption
consumption declines
declinesbyby2727%,%, electricity
electricity consumption
consumption
The new plant consists of shaft melting furnace and a 20 t even by 67 %. As a particularly
even by 67%. As a particularly sustainable solution, the
the plant
plant
holding furnace, a Hazelett twin-belt caster and a continuous is
is awarded
awarded with
withthe
theecoplants
ecoplantslabel.
label.Quality
Qualityunites – that
unites is what
– that is
rolling mill. Its 14 roll stands feature individual drives and the SMS
what group and the
SMS group andplant
theoperators proof with
plant operators proofthis successful
with this
latest electrical systems for optimum process control. The project.
successful project.
CONTIROD® ® * plant has a casting capacity of 48 t/h with a
plant has a casting capacity of 48 t/h with a cast-

*CONTIROD® is a registered trademark of Aurubis Belgium

4€ /t
is what plant operators
save when producing
with Ecoplants compared
with the predecessor
technology.
67%
is the Ecoplant’s saving
potential in electricity
27%
is the Ecoplant’s saving
potential in fuel con-
consumption compared sumption compared
with the predecessor with the predecessor
technology. technology.
SMS GROUP GMBH
Business Unit Forging Plants
Copper Plants

Ohlerkirchweg 66
41069 Mönchengladbach
C1300.04/13 en · Printed in Germany

Germany

Phone: +49 2161 350-2321

Fax: +49 2161 350-2318
C1300.07/15

copperplants@sms-group.com
www.sms-group.com

The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as de-
scribed and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver
products having particular characteristics shall only exist if expressly agreed in the terms of the contract.