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.
Brief Technological Process
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.
Technical Specifications
| Model |
Rod Diameter (mm) |
Rolling Times |
Capacity (t/h) |
Roller Mode |
Melting Furnace (t) |
Holding Furnace (t) |
Furnace Energy |
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.
Main Parts & System Integration
- 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
Purpose: One-step continuous production from molten aluminum to finished high-conductivity rod coils, maximizing efficiency and minimizing handling damage.
Primary Applications
- 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.
Detailed FAQs – Answering Your Customers’ Real Questions
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?
- Reliable Quality: Every line undergoes full-load testing; consistent rod quality with superior conductivity and mechanical properties.
- Customized Service: Tailored to your alloy mix, capacity, factory layout, and local energy infrastructure in Saudi Arabia & GCC.
- Long-term Partnership: Complete installation, operator training, spare parts supply, remote diagnostics, and performance-based maintenance contracts.
- Vision 2030 Ready: Proven technology supporting Saudi Green Initiative and local content requirements for overhead conductors.
Inquiry Now
Contact our technical team today. Within 48 hours 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?
Inquiry Now — 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.
Aluminum Alloy Rod Continuous Casting and Rolling Line
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.
Product SKU:
CCR-AL-4.5T / CCR-AL-7.5T
Product Brand:
RLB Machinery
Product Currency:
USD
Product Price:
Contact for Quote
Product In-Stock:
InStock
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