Mine to Wire – Manufacturing

Navigating Mine to Wire

The "Mine to Wire" manufacturing process refers to the comprehensive journey of electrical conductors, from the extraction of raw materials in mines to the final production of wires. This intricate value chain involves several stages, each with specific tasks and considerations.

The manufacturing process involves a meticulous journey from the extraction of raw materials through refining, alloying, conductor manufacturing, quality control, and final product assembly.

This comprehensive approach ensures the production of high-quality electrical conductors that meet the stringent requirements of diverse applications.

mjlee consult offers tailored face to face (typically over three days including a factory/ cast house audit) and online training modules (in two to three hour blocks)

Book Now

Half Day Course Why is my wire breaking?

How many wire breaks is your plant experiencing? One every 100t, 500t, 1000t...?

Why is the wire breaking? Is it a problem with my machines, procedures, raw material...the weather?

If your plant can draw one tonne of aluminium or copper with no wire breaks why not 1,000,000+ ?

This half day course draws on the broader Mine to Wire course and focuses on wire breaks delving into the source and prevention measures to move to eliminating wire breaks.

mjlee consult offers the Wire Breaks module face to face and online.

Book Now

Raw Material Extraction

Mining Operations include the extraction of metals like copper and aluminium, which begins in mines where ore deposits are located. Metallurgical experts assess the quality and composition of ores to ensure suitability for conductors.

Refining and Smelting

Ore Refining

Ores undergo refining processes to eliminate impurities and obtain high-purity metals. Refining techniques, such as electrolysis, are employed to achieve the desired material quality.

Smelting

Smelting involves melting the refined metal to create ingots or billets. The metallurgical properties are closely monitored to meet the conductivity requirements for conductors.

Alloying and Composition Control

Alloy Formation

Alloying is a critical step, especially for conductors like aluminium, where alloying elements are added to enhance specific properties - normally strength. Or more importantly for conductors the detrimental effects of allying elements on conductivity.

Strict control over alloy composition is maintained to achieve optimal electrical and mechanical characteristics.

Conductor Manufacturing

Wire Drawing

The alloyed metal is processed through wire drawing machines to reduce its diameter gradually. This process enhances the metal's tensile strength and elongation properties.

The equations to manage the drawing process are striaghtforward. The operation, housekeeping, and quality control distinguish different drawing factories from others

Stranding and Insulation

Multiple wires are stranded together to form a conductor. Insulation materials, such as polymers, are applied to prevent electrical leakage and protect against environmental factors.

Quality Control and Testing

Metallurgical Testing

Conductors undergo rigorous metallurgical testing to verify their chemical composition and physical properties. Testing includes tensile strength, conductivity, and resistance measurements.

Conductivity testing and mechanical property run charts compared to wire break frequency is discussed

Bringing it all together

Wire breaks, lots of moving parts, adding grease, compacting wires...maintaining standards and keeping customer happy.

Housekeeping, value chains, work practices

Final Product Manufacturing

Drums, containers, trucks...

Packaging and handling can make or break a quality delivery

Connect With Industry Peers

Connect with industry peers, experts, and professionals who share your interest in the Mine to Wire manufacturing process.

Let’s Talk

Connect with us at mjlee consult to access exclusive resources, network with like-minded individuals, and contribute to shaping the future of manufacturing advancements in the field.

Book Now