Copper wire production is a beautiful and loud process. We are going to trace it from the start to the finish in the shops of the “Russian copper company”.
First of all they bring copper scrap to the factory.
There may be different kinds of scrap, everything that contains copper can be made use of.
Then the scrap is heated to make a “soup” of molten copper. Practically all casings burn off.
To reach a high temperature, they inject oxygen under pressure by means of a special “syringe”.
The temperature is getting higher and the “soup” starts boiling.
The copper is boiled in a “cannon” like tha.
Extraction systems are activated and the whole mechanism starts rotating.
The process of separation.
When the copper scrap is separated into fractions, the part containing copper is used for further remelting.
Being close is hard, it’s very hot there.
The “pot” is already on the stove.
This copper still contains many impurities.
Molten metal is poured into molds.
The camera taking these pictures was damaged right here.
Copper alloy is rotating and cooling down.
One of the shops.
Frozen molds are moved by a manipulator into the water bath for further cooling.
When the mold is close to the water, the water starts boiling.
After all of these operations, they get workpieces like these – as you can see they still have impurities.
The workpieces are turned into blocks which are then transported to the shop where the huge electrolysis baths are.
Electrode loading is automatic.
The electrolysis process.
After unloading, the baths are cleared of sediment that has settled on the bottom, from which they subsequently extract gold, silver, selenium, and tellurium.
Unloading of cassettes.
After the baths the pure copper plates are sorted and briquetted.
Another shop is used for melting copper, it is required to make wire.
The process is very beautiful.
The workpiece has to be shaped.
All protruding parts are cut off.
Then they are cooled down to the necessary temperature…
… to be heated again and stretched to the required diameter.