In modern aluminum wire and overhead conductor manufacturing, the continuous casting and rolling (CCR) process is the most efficient way to produce high-quality aluminum and aluminum alloy rods. The RLB Aluminum Alloy Rod Continuous Casting and Rolling Production Line delivers premium 9.5 mm, 12.5 mm, and 15 mm rods in EC1350, Series 3#, 5# (5005/5154), 6# (6101/6201), and Series 8# (8176/8030) alloys — fully compliant with European and American standards.
This fully integrated line combines melting, casting, rolling, and take-up into one continuous, high-output process, offering outputs of 4.5 t/h or 7.5 t/h with exceptional rod density, uniform grain structure, and superior electrical conductivity.
Processus technologique bref
Complete Continuous Route (melting furnace prepared by customer): A00 aluminum ingots / scraps → Holding furnace → Online degassing & filtration → Four-wheel continuous casting machine (H-type crystallization wheel) → Straightening machine → Front haulage device → Rolling shear → Medium-frequency induction heater (optional) → Feeding device → Continuous rolling mill (2-roller / 3-roller / 2+3 roller) → Cooling & emulsion system → Automatic coiling stand → Finished high-conductivity aluminum alloy rod coils.
The H-type four-side cooling crystallization wheel (diameter 1400–2300 mm, cross-section area 1600–3300 mm²) ensures rapid, uniform solidification with minimal porosity and excellent internal structure.
Core Technical Advantages & Operational Excellence
Engineered for the demanding GCC climate and high-volume overhead conductor production, our Aluminum Alloy Rod CCR Line offers measurable performance:
- H-Type Four-Side Cooling Crystallization Wheel: Produces dense, uniform ingots with superior surface quality and minimal defects — critical for high-conductivity EC1350 and alloy rods.
- Flexible Roller Configurations: 3-roller (Y-type), 2-roller, or combined 2+3 roller modes optimized for different alloy grades and diameters (excellent roundness and mechanical properties).
- Advanced Medium-Frequency Induction Heater: Maintains precise rolling temperature, enables online quenching, and reduces oxidation.
- Intelligent PLC + HMI Control: Full-line linkage, real-time monitoring of speed, temperature, tension, and emulsion flow; recipe storage for multiple alloys.
- High-Capacity Output: 4.5–5 t/h (4.5T model), 5–6.8 t/h (6.8T model), or 6–7.5 t/h (7.5T model) with low scrap rates and energy-efficient operation.
- Complete Turnkey Integration: Includes lubrication, emulsion cooling, filtration, and automatic coiling systems for seamless 24/7 production.
These features deliver 15–25% higher output, significantly lower energy consumption, and consistent rod quality compared with separate casting and rolling processes.
Spécifications techniques
| Modèle | Rod Diameter (mm) | Rolling Times | Capacité (t/h) | Roller Mode | Melting Furnace (t) | Holding Furnace (t) | Énergie du four | Applicable Alloys |
|---|
| 4.5T | 9.5 / 12 / 15 | 15 | 4.5–5 | 3-roller | 6 | 10–15 | Natural gas / LPG | EC1350, 3#, 5#, 6#, 8# |
| 7.5T | 9.5 / 12 | 10 or 14 | 6–7.5 | 2-roller + 3-roller | 12 | 20–25 | Natural gas / LPG | EC1350, 3#, 5#, 6#, 8# |
Line speed up to 8 m/s. Coil weight 2–3 tons. Custom capacities and configurations available upon request.
Composants principaux et intégration du système
- Melting & holding furnaces (customer supply or optional)
- Four-wheel continuous casting machine with H-type crystallization wheel
- Straightening & front haulage device
- Rolling shear + medium-frequency heater (optional)
- Continuous rolling mill (2/3/2+3 roller)
- Lubrication & emulsion cooling system
- Automatic coiling stand with arc guiding pipe and pre-deformation protection
- Intelligent PLC + HMI electrical control system
But: One-step continuous production from molten aluminum to finished high-conductivity rod coils, maximizing efficiency and minimizing handling damage.
Applications principales
- Production of EC grade aluminum rod for electrical conductors
- Aluminum alloy rod for overhead transmission lines (AAC, AAAC, ACSR)
- High-tensile conductive rods for power cables and building wire
- Aluminum alloy rod for automotive and industrial applications
- Precursor material for further wire drawing and stranding
The RLB CCR line is the ideal turnkey solution for aluminum rod producers seeking European/American quality standards with maximum efficiency and reliability.
FAQ détaillées – Répondre aux vraies questions de vos clients
Q1: What is the main advantage of the H-type crystallization wheel?
A: Four-side cooling ensures rapid, uniform solidification, producing dense ingots with minimal porosity and excellent internal structure — directly improving final rod conductivity and mechanical properties.
Q2: How do I choose between 2-roller, 3-roller, or 2+3 roller configurations?
A: 3-roller (Y-type) offers best roundness for standard EC1350; 2+3 combination provides superior control for high-strength alloys (6101/6201/8176); 2-roller suits high-speed production of simpler grades.
Q3: What energy sources are supported and how efficient is the line?
A: Natural gas, LPG, heavy oil, diesel, or coal gas with regenerative options. Typical energy consumption is significantly lower than separate processes, with 15–25% savings reported in GCC installations.
Q4: Can the line produce multiple alloy grades without major reconfiguration?
A: Yes. PLC recipe storage and modular roller/heater design allow quick changeover between EC1350, 5005, 6101, 8176, etc.
Q5: What is the typical scrap rate and rod quality?
A: Scrap rate <1.5% with proper degassing/filtration. Rods meet or exceed international conductivity and tensile standards with bright surface finish.
Q6: Does the line integrate with existing melting furnaces?
A: Fully compatible. We supply matching launders, flow control, and synchronization systems for seamless integration.
Q7: What is the expected payback period?
A: 12–18 months for plants running 6,000+ hours/year through higher output, lower energy use, and reduced scrap.
Q8: Do you provide installation, training, and after-sales support in Saudi Arabia?
A: Yes. Full turnkey installation, commissioning, operator training (Arabic/English), and 24/7 remote + on-site support with local spare parts stock in the Eastern Province.
Why Choose RLB Aluminum Alloy Rod CCR Line?
- Qualité fiable: Every line undergoes full-load testing; consistent rod quality with superior conductivity and mechanical properties.
- Service personnalisé: Tailored to your alloy mix, capacity, factory layout, and local energy infrastructure in Saudi Arabia & GCC.
- Partenariat à long termeInstallation complète, formation des opérateurs, fourniture de pièces détachées, diagnostic à distance et contrats de maintenance basés sur la performance.
- Prêt pour la Vision 2030: Proven technology supporting Saudi Green Initiative and local content requirements for overhead conductors.
Demande d'informations
Contactez notre équipe technique dès aujourd'hui. 48 heures we will deliver a detailed configuration proposal, ROI calculation, layout drawings, and reference cases from similar GCC projects.
Ready to upgrade your aluminum rod production?
Demande d'informations — Let us deliver the reliable, high-efficiency Aluminum Alloy Rod Continuous Casting and Rolling Line that powers your conductor manufacturing success in Saudi Arabia and the GCC.
Ligne de coulée continue et de laminage de tiges en alliage d'aluminium
High-efficiency Aluminum Alloy Rod Continuous Casting and Rolling Line producing premium 9.5 mm, 12.5 mm and 15 mm rods in EC1350, 3#, 5# (5005/5154), 6# (6101/6201) and 8# (8176/8030) alloys. 4.5–7.5 t/h output with H-type crystallization wheel and flexible 2/3/2+3 roller configurations.
SKU du produit: CCR-AL-4.5T / CCR-AL-7.5T
Marque de produit: Machines RLB
Devise: USD
Prix du produit: Contactez-nous pour un devis
Produit en stock: En stock
Note de l’éditeur/éditrice : 4.9 
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