Proposal for the Production Project of 6500 Tons per Year of Copper Clad Aluminum Bimetallic Composite Wire and Enamel Wire Derivatives
( Proposal for the production of 6,500 tons of copper-clad aluminum bimetallic composite conductors and enameled wire derivative products per year )
Part 1: Annual output of 6,500 tons of copper-clad aluminum project
Project investment: Total investment of the project is RMB 50 million
Construction scale: Annual output of 35,000 tons of copper-clad aluminum busbars and 3,000 tons of copper-clad aluminum wires
Labor quota: 20 people
Working system: 300 days of production per year, maximum annual production hours 7200h
The planned land area of the project is 14,397 square meters, and the building area is 15,160 square meters.
The factory area is organized from north to south into production and living quarters. Within the production area, buildings 1 and 2 are arranged from north to south. The living quarters, located on the south side of the factory, are a four-story overall, with partial five-story frame structures, designed for office and living accommodation. Roads within the factory area are arranged in a circular pattern around the workshops, meeting the project's production and firefighting transportation needs.
1Product Solution
6500 tons of copper-clad aluminum conductor product solution list
| Product Name | Total product volume | Specification |
| Copper clad aluminum bimetallic composite conductor | 3500 tons/year | 1<φ≤5mm |
| 3000 tons/year | 0.1<φ≤1mm |
List of main technical parameters of 6500 tons copper-clad aluminum conductor products
| Product Name | parameter | index |
| Copper clad aluminum bimetallic composite conductor
| Resistivity (Ω) | 42 / 20℃ |
| Tensile strength (MPa) | 220~230 | |
| Elongation (%) | 8~18 | |
| Copper layer thickness (μm) | 2~3 | |
| Density (g/cm 3 ) | ≤2.76 |
2 Main construction contents
The main construction contents include a comprehensive building, 1# and 2# factory buildings, a raw material warehouse, a finished product warehouse, a hazardous waste temporary storage room, a general solid waste temporary storage room, a testing area and related supporting facilities.
The main construction contents include a comprehensive building, 1# and 2# factory buildings, a raw material warehouse, a finished product warehouse, a hazardous waste temporary storage room, a general solid waste temporary storage room, a testing area and related supporting facilities.
Project construction content list
1# Factory
It is mainly used for large-diameter copper-clad aluminum bimetallic composite conductors (specification 1＜φ≤5mm), and is equipped with 106 equipment including covering machines, Wire Drawing Machines, pit-type annealing furnaces, eddy current flaw detectors, inverted wire take-ups, etc.
One-story steel structure with a construction area of 2,932 square meters .
Factory Building 2
It is mainly used for small-diameter copper-clad aluminum bimetallic composite conductors (specification 0.1＜φ≤1mm), and is equipped with 173 equipment including wire drawing machines, tubular annealing furnaces, and reeling machines .
1-story steel structure with a construction area of 7,012 square meters .
Raw material warehouse
Located in Factory Building 1, the planned area is approximately 200 square meters .
Finished product warehouse
Located on the southeast side of workshop 2#, the finished products are transported to the downstream in a timely manner. The finished product warehouse covers an area of about 500 square meters .
Comprehensive Building
The building has four floors in total and five floors in part, with a construction area of 2,225 square meters, used for office and living .
Detection Area
It is mainly used for physical tests such as product elongation. It is located in the northeast corner of the 1# plant and covers an area of about 50 square meters .
distribution room
Located in the southwest corner of Factory Building 2#, the planned building area is 24 square meters .
water supply
The water supply comes from the municipal water supply network, with a water consumption of 7230t/a .
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Supplied by the municipal power grid, the annual electricity consumption is 4.8 million kWh/a .
List of main raw and auxiliary material consumption for 6,500 tons of copper-clad aluminum conductor
| Serial number | name | Annual usage | Cycle storage capacity |
| 1 | Copper Strip | 685t/a | 50 tons |
| 2 | Copper clad aluminum rod | 6145t/a | 500 tons |
| 3 | Aluminum drawing oil | 1.5t/a | 150kg , 25kg/barrel |
| 4 | Argon | 5t/a | 400kg , 40kg/bottle |
| 5 | engine oil | 0.05t/a | 25kg/barrel |
| 6 | Rags and gloves | 500kg/a |
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| Aluminum drawing oil: a metalworking oil, also known as aluminum stretching oil, aluminum drawing oil. This project uses a water-soluble additive for the drawing process of aluminum and its alloys, with lubrication, cleaning, cooling, and rust prevention functions. | |||
List of main production equipment for 6,500-ton copper-clad aluminum conductor
| Serial number | Project Name | quantity | Remark |
| 1 | 8 | Workshop 1# | |
| 2 | wire drawing machine | 60 | Workshop 1# |
| 3 | Pit annealing furnace | 12 | Workshop 1# |
| 4 | Eddy current flaw detector | 12 | Workshop 1# |
| 5 | Inverted wire take-up machine | 16 | Workshop 1# |
| 6 | wire drawing machine | 140 | Workshop 2# |
| 7 | Tubular annealing furnace | 25 | Workshop 2# |
| 8 | Rewinding Machine | 8 | Workshop 2# |
| 9 | Elongation tensile testing machine | 2 | 1# workshop inspection area |
| 10 | Intelligent low resistance tester | 2 | 1# workshop inspection area |
II : Derivative expansion project with an annual output of 6,000 tons of enameled wire
Project investment: total investment of 2 million yuan
Construction scale: Annual output of 4,000 tons of copper-clad aluminum enameled wire and 2,000 tons of copper enameled wire
Labor quota: 30 new people
Working system: 300 days of production per year, maximum annual production hours 7200h, three shifts.
List of main construction contents of the 6,000-ton enameled wire expansion project
Copper enameled wire production line
The wire drawing, pay-off, annealing and hot air drying processes are located on the first floor of the 2# plant, while the painting, baking, cooling, winding and testing processes are located on the second floor of the 2# plant, producing 2,000t/a of copper enameled wire .
Small diameter copper-clad aluminum bimetallic composite conductors, and 20 additional wire drawing machines .
Copper clad aluminum enameled wire production line
The wire drawing, pay-off, annealing and hot air drying processes are located on the first floor of the 2# plant, while the painting, baking, cooling, winding and testing processes are located on the second floor of the 2# plant, producing 4,000t/a of copper-clad aluminum enameled wire .
Small diameter copper-clad aluminum bimetallic composite conductors, and 20 additional wire drawing machines .
Detection Area
It is mainly used for physical tests such as product elongation. It is located in the northeast corner of the 1# plant and covers an area of about 50 square meters .
distribution room
Located in the southwest corner of Factory Building 2#, the planned building area is 24 square meters .
Hazardous chemicals warehouse (Class A)
Located on the first floor of workshop 2#, it covers an area of about 50 square meters .
Raw material warehouse (Class B)
Located on the first floor of Building 1, it covers an area of approximately 200 square meters .
Finished product warehouse
Located on the southeast side of the first floor of workshop 2#, it covers an area of approximately 500 square meters .
Water supply project
The tap water consumption of the expansion project is 1,800t/a (6t/d), and the municipal water supply network in the park is used by the municipal government .
Pure water preparation
A new pure water station is built in the west of the 1# production workshop. The pure water of this project adopts the first-level reverse osmosis preparation process with a water production capacity of 8m3/h .
Power supply project
The expansion project consumes 4 million kW·h of electricity, and the power supply within the factory is connected to the park's power supply network
Waste gas treatment measures
(1) Enameling exhaust gas: Painting and drying are sealed, and 18 sets of three-stage catalytic combustion devices are installed; the enameling workshop is equipped with a 25-meter exhaust pipe (each exhaust pipe collects 9 horizontal enameling machines);
(2) Wire drawing exhaust gas: A cooling tower is used to cool the wire drawing oil to reduce the generation of oil mist; the wire drawing machine is equipped with a PVC collection pipe to introduce the oil mist into the wire drawing oil pool, the wire drawing oil is covered and sealed, and non-woven filter cotton is used at the air outlet of the wire drawing oil pool to filter the oil mist; the air vents of the wire drawing oil room are sealed with sponges;
2. Product Solution
The expansion project is mainly engaged in the production of enameled wire, mainly including aluminum enameled wire and aluminum-clad copper enameled wire.
Expansion Project Product Plan Statistics
| Product Categories | Specifications (mm) | Designed capacity (t/a) | Paint layer thickness (mm) | Number of coatings |
| Copper enameled wire | Φ0.03 | 10 | 0.008 | 5~7 |
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| Φ0.05 | 20 | 0.008 | 5~7 |
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| Total 2000 |
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| Copper clad aluminum enameled wire | Φ0.08 | 20 | 0.010 | 5~7 |
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| Φ0.1 | 30 | 0.01 | 5~7 |
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| Total 4000 |
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Main raw materials and energy consumption
(1) Consumption of raw and auxiliary materials
List of main raw and auxiliary material consumption during the production process of this project
| Raw material name | Annual consumption | Storage period (d) | Maximum storage capacity | Packaging specifications | Storage Location |
| Copper rod | 2009t | 50 | 334.8t | Bags, 2t/4t | Raw material warehouse |
| Copper clad aluminum rod | 3750t | 50 | 625t | Bags, 2t/4t | Raw material warehouse |
| Polyester paint | 573.78t | 12 | 22.95t | 500kg/barrel | Hazardous chemicals warehouse |
| polyurethane paint | 270.4 t | 12 | 10.82t | 500kg/barrel | Hazardous chemicals warehouse |
| drawing oil | 0.6t | 100 | 0.2t | 200kg/iron drum | Hazardous chemicals warehouse |
| paraffin oil | 18t | 7 | 0.42t | 200kg/iron drum | Hazardous chemicals warehouse |
| catalyst | 4.32t | 365 | 4.32t | Boxed | Hazardous chemicals warehouse |
| water | 1800t/a |
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| electricity | 4 million KWh/a |
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(2) Calculation of insulating paint usage
This project has an annual production capacity of 2,000 tons of copper enameled wire and 4,000 tons of copper-clad aluminum enameled wire. According to the data, the diameter of the copper enameled wire produced ranges from 0.03 to 3.0 mm, the thickness of the paint layer ranges from 0.002 to 0.103 mm, and the number of coatings is 6 to 9. The product uses two types of insulating paint (polyurethane paint and polyester paint). This evaluation calculates the amount of insulating paint based on the average distribution of the two paints. According to the formula: V = m / ρ = (r outside
2 -r 2 )*π*L, the total solid content of polyurethane paint for enameled wire is calculated to be 148.72t/a. If the solid content of polyurethane paint is 55%, the theoretical consumption of polyurethane paint is 270.4t/a. The total solid content of polyester paint for enameled wire is 183.61t/a. If the solid content of polyester paint is 32%, the theoretical consumption of polyurethane paint is 573.78t/a. The total consumption of insulating paint for this project is 844.18t/a.
